CN117156985A

CN117156985A - Aerosol-generating article comprising a wrapper having an overlap region

Info

Publication number: CN117156985A
Application number: CN202280025969.7A
Authority: CN
Inventors: A·J·卢韦
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2021-04-12
Filing date: 2022-04-08
Publication date: 2023-12-01
Also published as: JP2024513111A; EP4322774A1; WO2022218887A1; KR20230170700A; BR112023020951A2

Abstract

An aerosol-generating article (10) comprising an aerosol-forming substrate (11) and a wrapper (30) defining the aerosol-forming substrate. The wrapper defines an overlap region (41) in which the wrapper overlaps itself, the overlap region comprising a first section (42) and a second section (43) externally disposed on the first section. The second section includes a fold (44) defining a folded section (45) at one end of the wrapper, and the folded section is sandwiched between the first section and the second section. An external adhesive is disposed between the folded section and the second section.

Description

Aerosol-generating article comprising a wrapper having an overlap region

Technical Field

The present invention relates to aerosol-generating articles comprising an aerosol-forming substrate. The aerosol-generating article may be used to generate an inhalable aerosol when heated.

Background

Aerosol-generating articles are known in the art in which an aerosol-forming substrate, such as a tobacco-containing substrate, is heated rather than combusted. The purpose of such heatable aerosol-generating articles is to reduce the potentially harmful by-products generated by combustion and pyrolytic degradation of tobacco in conventional cigarettes.

In heatable aerosol-generating articles, the inhalable aerosol is typically generated by heat transfer from the heater to the aerosol-forming substrate. During heating, volatile compounds are released from the aerosol-forming substrate and become entrained in the air. For example, volatile compounds may be entrained in air drawn through, over, around, or otherwise in the vicinity of the aerosol-generating article. As the released volatile compounds cool, the compounds condense to form an aerosol. The aerosol may be inhaled by the user. The aerosol may contain flavors, fragrances, nicotine, and other desired ingredients.

The heating element may be comprised in an aerosol-generating device. The combination of the aerosol-generating article and the aerosol-generating device may form an aerosol-generating system.

The heatable aerosol-generating article may comprise one or more wrappers defining at least a portion of the aerosol-generating article. Advantageously, the one or more packages may prevent a user from handling the aerosol-forming substrate, which may help to maintain a high level of hygiene. The provision of one or more wrappers may also assist in securing together the components of the aerosol-generating article.

However, when the wrapper defines at least a portion of the aerosol-generating article, the wrapper may comprise at least one free end disposed on a section of the wrapper overlapped by the free end. Such an arrangement may be detrimental to the mechanical stability of the aerosol-generating article. It may also hinder the manufacture and handling of the aerosol-generating article.

It would therefore be desirable to provide an aerosol-generating article comprising one or more packages and having improved mechanical stability.

Disclosure of Invention

An aerosol-generating article may be provided. The aerosol-generating article may comprise a wrapper defining an aerosol-forming substrate. The wrapper may define an overlap region in which the wrapper overlaps itself, the overlap region including a first section and a second section externally disposed on the first section. The second section may comprise a fold or pleat defining a folded section at one end of the wrapper. The folded section may be sandwiched between the first section and the second section.

An aerosol-generating article may be provided, the aerosol-generating article comprising:

an aerosol-forming substrate; and

A package defining the aerosol-forming substrate;

wherein the wrapper defines an overlap region in which the wrapper overlaps itself, the overlap region comprising a first section and a second section externally disposed on the first section;

wherein the second section comprises a fold or pleat defining a folded section at one end of the wrapper; and is also provided with

Wherein the folded section is sandwiched between the first section and the second section.

The term "aerosol-generating article" is used herein to refer to articles in which an aerosol-forming substrate may be heated to produce an inhalable aerosol and deliver the inhalable aerosol to a consumer. As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate is typically part of an aerosol-generating article.

The aerosol-forming substrate may comprise nicotine. The nicotine-containing aerosol-forming substrate may be a nicotine salt substrate.

The aerosol-forming substrate may comprise a liquid. The aerosol-forming substrate may comprise a solid component and a liquid component. Preferably, the aerosol-forming substrate may comprise a solid.

The aerosol-forming substrate may comprise a plant-based material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material comprising volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise a homogenized plant based material.

As used herein, the term "aerosol-generating device" refers to a device that typically includes a heater that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol.

As used herein with reference to the present invention, the term "strip" is used to denote a generally cylindrical element of substantially circular, oval or elliptical cross-section.

As used herein, the term "longitudinal" refers to a direction corresponding to the major longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. As used herein, the terms "upstream" and "downstream" describe the relative positions of an element or portion of an element of an aerosol-generating article with respect to a direction in which an aerosol is transported through the aerosol-generating article during use.

During use, air is drawn through the aerosol-generating article in the longitudinal direction. The term "transverse" refers to a direction perpendicular to the longitudinal axis. Unless otherwise indicated, any reference to an aerosol-generating article or a "cross-section" of a component of an aerosol-generating article refers to a cross-section.

The term "length" denotes the dimension of a component of the aerosol-generating article in the longitudinal direction.

By providing a folded section at one end of the wrapper and the folded section being sandwiched between the first and second sections of the wrapper, the end of the wrapper is not the free end of the second section which is provided in an overlapping manner on the first section of the wrapper. Thus, the folded section may improve the mechanical stability of the aerosol-generating article comprising the wrapper.

The folded section does cause significant irregularities in the outer surface of the package as it is sandwiched between the first section and the second section. This may be advantageous in facilitating handling of the aerosol-generating article during manufacture and transportation.

In contrast to other arrangements of packages comprising a folding section, an arrangement in which the folding section is defined by folds or pleats comprised in the second section of the package may be desirable, as this arrangement may avoid forming irregular recesses in the interior space defined by the package or minimize the size of the irregular recesses. Such an arrangement may enable a reduction in the amount of aerosol-forming substrate required for manufacturing the aerosol-generating article, since the interior space defined by the wrapper may be expected to contain aerosol-forming substrate. It may also improve the manufacturing process, as irregular recesses may make insertion of the aerosol-forming substrate more difficult and time consuming.

An internal adhesive may be disposed between the folded section and the first section. An external adhesive may be disposed between the folded section and the second section. The provision of an internal or external adhesive may help to improve the mechanical stability of the aerosol-generating article. When the internal and external adhesives are provided, a greater improvement in mechanical stability can be achieved.

The inner adhesive and the outer adhesive may be the same adhesive.

The folded section may extend over at least about 0.75 millimeters of the perimeter of the aerosol-forming substrate, or at least about 1 millimeter of the perimeter of the aerosol-forming substrate.

The folded section may extend over up to about 2.5 millimeters of the perimeter of the aerosol-forming substrate, or up to about 2 millimeters of the perimeter of the aerosol-forming substrate.

Preferably, the folded section extends over between about 0.75 mm and about 2.5 mm of the perimeter of the aerosol-forming substrate, or between about 0.75 mm and about 2 mm of the perimeter of the aerosol-forming substrate, or between about 1 mm and 2.5 mm of the perimeter of the aerosol-forming substrate. More preferably, the folded section extends over between about 1 mm to about 2 mm of the perimeter of the aerosol-forming substrate.

The folded section may extend over at least about 3% of the perimeter of the aerosol-forming substrate, or at least about 4% of the perimeter of the aerosol-forming substrate.

The folded section may extend over up to about 12% of the perimeter of the aerosol-forming substrate, or up to about 10% of the perimeter of the aerosol-forming substrate.

Preferably, the folded section extends over between about 3% and about 12% of the perimeter of the aerosol-forming substrate, or between about 3% and about 10% of the perimeter of the aerosol-forming substrate, or between about 4% and about 12% of the perimeter of the aerosol-forming substrate. More preferably, the folded section extends over between about 4% and about 10% of the aerosol-forming substrate.

The second section may extend over at least about 0.75 millimeters of the perimeter of the aerosol-forming substrate, or at least about 1 millimeter of the perimeter of the aerosol-forming substrate.

The second section may extend over up to about 2.5 millimeters of the perimeter of the aerosol-forming substrate, or up to about 2 millimeters of the perimeter of the aerosol-forming substrate.

Preferably, the second section extends over between about 0.75 mm and about 2.5 mm of the perimeter of the aerosol-forming substrate, or between about 0.75 mm and about 2 mm of the perimeter of the aerosol-forming substrate, or between about 1 mm and 2.5 mm of the perimeter of the aerosol-forming substrate. More preferably, the second section extends over between about 1 mm to about 2 mm of the perimeter of the aerosol-forming substrate.

The second section may extend over at least about 3% of the perimeter of the aerosol-forming substrate, or at least about 4% of the perimeter of the aerosol-forming substrate.

The second section may extend over up to about 12% of the perimeter of the aerosol-forming substrate, or up to about 10% of the perimeter of the aerosol-forming substrate.

Preferably, the second section extends over between about 3% and about 12% of the perimeter of the aerosol-forming substrate, or between about 3% and about 10% of the perimeter of the aerosol-forming substrate, or between about 4% and about 12% of the perimeter of the aerosol-forming substrate. More preferably, the second section extends over between about 4% and about 10% of the aerosol-forming substrate.

The perimeter of the aerosol-forming substrate may also be referred to as the circumference of the aerosol-forming substrate.

The wrapper may have a basis weight of between about 10 grams per square meter and 28 grams per square meter. Preferably, the wrapper may have a basis weight of between about 10 grams per square meter and 16 grams per square meter.

Such a range of basis weights may be advantageous in allowing the formation of folded sections in the wrapper.

The wrapper may have a porosity of between about 30 and about 80 Coresta units. Preferably, the wrapper may have a porosity of between about 30 and about 50 Coresta units. Most preferably, the wrapper may have a porosity of between 30 and 40 Coresta units.

The wrapper may have a roughness of between about 50Bekk seconds and about 1000Bekk seconds. More preferably, the wrapper may have a roughness of between about 100Bekk seconds and about 200Bekk seconds.

Roughness in Bekk seconds was measured by means of standard tests using Bekk smoothness gauges that generate a vacuum and measure the time it takes for the vacuum to drop from 50.66kPa to 48.00 kPa. This test is approved by the international standard ISO 5627.

The internal adhesive may include one or more of the following: gum arabic, natural or synthetic resins, starches and varnishes. The external adhesive may include one or more of the following: gum arabic, natural or synthetic resins, starches and varnishes. Such an adhesive may be used to provide a secure attachment in the overlapping area of the packages.

The heating element may be embedded within the aerosol-forming substrate. The embedded heating element is an internal heating element. As used herein, the term "internal heating element" refers to a heating element configured to be inserted or disposed in an aerosol-forming substrate or a flavor substrate.

An aerosol-generating article comprising a heating element embedded within an aerosol-forming substrate may be advantageous in that an enhanced heat distribution from the heating element to the aerosol-forming substrate may be achieved when the aerosol-generating article is in use.

The heating element may be a susceptor.

As used herein, the term "susceptor" refers to an element comprising a material capable of converting magnetic energy into heat. The susceptor is heated when it is in a varying magnetic field, such as the varying magnetic field generated by an inductor coil.

Heating of the susceptor may be a result of hysteresis losses and/or eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material. In ferromagnetic or ferrimagnetic susceptor materials, hysteresis losses occur as a result of magnetic domains within the material being switched under the influence of a varying electromagnetic field. Eddy currents can be induced if the susceptor material is electrically conductive. In the case of conductive ferromagnetic or ferrimagnetic susceptor materials, heat may be generated due to both eddy currents and hysteresis losses. Thus, the susceptor may be heatable due to at least one of hysteresis loss or eddy currents, depending on the electrical and magnetic properties of the susceptor material.

The heating element may be entirely surrounded by the aerosol-forming substrate and extend along the entire length of the aerosol-forming substrate. This may provide an optimized heat distribution within the aerosol-forming substrate when the heating element is heated.

The susceptor may have a thickness of about 35 microns to about 85 microns. The susceptor may have a thickness of about 45 microns to about 75 microns. The susceptor may have a thickness of about 55 microns to about 65 microns.

It has been found that in aerosol-generating articles in which a susceptor having a thickness as described above is provided, the generation and distribution of heat throughout the aerosol-forming substrate can be achieved in a particularly effective and efficient manner. Without wishing to be bound by theory, the inventors believe that this is possible because such susceptors are adapted to provide optimal heat generation and heat transfer by means of susceptor surface area and inductive power. In contrast, thinner susceptors may be too easily deformed and may not be able to maintain a desired shape and orientation within the aerosol-forming substrate during manufacture of the aerosol-generating article, which may result in a less uniform and less finely tuned heat distribution during use. At the same time, thicker susceptors may be more difficult to cut to length in an accurate and consistent manner, and this may also affect how the susceptors may be accurately arranged in longitudinal alignment within the aerosol-forming substrate, thus also potentially affecting the uniformity of the heat distribution within the aerosol-forming substrate. These advantageous effects are particularly felt when the susceptor extends all the way to the downstream end of the aerosol-forming substrate. This is believed to be because the resistance to suction (RTD) downstream of the susceptor may thus be substantially minimized, since there is no aerosol-forming substrate within the aerosol-forming substrate at a location downstream of the susceptor that may contribute to the RTD.

The susceptor may be an elongated susceptor arranged substantially longitudinally within the aerosol-forming substrate.

When used to describe a susceptor, the term "elongated" means that the susceptor has a length dimension that is greater than its width dimension or its thickness dimension, for example greater than twice its width dimension or its thickness dimension.

The susceptor may be arranged substantially longitudinally within the aerosol-forming substrate. This means that the length dimension of the elongated susceptor is arranged approximately parallel to the longitudinal direction of the aerosol-forming substrate, for example within plus or minus 10 degrees of parallel to the longitudinal direction of the aerosol-forming substrate. The elongate susceptor may be located at a radially central position within the aerosol-forming substrate and extend along a longitudinal axis of the aerosol-forming substrate.

The susceptor may have substantially the same length as the aerosol-forming substrate.

The susceptor may be in the form of a needle, strip, tape or sheet.

The susceptor may have a length of about 5 mm to about 15 mm, for example about 6 mm to about 12 mm, more preferably about 8 mm to about 10 mm.

The susceptor may have a width of at least about 1 millimeter, more preferably at least about 2 millimeters. Typically, the susceptor may have a width of up to 8 mm, preferably less than or equal to about 6 mm.

When the susceptor has a constant cross-section, such as a circular cross-section, it may have a width or diameter of about 1 millimeter to about 5 millimeters.

When the susceptor has the form of a belt or sheet, the belt or sheet may have a rectangular cross-section with a width of preferably about 2 mm to about 8mm, more preferably about 3mm to about 6 mm. The susceptor in the form of a belt or sheet may have a width of about 4 mm.

The elongate susceptor may have a thickness of about 57 microns to about 63 microns. More preferably, the elongate susceptor may have a thickness of about 58 microns to about 62 microns. Most preferably, the elongate susceptor has a thickness of about 60 microns.

The aerosol-generating article may have a diameter of between about 3mm and about 8 mm.

The wrapper may have a thickness of between about 60 microns and about 200 microns, preferably between about 78 microns and about 160 microns, more preferably between 78 microns and about 140 microns, more preferably between about 100 microns and about 140 microns, most preferably between about 125 microns and about 140 microns.

A wrapper thickness in this range may result in a suitable balance between the total thickness of the overlap region and the thickness of the remainder of the wrapper.

The aerosol-forming substrate may comprise one or more of the following: tobacco, nicotine, gel components and flavoring agents.

Advantageously, the gel component may be solid at room temperature. By "solid" in this context is meant that the gel has a stable size and shape and does not flow. Room temperature in this context means 25 degrees celsius. A gel may be defined as a substantially dilute crosslinked system that does not exhibit fluidity at steady state. Gels may be predominantly liquid by weight, but they behave like solids due to the three-dimensional cross-linked network within the liquid. It is the crosslinking within the fluid that gives the gel its structure (hardness). Thus, a gel may be a dispersion of liquid molecules within a solid, wherein liquid particles are dispersed in a solid medium.

The aerosol-generating article may comprise a filter arranged downstream of the aerosol-forming substrate in the longitudinal direction.

The term "filter" is used to indicate a section of an aerosol-generating article configured to at least partially remove a gas phase or a particulate phase component or both gas and particulate phase components from a mainstream aerosol drawn through the filter.

The length of the aerosol-generating article may be between about 30mm and about 100 mm.

The aerosol-generating article may comprise a support element disposed downstream of the aerosol-forming substrate.

The support element is typically provided in the form of an annular tube of filter material, commonly referred to as a hollow acetate tube. Such hollow tubular support elements are configured to resist downstream movement of the aerosol-forming substrate during processing of the aerosol-generating article, for example during insertion of the heating element into the aerosol-forming substrate. The empty space within the hollow tubular support element may provide an opening for the flow of aerosol from the aerosol-forming substrate towards the mouth end of the aerosol-generating article.

The support element may be disposed immediately downstream of the aerosol-forming substrate.

When the aerosol-generating article comprises a filter and a support element, the filter may be arranged downstream of the support element in the longitudinal direction.

The filter may be arranged immediately downstream of the support element in the longitudinal direction.

Since the support element may be useful and sufficient for providing customization of the formed aerosol according to user preferences, the filter may be arranged immediately downstream of the support element, i.e. without intermediate components such as an aerosol cooling element. Thus, the aerosol-generating article may achieve a reduction in gas and particulate phase components while requiring fewer production steps and allowing for a more consistent experience.

However, the aerosol-generating article may comprise an aerosol-cooling element downstream of the support element. Preferably, the aerosol-cooling element may be disposed between the support element and the filter.

As used herein, an "aerosol-cooling element" refers to a component of an aerosol-generating article that is positioned downstream of an aerosol-forming substrate such that, in use, an aerosol formed from volatile compounds released from the aerosol-forming substrate passes through and is cooled by the aerosol-cooling element prior to inhalation by a consumer. Preferably, the aerosol-cooling element is positioned between the aerosol-forming substrate and the mouthpiece. The aerosol-cooling element has a large surface area but causes a low pressure drop. Filters and other high pressure drop generating mouthpieces (e.g., filters formed from fiber bundles) are not considered aerosol-cooling elements. The chambers and cavities within the aerosol-generating article are also considered to be not aerosol-cooling elements.

The support element may comprise a first hollow tubular section. The aerosol-cooling element may comprise a second hollow tubular section.

The aerosol-generating article may comprise a mouthpiece disposed on the downstream end of the aerosol-generating article. It may be desirable to provide a mouthpiece to facilitate inhalation of the aerosol by the user.

The aerosol-generating article may comprise an upstream element arranged on an upstream end of the aerosol-generating article. When the aerosol-generating article comprises a susceptor, this may ensure that the consumer cannot accidentally touch the heated susceptor after use. When the aerosol-generating article comprises a susceptor, the provision of the upstream element may advantageously prevent the susceptor from being displaced.

The aerosol-forming substrate may have any suitable cross-section. For example, the substrate may have a circular, oval, stadium-shaped, rectangular, or triangular cross-sectional shape. Preferably, the matrix has a circular cross-sectional shape.

The solid aerosol-forming substrate may comprise a tobacco rod. The tobacco rod may include, for example, one or more of the following: a powder, granule, pellet, chip, strand, ribbon or sheet comprising one or more of the following: herb leaves, tobacco ribs, expanded tobacco and homogenized tobacco. As used herein, the term "homogenized tobacco material" refers to a material formed by agglomerating particulate tobacco. Providing homogenized tobacco material may improve aerosol generation, nicotine content, and flavor profile of an aerosol generated during heating of an aerosol-generating article. In particular, the process of making homogenized tobacco involves grinding tobacco leaves, which more effectively achieve release of nicotine and flavor upon heating. Where the tobacco rod comprises homogenized tobacco material, the homogenized tobacco material may be in the form of a sheet. As used herein, the term "sheet" refers to a layered element having a width and a length that is substantially greater than its thickness.

The solid aerosol-forming substrate may comprise homogenized tobacco material. The solid aerosol-forming material may comprise a chip, strand or ribbon of homogenized tobacco material. The solid aerosol-forming substrate may comprise a sheet of homogenized tobacco material.

The aerosol-forming substrate may have a substantially homogeneous composition. The aerosol-forming substrate may have a substantially homogeneous composition at least in the longitudinal direction.

The sheet of homogenized tobacco material may be formed by agglomerating particulate tobacco obtained by grinding or otherwise pulverizing one or both of tobacco lamina and tobacco leaf stems. The sheet of homogenized tobacco material may comprise one or more of the following: tobacco dust, tobacco fines, and other particulate tobacco by-products formed during, for example, handling, processing, and shipping of tobacco. The sheet of homogenized tobacco material is preferably formed by a casting process of the type generally comprising: casting a slurry comprising particulate tobacco and one or more binders onto a conveyor belt or other support surface; drying the cast slurry to form a sheet of homogenized tobacco material; and removing the sheet of homogenized tobacco material from the support surface.

The solid aerosol-forming substrate may comprise an agglomerated sheet of homogenized tobacco material. As used herein, the term "gathered" is used to describe the sheet material being wrapped, folded or otherwise compressed or contracted substantially transverse to the longitudinal axis of the aerosol-generating article.

The aerosol-forming substrate comprises an agglomerated textured sheet of homogenized tobacco material. As used herein, the term "textured sheet" refers to a sheet that has been curled, embossed, gravure, perforated, or otherwise deformed. The use of a textured sheet of homogenized tobacco material may advantageously facilitate aggregation of the sheet of homogenized tobacco material to form an aerosol-forming substrate. The aerosol-forming substrate may comprise an agglomerated textured sheet of homogenized tobacco material comprising a plurality of spaced apart indentations, protrusions, perforations, or a combination thereof.

Preferably, the aerosol-forming substrate comprises an aggregated crimped sheet of homogenized tobacco material. As used herein, the term "curled sheet" means a sheet having a plurality of substantially parallel ridges or corrugations. Preferably, the substantially parallel ridges or corrugations extend along or parallel to the longitudinal axis of the aerosol-generating article. This advantageously facilitates aggregation of the crimped sheet of homogenized tobacco material to form an aerosol-generating article. However, it will be appreciated that the crimped sheet of homogenized tobacco material for inclusion in an aerosol-generating article may have a plurality of substantially parallel ridges or corrugations that are disposed at acute or obtuse angles relative to the longitudinal axis of the aerosol-generating article.

The aerosol-forming substrate may comprise tobacco-containing material and tobacco-free material.

The aerosol-forming substrate may comprise an aerosol-former. The aerosol-forming substrate may comprise a single aerosol-former or a combination of two or more aerosol-formers. As used herein, the term "aerosol-former" is used to describe any suitable known compound or mixture of compounds that facilitate the formation of an aerosol in use and that are substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article. Suitable aerosol formers include, but are not limited to: polyols such as propylene glycol, triethylene glycol, 1, 3-butanediol, and glycerol; esters of polyols, such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Preferred aerosol formers are polyols or mixtures thereof such as propylene glycol, triethylene glycol, 1, 3-butanediol and most preferably glycerol. The aerosol-forming substrate may have an aerosol former content of greater than 5% by dry weight. The gel aerosol-forming substrate may have an aerosol former content of between about 5% and about 30% on a dry weight basis. The aerosol-forming substrate may have an aerosol former content of about 20% on a dry weight basis.

The aerosol-forming substrate may comprise homogenized tobacco material, an aerosol-forming agent, and water.

The homogenized tobacco material may be provided in a sheet that is one of folded, rolled or cut into strips. The sheet may be cut into strips having a width of between about 0.2 millimeters and about 2 millimeters, more preferably between about 0.4 millimeters and about 1.2 millimeters. The width of the strip may be about 0.9 mm.

The aerosol-forming substrate may comprise an inner cavity. In other words, the aerosol-forming substrate may be a tubular substrate. The aerosol-forming substrate may comprise a substrate inner surface having a substrate inner diameter defining a lumen extending in a longitudinal direction within the aerosol-forming substrate. Providing the lumen into the aerosol-forming substrate may enable the heating element to be inserted into the aerosol-forming substrate in the lumen without penetrating the substrate and without changing the structure of the substrate. The provision of the inner cavity may also be beneficial in further reducing the thickness of the aerosol-forming substrate, thereby enhancing the heat transfer advantages explained above.

When the aerosol-forming substrate comprises a substrate inner surface defining a lumen, the substrate inner surface may have the same cross-sectional shape as the substrate outer surface. In particular, the inner surface of the matrix may have a substantially circular, oval or stadium-shaped cross-section.

The aerosol-generating article may comprise a layer of thermally conductive material. The layer of thermally conductive material may cover at least a portion of at least the otherwise exposed aerosol-forming substrate. The layer of thermally conductive material may be disposed at least on the outer surface of the substrate. The layer of thermally conductive material may be disposed at least on the inner surface of the substrate. The layer of thermally conductive material may be disposed at least on the inner surface of the substrate and on the outer surface of the substrate. Providing a layer of thermally conductive material on the otherwise exposed substrate surface may allow heat from the heating element received by or engaged with the substrate to be distributed over a wider area of the aerosol-forming substrate, thereby improving the heat transfer efficiency between the heating element and the aerosol-forming substrate. The layer of thermally conductive material may also create a physical separation between the heating element received in the inner cavity and the aerosol-forming substrate, which may reduce the risk of overheating of the aerosol-forming substrate in the region of the substrate proximate to the heating element. The layer of thermally conductive material may also increase the robustness of the tubular aerosol-forming substrate, which may be reduced by providing an internal cavity to reduce the thickness of the substrate.

As used herein, "thermally conductive" means that the material has a thermal conductivity of at least 10W/m.k, preferably at least 40W/m.k, more preferably at least 100W/m.k at 23 degrees celsius and 50% relative humidity. Preferably, the layer of thermally conductive material may comprise a material having a thermal conductivity of at least 40W/m.k, preferably at least 100W/m.k, more preferably at least 150W/m.k, and even more preferably at least 200W/m.k at 23 degrees celsius and 50% relative humidity.

Examples of suitable conductive materials include, but are not limited to, aluminum, copper, zinc, nickel, silver, and combinations thereof.

The aerosol-forming substrate may have a strip comprising a plurality of elongate tubular elements. The elongate tubular member may comprise tobacco material. The plurality of elongated tubular elements comprised in the aerosol-forming substrate is never wrong for tubular elements arranged downstream of the aerosol-forming substrate.

By adjusting the number, equivalent diameter and thickness of the elongated tubular elements in the strip, it is possible to advantageously adjust the density and porosity of the strip. Generally, aerosol-forming substrates comprising a plurality of elongate tubular elements of homogenized tobacco may advantageously exhibit a more uniform density compared to aerosol-forming substrates comprising fragments of tobacco material. The geometry of the elongate tubular member may be such as to provide a particularly stable passage for airflow along the strip. This may advantageously allow for consistent fine tuning of the RTD such that an aerosol-forming substrate having a predetermined RTD may be consistently and highly accurately manufactured.

The weight of the aerosol-forming substrate comprising the elongate tubular elements of homogenized tobacco may be determined by the number, size, density and spacing of the tubular elements. This may reduce weight inconsistencies between aerosol-forming substrates of the same size and thus lower the rejection rate of aerosol-forming substrates having a weight falling outside the selected accepted range as compared to aerosol-forming substrates comprising fragments of tobacco material.

The variation in thickness of the elongate tubular member in the rod can also be advantageously used to adjust the content of homogenized tobacco in the rod. For example, in an elongated tubular element formed from a rolled strip of homogenized tobacco web, the adjustment of the thickness of the elongated tubular element may be achieved by varying the number of windings of the strip around the longitudinal axis or by varying the thickness of the homogenized tobacco web itself. This may give the aerosol-generating article greater design flexibility than an aerosol-generating article comprising fragments of tobacco material.

The size, geometry and arrangement of the elongate tubular elements in the strip may be easily adapted to facilitate insertion of the heating element into the strip of aerosol-generating article. Because the elongate tubular member is located substantially straight within the strip and extends longitudinally, insertion of a longitudinally extending internal heating element, such as a heater chip, may be facilitated. The regular arrangement of the elongated tubular elements in the strip may also advantageously facilitate optimizing the heat transfer from the heating element through the strip.

Inserting (and removing) the heater of the aerosol-generating device into the aerosol-forming substrate comprising the tobacco material fragments may tend to dislodge the tobacco material fragments from the aerosol-forming substrate. This may require more frequent cleaning of the heater element and other parts of the aerosol-generating device in order to remove dislodged debris. In contrast, inserting and removing a heater of an aerosol-generating device into an aerosol-forming substrate comprising a plurality of elongate tubular elements of homogenized tobacco material may advantageously have a significantly reduced tendency to remove material therefrom.

The strip comprising a plurality of elongate tubular elements may be manufactured in a continuous process which may be carried out at high speed and with high efficiency and which may be conveniently incorporated into existing production lines for manufacturing aerosol-generating articles.

The strips of aerosol-forming substrate may preferably have an outer diameter approximately equal to the outer diameter of the aerosol-generating article.

The strips of aerosol-forming substrate may have an outer diameter of at least 5 mm. The strips of aerosol-forming substrate may have an outer diameter of between about 5 mm and about 12 mm, for example between about 5 mm and about 10 mm or between about 6 mm and about 8 mm. Preferably, the strips of aerosol-forming substrate may have an outer diameter of within 7.2 mm to 10%.

The strips of aerosol-forming substrate may have a length of between about 5 millimeters and about 100 mm. Preferably, the strips of aerosol-generating substrate may have a length of at least about 5 mm, more preferably at least about 7 mm. The strips of aerosol-generating substrate may preferably have a length of less than about 80 mm, more preferably less than about 65 mm, even more preferably less than about 50 mm. Preferably, the strips of aerosol-generating substrate may have a length of less than about 35 mm, more preferably less than 25 mm, even more preferably less than about 20 mm. The strips of aerosol-forming substrate may have a length of about 10 mm; the strips of aerosol-forming substrate may have a length of about 12 mm.

The strip of aerosol-forming substrate may have a substantially uniform cross-section along the length of the strip. The strips of aerosol-forming substrate may preferably have a substantially circular cross-section.

The strip comprising the elongate tubular member may be defined by a wrapper. The elongate tubular member may be assembled such that the elongate tubular member extends in a longitudinal direction.

The plurality of elongated tubular elements of the rod of aerosol-generating articles according to the invention may be formed from a homogenized tobacco material, which may comprise particulate tobacco obtained by grinding. The plurality of elongate tubular members may all have substantially the same composition as one another. Likewise, the plurality of elongate tubular members may comprise tubular members of at least two different compositions.

The at least one elongate tubular element in the strip may comprise a rolled strip cut from a sheet or web of homogenized tobacco material.

The sheet or web of homogenized tobacco material may have a tobacco content of at least about 40 weight percent, based on dry weight, more preferably at least about 60 weight percent, based on dry weight, more preferably at least about 70 weight percent, based on dry weight, and most preferably at least about 90 weight percent, based on dry weight.

The sheet or web of homogenized tobacco material for use in an aerosol-forming substrate may comprise one or more intrinsic binders (i.e., tobacco endogenous binders), one or more extrinsic binders (i.e., tobacco exogenous binders), or a combination thereof, to aid in coalescing the particulate tobacco. The sheet of homogenized tobacco material for use in an aerosol-forming substrate may include other additives including, but not limited to, tobacco and non-tobacco fibers, aerosol-formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof.

Suitable extrinsic binders included in sheets or webs of homogenized tobacco material for use in aerosol-forming substrates are known in the art, including, but not limited to: gums such as, for example, guar gum, xanthan gum, acacia gum and locust bean gum; cellulosic binders such as, for example, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose; polysaccharides such as, for example, starch; organic acids such as alginic acid; conjugate base salts of organic acids such as sodium alginate, agar, and pectin; and combinations thereof.

Suitable non-tobacco fibers included in sheets or webs of homogenized tobacco material for use in aerosol-forming substrates are known in the art, including, but not limited to: cellulose fibers; cork fiber; a hardwood fiber; jute fibers and combinations thereof. The non-tobacco fibers may be treated by suitable processes known in the art prior to inclusion in the sheet of homogenized tobacco material for use in an aerosol-forming substrate, including, but not limited to: mechanical pulping; refining; chemical pulping; bleaching; pulping by sulfate; and combinations thereof.

The sheet or web of homogenized tobacco material may comprise an aerosol former.

The sheet or web of homogenized tobacco for use in the aerosol-generating article of the invention may be manufactured by methods known in the art, such as the method disclosed in international patent application WO-A-2012/164009A 2. A sheet of homogenized tobacco material for use in an aerosol-generating article may be formed from a slurry comprising particulate tobacco, guar gum, cellulose fibers, and glycerin by a casting process.

Likewise, an elongate tubular element of homogenized tobacco material for use in an aerosol-forming substrate according to the invention may be formed by extrusion. For example, a slurry comprising particulate tobacco obtained by grinding or otherwise pulverizing tobacco leaf lamina may be pushed through a die having a desired cross-section. Furthermore, additive manufacturing may also be used to manufacture tubular elements of homogenized tobacco material.

The elongate tubular member may have an equivalent diameter of about 0.03 mm to about 3 mm. Preferably, the elongate tubular member may have an equivalent diameter of at least about 0.1 mm. More preferably, the elongate tubular member may have an equivalent diameter of at least about 0.3 millimeters.

Likewise, the elongate tubular member may preferably have an equivalent diameter of less than about 2 millimeters. More preferably, the elongate tubular member may have an equivalent diameter of less than about 1 millimeter.

The elongate tubular member may have an equivalent diameter of about 0.7 millimeters to about 2.7 millimeters; the elongate tubular member may have an equivalent diameter of about 0.3 mm to about 1.1 mm.

In the case of forming an elongate tubular element by rolling up a strip of homogenised tobacco material, the strip may have a width of at least about 1 mm. Preferably, the strip of homogenized tobacco material may have a width of at least about 2 millimeters. More preferably, the strip of homogenized material may have a width of at least about 3 millimeters.

The strip of homogenized tobacco material may have a width of about 1 millimeter to about 3.5 millimeters; the rod of homogenized tobacco material may have a width of about 2.4 millimeters to about 8.2 millimeters.

Strips of homogenized tobacco material may be cut from a sheet or web having a thickness of at least about 40 microns, more preferably at least about 60 microns, more preferably at least about 80 microns, and most preferably at least about 100 microns. Likewise, strips of homogenized tobacco material may be cut from a sheet or web having a thickness of no more than about 5000 microns, more preferably no more than about 2000 microns, more preferably no more than about 1000 microns, and most preferably no more than about 500 microns. For example, the thickness of the sheet or web may be between about 40 microns and about 5000 microns, more preferably between about 60 microns and about 2000 microns, more preferably between about 80 microns and about 1000 microns, and most preferably between about 100 microns and about 500 microns.

The thickness of the elongate tubular member may be at least about 40 microns, more preferably at least about 80 microns, more preferably at least about 120 microns, and most preferably at least about 160 microns. Likewise, the thickness of the elongate tubular member may be less than about 5000 microns, more preferably less than about 2500 microns, and most preferably less than about 1000 microns.

The elongate tubular member may be formed of a porous tobacco material such that air flows through the wall of the tubular member; i.e. the air flow in the substantially radial direction in the strip is not hindered. In the case of an elongate tubular element formed by rolling up a strip of homogenised tobacco material, the strip itself may be formed of porous tobacco material.

As used herein with respect to homogenized tobacco material, the term "porous" may indicate that the tobacco material has been created within an inherent porosity such that sufficient pores or gaps are provided within the structure of the sheet or web such that air is able to flow through the sheet or web in a direction transverse to the sheet or web surface. Likewise, the term "porous" may indicate that each sheet or web of tobacco material includes a plurality of airflow apertures to provide the desired porosity. For example, a sheet of tobacco material may be pierced through the air flow hole pattern prior to performing a rolling operation of the elongate tubular member that produces the strip of aerosol-forming substrate. The air flow holes may be randomly or uniformly perforated in the sheet. The pattern of air flow holes may cover substantially the entire surface of the sheet, or may cover one or more specific areas of the sheet with the remaining areas being devoid of air flow holes.

The strip of homogenized tobacco material that may form the elongate tubular member may be textured. For example, the sheet or web from which the strips are cut may include a plurality of spaced apart indentations, protrusions, perforations, or a combination thereof. The texture may be provided on one side of each sheet or on both sides of each sheet.

The inclusion of one or more elongated tubular elements formed from a crimped ribbon may help to provide and maintain a spacing between adjacent tubular elements within the ribbon.

The additive may be applied to at least a portion of a surface of at least one of the plurality of tubular elements. The additive may be a solid additive, a liquid additive, or a combination of a solid additive and a liquid additive. Suitable solid and liquid additives for use in the present invention are known in the art and include, but are not limited to: fragrances such as, for example, menthol; adsorbents such as, for example, activated carbon; fillers such as, for example, calcium carbonate; and (3) a plant additive.

To form a substantially elongate tubular element, a strip of homogenized tobacco material may be wrapped at least about 345 degrees about a longitudinal axis. Preferably, the strip of homogenized tobacco material may be wrapped at least about 360 degrees about the longitudinal axis. More preferably, the strip of homogenized tobacco material may be wrapped at least about 540 degrees about the longitudinal axis. Likewise, the strip of homogenized tobacco material may preferably be wrapped less than about 1800 degrees around the longitudinal axis. More preferably, the strip of homogenized tobacco material may be wrapped less than about 900 degrees about the longitudinal axis. Preferably, the strip of homogenized tobacco material may be wrapped about a longitudinal axis between about 345 degrees and about 540 degrees.

Each elongate tubular member may have a length substantially equal to the length of the strip of aerosol-forming substrate. Each elongate tubular member may have a length of about 10 millimeters; each elongate tubular member may have a length of about 12 mm.

The rod of aerosol-forming substrate may comprise less than about 200 elongate tubular elements of homogenized tobacco material. More preferably, the strip of aerosol-forming substrate may comprise less than about 150 elongate tubular elements. Even more preferably, the strip of aerosol-forming substrate may comprise less than about 100 elongate tubular elements.

Likewise, the rod of aerosol-forming substrate may comprise at least about 15 elongate tubular elements of homogenized tobacco material. More preferably, the strip of aerosol-forming substrate may comprise at least about 30 elongate tubular elements. Even more preferably, the strip of aerosol-forming substrate may comprise at least about 40 elongate tubular elements. The rod of aerosol-forming substrate may comprise from about 15 to about 100 strands of non-tobacco material.

In the strip of aerosol-forming substrate, the elongate tubular elements may be aligned substantially parallel to each other.

The elongate tubular element of homogenised tobacco material may have a substantially oval cross-section; it may have a substantially elliptical cross-section; which may have a substantially circular cross-section. As described above, an elongate tubular element for use in an aerosol-generating article may be effectively formed by wrapping a strip of homogenized tobacco material around its longitudinal axis by slightly less than 360 degrees. This effectively results in an element having a C-shaped cross section with the slit extending longitudinally throughout the length of the elongate tubular element.

An aerosol-generating system may be provided. The aerosol-generating system may comprise any of the aerosol-generating articles and aerosol-generating devices disclosed above. The aerosol-generating device may comprise a heating element or a part of a heating element for heating the aerosol-generating article.

As used herein, the term "aerosol-generating system" refers to a combination of an aerosol-generating device and an aerosol-generating article.

Since the aerosol-generating system of the present disclosure comprises an aerosol-generating article according to the previous disclosure, the advantages specified above for the aerosol-generating article also apply to the system itself.

The heating element may be any suitable type of heating element. The heating element may be an internal heating element. The heating element may be an elongate heating element. The elongate heating element may be sheet-shaped. The elongate heating element may be needle-shaped. The elongate heating element may have a tapered shape or at least a tapered end. The elongate heating element may have a tip. The heating element may be conical. The elongate heating element may have any suitable shape arranged to facilitate insertion of the heating element into the aerosol-forming substrate. Advantageously, the elongate heating element may provide easier engagement or disengagement or both of the aerosol-generating article and the heating element of the device.

The heating element may be an external heating element. As used herein, the term "external heating element" refers to a heating element configured to heat the outer surface of an aerosol-forming substrate. The external heating element may at least partially define a cavity for receiving the aerosol-forming substrate.

The heating element may comprise at least one resistive heating element.

The at least one resistive heating element may comprise an electrically insulating substrate and one or more electrically conductive tracks on the electrically insulating substrate.

The electrically insulating matrix may be stable at the operating temperature of the at least one heating element. The electrically insulating matrix may be stable at temperatures up to about 400 degrees celsius, more preferably about 500 degrees celsius, more preferably about 600 degrees celsius, more preferably about 700 degrees celsius, most preferably about 800 degrees celsius.

The operating temperature of the at least one resistive heating element during use may be at least about 200 degrees celsius. The operating temperature of the at least one resistive heating element during use may be less than about 700 degrees celsius. The operating temperature of the at least one resistive heating element during use may be less than about 600 degrees celsius. The operating temperature of the at least one resistive heating element during use may be less than about 500 degrees celsius. The operating temperature of the at least one resistive heating element during use may be less than about 400 degrees celsius.

The electrically insulating matrix may comprise any suitable material. For example, the electrically insulating matrix may include one or more of the following: paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may include mica, alumina (Al ₂ O ₃ ) Or zirconia (ZrO ₂ ). The electrically insulating matrix may have a value less than or equal toA thermal conductivity of about 40 watts/meter-kelvin, preferably less than or equal to about 20 watts/meter-kelvin, and desirably less than or equal to about 2 watts/meter-kelvin.

Suitable materials for forming the resistive heating element and in particular the one or more conductive tracks may include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made of ceramic materials and metal materials. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-containing alloys, zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, and iron-containing alloys, and superalloys based on nickel, iron, cobalt, stainless steel, Iron-manganese-aluminum based alloys.

The resistive heating element may include one or more stamped portions of resistive material, such as stainless steel. The at least one resistive heating element may comprise a heating wire or filament, such as a Ni-Cr (nickel-chromium), platinum, tungsten or alloy wire.

The heating element may comprise at least one induction heating means.

The at least one induction heating means may comprise at least one inductor coil. The inductor coil is arranged to generate a varying magnetic field upon receiving a varying current from the power supply. Such varying current may be between about 5 kilohertz and about 500 kilohertz. The varying current may be a high frequency varying current. As used herein, the term "high frequency varying current" refers to a varying current having a frequency between about 500 kilohertz and about 30 megahertz. The high frequency varying current may have a frequency between about 1 megahertz and about 30 megahertz (such as between about 1 megahertz and about 10 megahertz, or such as between about 5 megahertz and about 8 megahertz). The varying current may be an alternating current that generates an alternating magnetic field.

The inductor coil may have any suitable form. For example, the inductor coil may be a flat inductor coil. The flat inductor coil may be wound in a spiral manner substantially in a plane. Preferably, the inductor coil may be a tubular inductor coil. Typically, the tubular inductor coil may be helically wound about the longitudinal axis. The inductor coil may be elongate. Particularly preferably, the inductor coil may be an elongated tubular inductor coil. The inductor coil may have any suitable cross-section. The inductor coil may have a circular, oval, square, rectangular, triangular or other polygonal cross-section.

The inductor coil may be formed of any suitable material. The inductor coil may be formed of a conductive material. Preferably, the inductor coil may be formed of a metal or metal alloy.

As used herein, "electrically conductive" means having less than or equal to 1x10 at twenty degrees celsius ^-4 Ohmic-meter (Ω -m) resistivity.

The at least one induction heating means may comprise at least one susceptor. As discussed above, susceptors may also be included in aerosol-generating articles.

The susceptor is arranged such that when the aerosol-generating article is received in the aerosol-generating device, the oscillating electromagnetic field generated by the inductor coil may induce an electric current in the susceptor, thereby causing the susceptor to heat up. Preferably, the aerosol-generating device may be capable of generating a fluctuating electromagnetic field having a magnetic field strength (H field strength) of between 1 kiloamp/meter and 5 kiloamps/meter (kA/m), preferably between 2kA/m and 3kA/m (e.g. about 2.5 kA/m). Preferably, the aerosol-generating device may be capable of generating a fluctuating electromagnetic field having a frequency between 1MHz and 30MHz, for example between 1MHz and 10MHz, for example between 5MHz and 7 MHz.

The susceptor may comprise any suitable material. The susceptor may be formed of any material capable of being inductively heated to a temperature sufficient to release volatile compounds from the aerosol-forming substrate or the flavour substrate. Preferred susceptors may be heated to a temperature in excess of about 250 degrees celsius. Preferred susceptors may be formed of an electrically conductive material. Suitable materials for the susceptor include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptors may comprise metal or carbon. Some preferred susceptors may include ferromagnetic materials, such as ferrite iron, ferromagnetic alloys (such as ferromagnetic steel or stainless steel), ferromagnetic particles, and ferrite. Some preferred susceptors may be composed of ferromagnetic materials. Suitable susceptors may include aluminum. Suitable susceptors may be composed of aluminum. The susceptor may comprise at least about 5%, at least about 20%, at least about 50%, or at least about 90% ferromagnetic or paramagnetic material.

The susceptor may be formed of a substantially gas impermeable material. In other words, preferably, the susceptor may be formed of a gas impermeable material.

The susceptor may have any suitable form. For example, the susceptor may be elongate. The susceptor may have any suitable cross-section. For example, the susceptor may have a circular, oval, square, rectangular, triangular, or other polygonal cross-section. The susceptor may be tubular.

The susceptor may include a susceptor layer disposed on a support. Placement of the susceptor in a varying magnetic field induces eddy currents in close proximity to the susceptor surface, an effect known as the skin effect. Thus, it is possible to form the susceptor from a relatively thin susceptor material layer while ensuring that the susceptor is effectively heated in the presence of a varying magnetic field. Manufacturing susceptors from a support and a relatively thin susceptor layer may facilitate the manufacture of simple, inexpensive, and robust aerosol-generating articles.

The support may be formed of a material that is not susceptible to induction heating. Advantageously, this may reduce heating of the surface of the susceptor not in contact with the aerosol-forming substrate, wherein the surface of the support forms the surface of the susceptor not in contact with the aerosol-forming substrate.

The support may comprise an electrically insulating material. As used herein, "electrically insulating" means having at least 1x10 at twenty degrees celsius ⁴ Ohmic-meter (Ω) resistivity.

Forming the support from a thermally insulating material may provide a thermally insulating barrier between the susceptor layer and other components of the induction heating apparatus, such as an inductor coil defining an induction heating element. Advantageously, this may reduce heat transfer between the susceptor and other components of the induction heating system.

The thermal insulation material may also have a volumetric thermal diffusivity of less than or equal to about 0.01 square centimeters per second (cm 2/s), as measured using a laser flash method. Providing a support with such thermal diffusivity may result in a support with high thermal inertia, which may reduce heat transfer between the susceptor layer and the support, and reduce temperature variations of the support.

The susceptor may be provided with a protective outer layer, such as a protective ceramic layer or a protective glass layer. The protective outer layer may improve the durability of the susceptor and facilitate cleaning of the susceptor. The protective outer layer may substantially surround the susceptor. The susceptor may include a protective coating formed of glass, ceramic, or an inert metal.

When the susceptor is comprised in an aerosol-generating device, the susceptor may be located in a device cavity. The susceptor may extend into the device cavity in a longitudinal direction of the device cavity. The susceptor may be elongate. The elongate susceptor may be sheet-shaped. The elongate susceptor may be needle-shaped. The elongate susceptor may have a tapered shape or at least a tapered end. The elongate susceptor may have a tip. The elongate element may be conical.

When the susceptor is comprised in an aerosol-generating device, the susceptor may be an internal heating element configured to be at least partially inserted into an aerosol-forming substrate of the aerosol-generating article when the aerosol-generating article is received in the device cavity. Where the aerosol-forming substrate comprises an inner cavity, the susceptor may be configured to be at least partially inserted into the inner cavity of the aerosol-forming substrate when the aerosol-generating article is received in the device cavity.

The aerosol-generating device may comprise a power supply. The power source may be a DC voltage source. The power source may be a battery. For example, the power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, or a lithium polymer battery. The power source may be another form of charge storage device, such as a capacitor. The power supply may need to be recharged and may have a capacity that allows storing sufficient energy for use of the aerosol-generating device.

A power supply may be electrically connected to the heater for supplying power to heating elements such as the substrate heating element and downstream heating elements. The heating element may generate heat when the heating element receives power from a power source. The power source may be configured to supply sufficient power to the heating element to heat the aerosol-forming substrate to a temperature at which volatile compounds are released from the aerosol-forming substrate.

The aerosol-generating device may comprise a housing. The housing may at least partially define a cavity for receiving the aerosol-generating article.

The aerosol-generating device may comprise at least one device air inlet in fluid communication with the cavity. When the aerosol-generating device comprises a housing, the housing may at least partially define at least one device air inlet. It may be desirable for the device air inlet to enable ambient air to be drawn into the upstream end of the aerosol-forming substrate.

The aerosol-generating device may comprise a controller. The controller may be configured to control the supply of electrical power from the power source to the heating element. The controller may be any suitable controller. The controller may include any suitable circuitry and electrical components. The controller may include a processor and a memory. The controller may comprise a microprocessor, which may be a programmable microprocessor.

The aerosol-generating device may comprise a sensor to detect an airflow indicative of the user taking a puff. The airflow sensor may be an electromechanical device. The air flow sensor may be any one of the following: mechanical devices, optical devices, electro-mechanical devices, and microelectromechanical system (MEMS) based sensors. The aerosol-generating device may comprise a manually operable switch for a user to initiate the inhalation.

The aerosol-generating device may comprise an indicator for indicating when the at least one heating element is activated. The indicator may comprise a light that is activated when the at least one heating element is activated.

The aerosol-generating device may comprise at least one electrical connector. The at least one electrical connector may be configured to charge a power source. At least one electrical connector may be configured to connect to another electrical device. The at least one electrical connector may comprise an external plug or socket comprising at least one external electrical contact allowing the aerosol-generating device to be connected to another electrical device. For example, the aerosol-generating device may comprise a USB plug or a USB socket to allow the aerosol-generating device to be connected to another USB-enabled device. For example, a USB plug or socket may allow the aerosol-generating device to be connected to a USB charging device, thereby charging a rechargeable power source within the aerosol-generating device. The USB plug or socket may support data transmission to or from the aerosol-generating device, or both to and from the aerosol-generating device. Also, the aerosol-generating device may be connected to a computer to transmit data to the device, such as a new heating profile for a new aerosol-generating article.

When the aerosol-generating device comprises a USB plug or socket, the aerosol-generating device may further comprise a removable cover covering the USB plug or socket when not in use. When the USB plug or socket is a USB plug, the USB plug may be selectively retracted into the device.

The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of the features of these examples may be combined with any one or more features of another example, embodiment, or disclosure described herein.

Ex1 an aerosol-generating article comprising:

an aerosol-forming substrate; and

a package defining the aerosol-forming substrate;

An aerosol-generating article according to claim Ex2, wherein an internal adhesive is provided between the folded section and the first section.

Ex3 the aerosol-generating article according to any one of Ex1 to Ex2, wherein an external adhesive is disposed between the folded section and the second section.

The aerosol-generating article of any one of E2 to Ex3, wherein the binder comprises one or more of: gum arabic, natural or synthetic resins, starches and varnishes.

Ex5 the aerosol-generating article according to any one of Ex1 to Ex4, further comprising a heating element embedded within the aerosol-forming substrate.

Ex6 an aerosol-generating article according to Ex5, wherein the heating element is a susceptor.

An aerosol-generating article according to any of Ex5 to Ex6, wherein the heating element is fully surrounded by the aerosol-forming substrate and extends along the entire length of the aerosol-forming substrate.

Ex8 the aerosol-generating article according to any of Ex1 to Ex7, wherein the aerosol-generating article has a diameter of between about 3mm and about 8 mm.

The aerosol-generating article according to any one of Ex1 to Ex8, wherein the wrapper has a thickness of between about 60 microns and about 200 microns, preferably between about 78 microns and about 160 microns, more preferably between 78 microns and about 140 microns, more preferably between about 100 microns and about 140 microns, most preferably between about 125 microns and about 140 microns.

Ex10 the aerosol-generating article according to any one of Ex1 to Ex9, wherein the aerosol-forming substrate comprises one or more of tobacco, nicotine, a gel component and a flavour substrate.

Ex11 the aerosol-generating article according to any one of Ex1 to Ex10, wherein the wrapper has a basis weight of between about 10 and 28 grams per square meter, preferably between about 10 and 16 grams per square meter.

An aerosol-generating article according to any one of Ex1 to Ex11, wherein the wrapper has a porosity of between about 30 and about 80 Coresta units, preferably between about 30 and about 50 Coresta units, most preferably between 30 and 40 Coresta units.

The aerosol-generating article according to any one of Ex1 to Ex12, wherein the wrapper has a roughness of between about 50Bekk seconds and about 1000Bekk seconds, more preferably between about 100Bekk seconds and about 200Bekk seconds.

Ex14 the aerosol-generating article according to any of Ex1 to Ex13, further comprising a filter disposed downstream of the aerosol-forming substrate.

Ex15 the aerosol-generating article according to any of Ex1 to Ex14, further comprising a support element disposed downstream of the aerosol-forming substrate.

Ex16 the aerosol-generating article according to Ex15, wherein the support element comprises a first hollow tubular section.

An aerosol-generating article according to any one of Ex15 to Ex16, wherein the support element is arranged immediately downstream of the aerosol-forming substrate in the longitudinal direction.

An aerosol-generating article according to any one of Ex15 to Ex17 when dependent on Ex14, wherein the filter is arranged immediately downstream of the support element in the longitudinal direction.

The aerosol-generating article according to any one of Ex15 to Ex18, further comprising an aerosol-cooling element arranged downstream of the support element in the longitudinal direction.

Ex20 the aerosol-generating article of Ex19, wherein the aerosol-cooling element comprises a second hollow tubular section.

Ex21 an aerosol-generating article according to any one of Ex19 to Ex20 when dependent on Ex14, wherein the aerosol-cooling element is disposed between the support element and the filter.

An aerosol-generating article according to any of Ex1 to Ex21, further comprising a mouthpiece disposed on the downstream end of the aerosol-generating article.

Ex23 the aerosol-generating article according to any one of Ex1 to Ex22, further comprising an upstream element disposed on an upstream end of the aerosol-generating article.

Ex24 the aerosol-generating article according to any one of Ex1 to Ex23, wherein the aerosol-forming substrate comprises a liquid component.

An aerosol-generating article according to any one of Ex1 to Ex24, wherein the aerosol-forming substrate comprises a solid component.

Ex26 the aerosol-generating article according to any of Ex1 to Ex25, wherein the aerosol-forming substrate comprises a plant-based material, preferably comprises a homogenized plant-based material.

The aerosol-generating article of any one of Ex1 to Ex26, wherein the aerosol-forming substrate comprises a non-tobacco material.

Ex28 the aerosol-generating article according to any one of Ex1 to Ex27, wherein the aerosol-forming substrate comprises a solid homogenized tobacco material.

Ex29 an aerosol-generating article according to Ex29, wherein the aerosol-forming substrate comprises at least one gathered sheet of solid homogenized tobacco material.

Ex30 the aerosol-generating article of Ex29, wherein the at least one aggregated sheet comprises a textured sheet, a curled sheet, or both.

An aerosol-generating article according to any one of Ex28 to Ex30, wherein the solid homogenized tobacco material comprises a strip of tobacco material.

An aerosol-generating article according to any one of Ex25 to Ex31 when dependent on Ex25, wherein the aerosol-forming substrate has a strip comprising a plurality of elongate tubular elements.

Ex33 an aerosol-generating article according to Ex32 when dependent on Ex28, wherein the plurality of elongate tubular elements comprises a solid homogenized tobacco material.

Ex34 an aerosol-generating article according to Ex33, wherein the at least one elongate tubular material comprises a rolled strip cut from a sheet or web of solid homogenized tobacco material.

The aerosol-generating article according to any one of Ex1 to Ex34, wherein the aerosol-forming substrate is a hollow tubular substrate defining an inner cavity.

Ex36 the aerosol-generating article according to any of Ex1 to Ex35, further comprising a layer of thermally conductive material.

The aerosol-generating article of any one of Ex1 to Ex36, wherein the aerosol-forming substrate comprises an aerosol-former.

Ex38 an aerosol-generating device comprising a heating element or a portion of a heating element.

Ex39 an aerosol-generating device according to Ex38, wherein the heating element comprises at least one resistive heating element.

Ex40 the aerosol-generating device of Ex39, wherein the at least one resistive heating element comprises an electrically insulating substrate and one or more electrically conductive tracks on the electrically insulating substrate.

An aerosol-generating device according to any of Ex38 to Ex40, wherein the heating element comprises at least one induction heating device, each induction device comprising at least one inductor coil and optionally at least one susceptor.

Ex42 the aerosol-generating device according to Ex41, wherein the at least one inductor coil is arranged to generate a varying magnetic field upon receiving a varying current from a power supply, the varying current being between about 5 kilohertz and about 500 kilohertz.

Ex43 the aerosol-generating device according to Ex41, wherein the at least one inductor coil is arranged to generate a varying magnetic field upon receiving a varying current from a power supply, the varying current being between about 500 kilohertz and about 5 megahertz.

Ex44 an aerosol-generating device according to any of Ex41 to Ex43, wherein the at least one inductor coil is a flat inductor coil, such as a flat inductor coil wound in a spiral manner substantially in a plane.

Ex45 an aerosol-generating device according to any of Ex41 to Ex43, wherein the at least one inductor coil is a tubular inductor coil, such as a tubular inductor coil helically wound about a longitudinal axis.

Ex46 the aerosol-generating device according to any of Ex41 to Ex45, wherein the at least one inductor coil is formed from an electrically conductive material.

Ex47 the aerosol-generating device according to any one of Ex41 to Ex46 when dependent on Ex6 or when the aerosol-generating device comprises at least one susceptor, wherein the at least one susceptor is formed of an electrically conductive material.

Ex48 an aerosol-generating device according to any of Ex41 to Ex47 when dependent on Ex6 or when the aerosol-generating device comprises at least one susceptor, wherein the at least one susceptor comprises a susceptor layer arranged on a support, the support preferably comprising a thermally insulating material.

Ex49 an aerosol-generating device according to any of Ex39 to Ex48, wherein the heating element comprises at least one resistive heating element and at least one inductive heating device.

An aerosol-generating device according to any of Ex38 to Ex49, wherein the heating element comprises an internal heating element.

Ex51 an aerosol-generating device according to any of Ex38 to Ex50, wherein the heating element comprises an external heating element.

Ex52 the aerosol-generating device according to any of Ex38 to Ex51, further comprising a power supply.

Ex53 an aerosol-generating device according to Ex52, wherein the power supply is electrically connected to the heating element.

The aerosol-generating device according to any of Ex38 to Ex53, further comprising a cavity for receiving the aerosol-generating article.

Ex55 the aerosol-generating device according to any of Ex38 to Ex54, further comprising a device housing.

Ex56 an aerosol-generating device according to Ex54 and Ex55, wherein the device housing at least partially defines the cavity for receiving the aerosol-generating article.

Ex57 the aerosol-generating device according to any of Ex38 to Ex56, further comprising at least one device air inlet.

Ex58 an aerosol-generating device according to Ex57 when dependent on Ex55, wherein the device housing comprises the at least one device air inlet.

Ex59 the aerosol-generating article of any one of Ex38 to Ex58, further comprising a controller.

The aerosol-generating article of any of Ex38 to Ex59, further comprising a sensor configured to detect an airflow indicative of user inhalation.

The aerosol-generating article of any one of Ex38 to Ex60, further comprising at least one electrical connector.

Ex62 the aerosol-generating article according to Ex61, wherein the at least one electrical connector comprises an external plug or socket, such as a USB plug or socket.

Ex63 an aerosol-generating system comprising an aerosol-generating article according to any of Ex1 to Ex37 and an aerosol-generating device according to any of Ex38 to Ex62.

Drawings

These and other features and advantages of the invention will become more apparent from the following detailed description of a preferred embodiment, given by way of illustrative and non-limiting example only, with reference to the accompanying drawings:

figure 1 depicts a longitudinal section of an aerosol-generating article comprising an embedded susceptor and a wrapper.

Fig. 2a shows a cross-section of the aerosol-generating article of fig. 1.

Fig. 2b shows a cross-section of the overlap region defined by the wrapper of the aerosol-generating article encircled in fig. 2 a.

Fig. 3 shows a longitudinal section of an aerosol-generating article comprising a tubular element and a filter.

Fig. 4 shows a longitudinal section of an aerosol-generating article comprising an upstream element and an aerosol-cooling element.

Fig. 5 shows a longitudinal section of an aerosol-generating system comprising an aerosol-generating device and any of the aerosol-generating articles of fig. 1 to 4.

Fig. 6 depicts an external view of the aerosol-generating system of fig. 5.

Detailed Description

Fig. 1 depicts a longitudinal section of an aerosol-generating article 10 having an upstream end 13 and a downstream end 14, the aerosol-generating article 10 defining a longitudinal direction between the upstream end 13 and the downstream end 14. The article 10 comprises an aerosol-forming substrate 11 and a wrapper 30 defining the aerosol-forming substrate 11.

In the embodiment of fig. 1, the heating element 40 is embedded within the aerosol-forming substrate 11. The heating element 40 is a susceptor 40. The susceptor 40 extends along the entire length of the aerosol-forming substrate 11.

Fig. 2a shows a cross-section of the aerosol-generating article 10 of fig. 1. This figure shows that the wrapper 30 defines an overlap region 41 in which the wrapper 30 overlaps itself. The overlap region 41 comprises a first section 42 and a second section 43, which is arranged externally on the first section 42. The second section 43 comprises a fold 44 (or pleat) defining a folded section 45 at one end of the wrapper 40. The folded section 45 is sandwiched between the first section 42 and the second section 43.

An internal adhesive 50 is disposed between the folded section 45 and the first section 42. An external adhesive 51 is disposed between the folded section 45 and the second section 43.

The overlapping area of fig. 2a is shown in more detail in fig. 2b for clarity.

Fig. 3 shows an aerosol-generating article, similar to the aerosol-generating article of fig. 1 and 2, comprising an aerosol-forming substrate 11 and a wrapper 30. The aerosol-generating article 10 further comprises a support element 12 arranged immediately downstream of the aerosol-forming substrate 11. The support element 12 defines an opening extending in a longitudinal direction and adapted for the flow of the matrix aerosol towards the downstream end 14. In other words, the support element 12 comprises a hollow tubular section. In the embodiment of fig. 3, the filter 17 is arranged immediately downstream of the support element 12 in the longitudinal direction. The package 30 is identical to the package of the aerosol-generating article 10 of fig. 1 and 2. The susceptor 40 extends along the entire length of the aerosol-forming substrate 11.

Fig. 4 shows an aerosol-generating article 10 comprising the wrapper 30 of fig. 1, 2 and 3. The aerosol-generating article 10 of fig. 4 will be described below as being different from the aerosol-generating article 10 of fig. 1, 2 and 3.

The aerosol-generating article 10 of fig. 4 comprises a support element 12 positioned immediately downstream of the aerosol-forming substrate 11. In the embodiment of fig. 4, the upstream end of the support element 12 abuts the downstream end of the aerosol-forming substrate 11. Furthermore, the aerosol-generating article 10 comprises an aerosol-cooling element 15 positioned immediately downstream of the support element 22. In the embodiment of fig. 4, the upstream end of the aerosol-cooling element 15 abuts the downstream end of the support element 12.

The support element 12 comprises a first hollow tubular section. The aerosol-cooling element 15 comprises a second hollow tubular section. The hollow tubular section is provided in the form of a hollow cylindrical tube made of cellulose acetate. Other configurations in which the support element, the aerosol-cooling element, or both do not include hollow tubular segments are also compatible with the embodiment of fig. 4.

In fig. 4, the support element 12 and the aerosol-cooling element 15 together define a central hollow section of the aerosol-generating article 10. Overall, the intermediate hollow section is adapted for flow of the matrix aerosol toward the downstream end 14 and does not substantially contribute to the overall resistance to draw of the aerosol-generating article 10.

In the embodiment of fig. 4, the filter 17 is arranged immediately downstream of the aerosol-cooling element 15 in the longitudinal direction. As shown in fig. 4, the upstream end of the filter 17 abuts the downstream end of the aerosol-cooling element 15.

The filter 17 is provided in the form of a cylindrical filter segment of low density cellulose acetate.

In fig. 4, the aerosol-generating article 10 comprises an upstream element 16. The upstream element 16 abuts the upstream end of the aerosol-forming substrate 11. This advantageously prevents the susceptor 40 from being displaced. In addition, this ensures that the consumer does not accidentally touch the heated susceptor 40 after use.

The upstream element 16 is provided in the form of a cylindrical filter segment of cellulose acetate.

In some not shown examples of the embodiments of fig. 3 and 4, the aerosol-generating article 10 comprises a mouthpiece disposed immediately downstream of the filter 17.

Fig. 5 shows a schematic longitudinal section of an aerosol-generating system comprising an aerosol-generating device 200 and an aerosol-generating article 10. The aerosol-generating article 10 may be any of the articles of fig. 1 to 4.

The aerosol-generating device 200 comprises a substantially cylindrical device housing 207 having a shape and size similar to a conventional cigar.

The aerosol-generating device 200 further comprises a power supply 201 in the form of a rechargeable nickel cadmium battery, a controller 202 in the form of a printed circuit board comprising a microprocessor, an electrical connector 203 and a heating element 204. The heating element 204 is configured to heat the aerosol-forming substrate 11.

In the embodiment of fig. 5, the heating element 204 is an induction heating device 204 comprising at least one inductor coil 206 intended to cooperate with the susceptor 40 of the aerosol-generating article 10. However, other forms of heating elements may be used, such as resistive heating elements. Also, the induction heating device 204 may include a susceptor. The latter device is preferably used with aerosol-generating articles that do not comprise a susceptor.

The power supply 201, the controller 202, and the inductor coil 206 are all housed within the device housing 207. The inductor coil 206 of the aerosol-generating device 200 is arranged at the proximal end of the device 200. The electrical connector 203 is disposed at the distal end of the device housing 207.

As used herein, the term "proximal" refers to the user end or mouth end of an aerosol-generating device or aerosol-generating article. The proximal end of the aerosol-generating device or component of the aerosol-generating article is the end of the component closest to the user end or mouth end of the aerosol-generating device or aerosol-generating article. As used herein, the term "distal" refers to the end opposite the proximal end.

The controller 202 is configured to control the supply of electrical power from the power source 201 to the inductor coil 206. The controller 202 also includes a DC/AC inverter including a class D power amplifier. The controller 202 is also configured to control recharging of the power supply 201 from the electrical connector 203. The controller 202 also includes a puff sensor (not shown) configured to sense when a user puffs on the aerosol-generating article received in the device cavity 208.

The inductor coil 206 is connected to the controller 202 and the power supply 201, and the controller 202 is configured to supply varying currents to the substrate inductor coil 206. When a varying current is supplied to the inductor coil 206, the inductor coil generates a varying magnetic field that heats the susceptor 40 by induction.

As shown in fig. 6, the device housing 207 also defines a device air inlet 213 proximate to the distal end of the cavity 208 for receiving the aerosol-generating article 10. The device air inlet 213 is configured to enable ambient air to be drawn into the device housing 207 towards the aerosol-forming substrate 11.

Claims

1. An aerosol-generating article comprising:

an aerosol-forming substrate; and

a package defining the aerosol-forming substrate;

wherein the second section comprises a fold defining a folded section at one end of the wrapper;

wherein the folded section is sandwiched between the first section and the second section; and is also provided with

Wherein an external adhesive is disposed between the folded section and the second section.

2. An aerosol-generating article according to claim 1, wherein an internal adhesive is provided between the folded section and the first section.

3. An aerosol-generating article according to any one of the preceding claims, wherein the binder comprises one or more of the following: gum arabic, natural or synthetic resins, starches and varnishes.

4. An aerosol-generating article according to any preceding claim, further comprising a heating element embedded within the aerosol-forming substrate.

5. An aerosol-generating article according to claim 4, wherein the heating element is an induction susceptor.

6. An aerosol-generating article according to any of claims 4 to 5, wherein the heating element is fully surrounded by the aerosol-forming substrate and extends along the entire length of the aerosol-forming substrate.

7. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article has a diameter of between about 3mm and about 8 mm.

8. An aerosol-generating article according to any one of the preceding claims, wherein the wrapper has a thickness of between about 60 microns and about 200 microns, preferably between about 78 microns and about 160 microns, more preferably between 78 microns and about 140 microns, more preferably between about 100 microns and about 140 microns, most preferably between about 125 microns and about 140 microns.

9. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate comprises one or more of tobacco, nicotine, a gel component and a flavour substrate.

10. An aerosol-generating article according to any of the preceding claims, further comprising a filter disposed downstream of the aerosol-forming substrate.

11. An aerosol-generating article according to any preceding claim, wherein the length of the aerosol-generating article is between about 30mm and about 100 mm.

12. An aerosol-generating system comprising:

an aerosol-generating article according to any preceding claim; and

an aerosol-generating device.

13. An aerosol-generating system according to claim 12, wherein the aerosol-generating device comprises a resistive heating element.

14. An aerosol-generating system according to any of claims 12 to 13, wherein the aerosol-generating device comprises an inductor coil.