EP4110096B1 - Aerosol-generating article including substrate with gel composition - Google Patents

Aerosol-generating article including substrate with gel composition Download PDF

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Publication number
EP4110096B1
EP4110096B1 EP21706317.1A EP21706317A EP4110096B1 EP 4110096 B1 EP4110096 B1 EP 4110096B1 EP 21706317 A EP21706317 A EP 21706317A EP 4110096 B1 EP4110096 B1 EP 4110096B1
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EP
European Patent Office
Prior art keywords
aerosol
percent
millimetres
weight
generating article
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP21706317.1A
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German (de)
English (en)
French (fr)
Other versions
EP4110096C0 (en
EP4110096A1 (en
Inventor
Gianpaolo D'AMBRA
Milica NESOVIC
Paola ORSOLINI
Jerome Uthurry
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Philip Morris Products SA
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Philip Morris Products SA
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Publication date
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Publication of EP4110096A1 publication Critical patent/EP4110096A1/en
Application granted granted Critical
Publication of EP4110096C0 publication Critical patent/EP4110096C0/en
Publication of EP4110096B1 publication Critical patent/EP4110096B1/en
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Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/18—Treatment of tobacco products or tobacco substitutes
    • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
    • A24B15/30—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/18—Treatment of tobacco products or tobacco substitutes
    • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
    • A24B15/30—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances
    • A24B15/302—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances by natural substances obtained from animals or plants
    • A24B15/303—Plant extracts other than tobacco
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
    • A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
    • A24C5/14—Machines of the continuous-rod type
    • A24C5/18—Forming the rod
    • A24C5/1885—Forming the rod for cigarettes with an axial air duct
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES OF CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/02—Cigars; Cigarettes with special covers
    • A24D1/025—Cigars; Cigarettes with special covers the covers having material applied to defined areas, e.g. bands for reducing the ignition propensity
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES OF CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/04—Cigars; Cigarettes with mouthpieces or filter-tips
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES OF CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/18—Selection of materials, other than tobacco, suitable for smoking
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES OF CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/20—Cigarettes specially adapted for simulated smoking devices
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES OF CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter tips or filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces of cigars or cigarettes
    • A24D3/04—Tobacco smoke filters characterised by their shape or structure
    • A24D3/043—Tobacco smoke filters characterised by their shape or structure with ventilation means, e.g. air dilution
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES OF CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter tips or filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces of cigars or cigarettes
    • A24D3/02—Manufacture of tobacco smoke filters
    • A24D3/0275—Manufacture of tobacco smoke filters for filters with special features
    • A24D3/0279—Manufacture of tobacco smoke filters for filters with special features with tubes

Definitions

  • the present invention relates to an aerosol-generating article comprising an aerosol-generating substrate and adapted to produce an inhalable aerosol upon heating.
  • Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than combusted, are known in the art.
  • an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source.
  • volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.
  • a number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles.
  • Such devices include, for example, electrically heated aerosol-generating devices in which an aerosol is generated by the transfer of heat from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of a heated aerosol-generating article.
  • electrically heated aerosol-generating devices have been proposed that comprise an internal heater blade which is adapted to be inserted into the aerosol-generating substrate.
  • inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor element arranged within the aerosol-generating substrate have been proposed by WO 2015/176898 .
  • a conventional cigarette is lit when a user applies a flame to one end of the cigarette and draws air through the other end.
  • the localised heat provided by the flame and the oxygen in the air drawn through the cigarette causes the end of the cigarette to ignite, and the resulting combustion generates an inhalable smoke.
  • an aerosol is generated by heating a flavour generating substrate, such as tobacco.
  • Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles and aerosol-generating articles in which an aerosol is generated by the transfer of heat from a combustible fuel element or heat source to a physically separate aerosol forming material.
  • the term “hollow tubular segment” is used to denote a generally elongate element defining a lumen or airflow passage along a longitudinal axis thereof.
  • tubular will be used in the following with reference to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit establishing an uninterrupted fluid communication between an upstream end of the tubular element and a downstream end of the tubular element.
  • alternative geometries for example, alternative cross-sectional shapes
  • the hollow tubular segment is an individual, discrete element of the aerosol-generating article which has a defined length and thickness.
  • the term "elongate” means that an element has a length dimension that is greater than its width dimension or its diameter dimension, for example twice or more its width dimension or its diameter dimension.
  • a hollow tubular segment provides an unrestricted flow channel. This means that the hollow tubular segment provides a negligible level of resistance to draw (RTD).
  • RTD resistance to draw
  • the flow channel should therefore be free from any components that would obstruct the flow of air in a longitudinal direction.
  • the flow channel is substantially empty.
  • an aerosol-generating substrate formed with a gel composition for forming the aerosol upon heating is desirable because it provides a uniform substrate that can generate a highly consistent aerosol.
  • the aerosol-generating article may further comprise a susceptor element within the aerosol-generating substrate.
  • the susceptor element may be an elongate susceptor element.
  • the susceptor element extend longitudinally within the aerosol-generating substrate.
  • the downstream section of the aerosol-generating article of the present invention comprises a mouthpiece element.
  • the mouthpiece element is preferably located at the downstream end or mouth end of the aerosol-generating article.
  • the mouthpiece element preferably comprises at least one mouthpiece filter segment for filtering the aerosol that is generated from the aerosol-generating substrate.
  • the mouthpiece element may comprise one or more segments of a fibrous filtration material. Suitable fibrous filtration materials would be known to the skilled person.
  • the at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed of cellulose acetate tow.
  • the downstream section may comprise a mouth end cavity at the downstream end, downstream of the mouthpiece element as described above.
  • the mouth end cavity may be defined by a hollow tubular element provided at the downstream end of the mouthpiece.
  • the mouth end cavity may be defined by the outer wrapper of the mouthpiece element, wherein the outer wrapper extends in a downstream direction from the mouthpiece element.
  • the mouthpiece element may optionally comprise a flavourant, which may be provided in any suitable form.
  • a flavourant which may be provided in any suitable form.
  • the mouthpiece element may comprise one or more capsules, beads or granules of a flavourant, or one or more flavour loaded threads or filaments.
  • a ratio between the length of the mouthpiece element and the length of the rod of aerosol-generating substrate is from about 0.6 to about 1.4, preferably from about 0.7 to about 1.4, more preferably from about 0.8 to about 1.4. In other embodiments, a ratio between the length of the mouthpiece element and the length of the rod of aerosol-generating substrate is from about 0.6 to about 1.3, preferably from about 0.7 to about 1.3, more preferably from about 0.8 to about 1.3. In further embodiments, a ratio between the length of the mouthpiece element and the length of the rod of aerosol-generating substrate is from about 0.6 to about 1.2, preferably from about 0.7 to about 1.2, more preferably from about 0.8 to about 1.2.
  • the inventors have found that a satisfactory cooling of the stream of aerosol generated upon heating the aerosol-generating substrate and drawn through one such aerosol-cooling element is achieved by providing a ventilation zone at a location along the hollow tubular segment. Further, the inventors have found that, as will be described in more detail below, by arranging the ventilation zone at a precisely defined location along the length of the aerosol-cooling element and by preferably utilising a hollow tubular segment having a predetermined peripheral wall thickness or internal volume, it may be possible to counter the effects of the increased aerosol dilution caused by the admission of ventilation air into the article.
  • the thickness of the peripheral wall of the hollow tubular segment relatively low ensures that the overall internal volume of the hollow tubular element - which is made available for the aerosol to begin the nucleation process as soon as the aerosol components leave the rod of aerosol-generating substrate - and the cross-sectional surface area of the hollow tubular segment are effectively maximised, whilst at the same time ensuring that the hollow tubular segment has the necessary structural strength to prevent a collapse of the aerosol-generating article as well as to provide some support to the rod of aerosol-generating substrate, and that the RTD of the hollow tubular segment is minimised.
  • the aerosol-cooling element preferably has an outer diameter that is approximately equal to the outer diameter of the rod of aerosol-generating substrate and to the outer diameter of the aerosol-generating article.
  • the aerosol-cooling element may have an outer diameter of between 5 millimetres and 12 millimetres, for example of between 5 millimetres and 10 millimetres or of between 6 millimetres and 8 millimetres. In a preferred embodiment, the aerosol-cooling element has an external diameter of 7.2 millimetres plus or minus 10 percent.
  • the aerosol-cooling element has a length of at least about 5 millimetres, more preferably at least about 6 millimetres, more preferably at least about 7 millimetres.
  • the aerosol-cooling element has a length of less than about 12 millimetres, more preferably less than about 10 millimetres.
  • the aerosol-cooling element has a length from about 5 millimetres to about 12 millimetres, preferably from about 6 millimetres to about 12 millimetres, more preferably from about 7 millimetres to about 12 millimetres. In further embodiments, the aerosol-cooling element has a length from about 5 millimetres to about 10 millimetres, preferably from about 6 millimetres to about 10 millimetres, more preferably from about 7 millimetres to about 10 millimetres.
  • the aerosol-cooling element has a length of less than 10 millimetres.
  • the aerosol-cooling element has a length of 8 millimetres.
  • the aerosol-cooling element therefore has a relatively short length compared to the aerosol-cooling elements of prior art aerosol-generating articles. A reduction in the length of the aerosol-cooling element is possible due to the optimised effectiveness of the hollow tubular segment forming the aerosol-cooling element in the cooling and nucleation of the aerosol.
  • a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate may be from about 0.25 to about 1.
  • a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is at least about 0.3, more preferably at least about 0.4, even more preferably at least about 0.5.
  • a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is less than about 0.9, more preferably less than about 0.8, even more preferably less than about 0.7.
  • a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.9, preferably from about 0.4 to about 0.9, more preferably from about 0.5 to about 0.9. In other embodiments, a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.8, preferably from about 0.4 to about 0.8, more preferably from about 0.5 to about 0.8. In further embodiments, a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.7, preferably from about 0.4 to about 0.7, more preferably from about 0.5 to about 0.7.
  • a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is about 0.66.
  • a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is at least about 0.13, more preferably at least about 0.14, even more preferably at least about 0.15.
  • a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is preferably less than about 0.3, more preferably less than about 0.25, even more preferably less than about 0.20.
  • a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.3, more preferably from about 0.14 to about 0.3, even more preferably from about 0.15 to about 0.3. In other embodiments, a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.25, more preferably from about 0.14 to about 0.25, even more preferably from about 0.15 to about 0.25.
  • a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is about 0.18.
  • the length of the mouthpiece element is at least 1 millimetre greater than the length of the aerosol-cooling element, more preferably at least 2 millimetres greater than the length of the aerosol-cooling element, more preferably at least 3 millimetres greater than the length of the aerosol-cooling element.
  • a reduction in the length of the aerosol-cooling element, as described above, can advantageously allow for an increase in the length of other elements of the aerosol-generating article, such as the mouthpiece element.
  • the potential technical benefits of providing a relatively long mouthpiece element are described above.
  • a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.9, preferably from about 0.4 to about 0.9, more preferably from about 0.5 to about 0.9. In other embodiments, a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.8, preferably from about 0.4 to about 0.8, more preferably from about 0.5 to about 0.8. In further embodiments, a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.7, preferably from about 0.4 to about 0.7, more preferably from about 0.5 to about 0.7.
  • a ratio between the length of the aerosol-cooling element and the length of the rod of aerosol-generating substrate is about 0.66.
  • a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.3, more preferably from about 0.14 to about 0.3, even more preferably from about 0.15 to about 0.3. In other embodiments, a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.25, more preferably from about 0.14 to about 0.25, even more preferably from about 0.15 to about 0.25.
  • a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.2, more preferably from about 0.14 to about 0.2, even more preferably from about 0.15 to about 0.2.
  • a ratio between the length of the aerosol-cooling element and the overall length of the aerosol-generating article substrate is about 0.18.
  • the length of the mouthpiece element is at least 1 millimetre greater than the length of the aerosol-cooling element, more preferably at least 2 millimetres greater than the length of the aerosol-cooling element, more preferably at least 3 millimetres greater than the length of the aerosol-cooling element.
  • a reduction in the length of the aerosol-cooling element, as described above, can advantageously allow for an increase in the length of other elements of the aerosol-generating article, such as the mouthpiece element.
  • the potential technical benefits of providing a relatively long mouthpiece element are described above.
  • the aerosol-cooling element has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, even more preferably at least about 90 percent.
  • the aerosol-cooling element is therefore able to provide a desirable level of hardness to the aerosol-generating article.
  • the radial hardness of the aerosol-cooling element of aerosol-generating articles in accordance with the invention may be further increased by circumscribing the aerosol-cooling element by a stiff plug wrap, for example, a plug wrap having a basis weight of at least about 80 grams per square metre (gsm), or at least about 100 gsm, or at least about 110 gsm.
  • a stiff plug wrap for example, a plug wrap having a basis weight of at least about 80 grams per square metre (gsm), or at least about 100 gsm, or at least about 110 gsm.
  • aerosol-generating articles should be aligned parallel in a plane and the same portion of each aerosol-generating article to be tested should be subjected to a set load for a set duration.
  • This test is performed using a known DD60A Densimeter device (manufactured and made commercially available by Heinr Borgwaldt GmbH, Germany), which is fitted with a measuring head for aerosol-generating articles, such as cigarettes, and with an aerosol-generating article receptacle.
  • the load is applied using two load-applying cylindrical rods, which extend across the diameter of all of the aerosol-generating articles at once.
  • the test should be performed such that twenty contact points occur between the aerosol-generating articles and the load applying cylindrical rods.
  • the hollow tube segments to be tested may be long enough such that only ten aerosol-generating articles are needed to form twenty contact points, with each smoking article contacting both load applying rods (because they are long enough to extend between the rods).
  • twenty aerosol-generating articles should be used to form the twenty contact points, with each aerosol-generating article contacting only one of the load applying rods, as further discussed below.
  • Two further stationary cylindrical rods are located underneath the aerosol-generating articles, to support the aerosol-generating articles and counteract the load applied by each of the load applying cylindrical rods.
  • the ventilation zone comprises a plurality of perforations through the peripheral wall of the aerosol-cooling element.
  • the ventilation zone comprises at least one circumferential row of perforations.
  • the ventilation zone may comprise two circumferential rows of perforations.
  • the perforations may be formed online during manufacturing of the aerosol-generating article.
  • each circumferential row of perforations comprises from 8 to 30 perforations.
  • ventilation level is used throughout the present specification to denote a volume ratio between of the airflow admitted into the aerosol-generating article via the ventilation zone (ventilation airflow) and the sum of the aerosol airflow and the ventilation airflow. The greater the ventilation level, the higher the dilution of the aerosol flow delivered to the consumer.
  • the aerosol-generating article may typically have a ventilation level of at least about 10 percent, preferably at least about 15 percent, more preferably at least about 20 percent.
  • Such critical cluster is identified as the key nucleation core from which droplets are expected to grow due to condensation of molecules from the vapour. It is assumed that virgin droplets that just nucleated emerge with a certain original diameter, and then may grow by several orders of magnitude. This is facilitated and may be enhanced by rapid cooling of the surrounding vapour, which induces condensation. In this connection, it helps to bear in mind that evaporation and condensation are two sides of one same mechanism, namely gas-liquid mass transfer. While evaporation relates to net mass transfer from the liquid droplets to the gas phase, condensation is net mass transfer from the gas phase to the droplet phase. Evaporation (or condensation) will make the droplets shrink (or grow), but it will not change the number of droplets.
  • the inventors have surprisingly found that the diluting effect on the aerosol - which can be assessed by measuring, in particular, the effect on the delivery of aerosol former (such as glycerol) included in the aerosol-generating substrate) is advantageously minimised when the ventilation level is within the ranges described above.
  • aerosol former such as glycerol
  • ventilation levels between 25 percent and 50 percent, and even more preferably between 28 and 42 percent, have been found to lead to particularly satisfactory values of glycerin delivery.
  • the extent of nucleation and, as a consequence, the delivery of nicotine and aerosol-former (for example, glycerol) are enhanced.
  • the ventilated hollow tubular segment substantially does not contribute to the overall RTD of the aerosol-generating article
  • the overall RTD of the article can advantageously be fine-tuned by adjusting the length and density of the rod of aerosol-generating substrate or the length and optionally the length and density of a segment of filtration material forming part of the mouthpiece or the length and density of a segment of filtration material provided upstream of the aerosol-generating substrate and the susceptor element.
  • the aerosol-generating article may further comprise an additional cooling element defining a plurality of longitudinally extending channels such as to make a high surface area available for heat exchange.
  • an additional cooling element is adapted to function substantially as a heat exchanger.
  • the plurality of longitudinally extending channels may be defined by a sheet material that has been pleated, gathered or folded to form the channels.
  • the plurality of longitudinally extending channels may be defined by a single sheet that has been pleated, gathered or folded to form multiple channels. The sheet may also have been crimped prior to being pleated, gathered or folded.
  • the plurality of longitudinally extending channels may be defined by multiple sheets that have been crimped, pleated, gathered or folded to form multiple channels.
  • the plurality of longitudinally extending channels may be defined by multiple sheets that have been crimped, pleated, gathered or folded together - that is by two or more sheets that have been brought into overlying arrangement and then crimped, pleated, gathered or folded as one.
  • 'sheet' denotes a laminar element having a width and length substantially greater than the thickness thereof.
  • the additional cooling element preferably offers a low resistance to the passage of air through additional cooling element.
  • the additional cooling element does not substantially affect the resistance to draw of the aerosol-generating article.
  • the porosity in a longitudinal direction is greater than 50 percent and that the airflow path through the additional cooling element is relatively uninhibited.
  • the longitudinal porosity of the additional cooling element may be defined by a ratio of the cross-sectional area of material forming the additional cooling element and an internal cross-sectional area of the aerosol-generating article at the portion containing the additional cooling element.
  • the support element may be formed from any suitable material or combination of materials.
  • the support element may be formed from one or more materials selected from the group consisting of: cellulose acetate; cardboard; crimped paper, such as crimped heat resistant paper or crimped parchment paper; and polymeric materials, such as low density polyethylene (LDPE).
  • LDPE low density polyethylene
  • the support element is formed from cellulose acetate.
  • Other suitable materials include polyhydroxyalkanoate (PHA) fibres.
  • the support element is preferably arranged substantially in alignment with the rod. This means that the length dimension of the support element is arranged to be approximately parallel to the longitudinal direction of the rod and of the article, for example within plus or minus 10 degrees of parallel to the longitudinal direction of the rod. In preferred embodiments, the support element extends along the longitudinal axis of the rod.
  • the support element preferably has an outer diameter that is approximately equal to the outer diameter of the rod of aerosol-generating substrate and to the outer diameter of the aerosol-generating article.
  • the support element may have an outer diameter of between 5 millimetres and 12 millimetres, for example of between 5 millimetres and 10 millimetres or of between 6 millimetres and 8 millimetres. In a preferred embodiment, the support element has an external diameter of 7.2 millimetres plus or minus 10 percent.
  • the support element has a wall thickness of at least 1 millimetre.
  • the support element preferably has a wall thickness of at least about 1.5 millimetres, more preferably at least about 2 millimetres.
  • the support element may have a length of between about 5 millimetres and about 15 millimetres.
  • the support element has a length of at least about 6 millimetres, more preferably at least about 7 millimetres.
  • the support element has a length of about 8 millimetres.
  • the intermediate hollow section has a total length of no more than about 18 millimetres, more preferably no more than about 17 millimetres, more preferably no more than 16 millimetres.
  • a ratio between the length of the support element and the length of the rod of aerosol-generating substrate may be from about 0.25 to about 1.
  • a ratio between the length of the support element and the length of the rod of aerosol-generating substrate is at least about 0.3, more preferably at least about 0.4, even more preferably at least about 0.5. In preferred embodiments, a ratio between the length of the support element and the length of the rod of aerosol-generating substrate is less than about 0.9, more preferably less than about 0.8, even more preferably less than about 0.7.
  • a ratio between the length of the support element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.9, preferably from about 0.4 to about 0.9, more preferably from about 0.5 to about 0.9. In other embodiments, a ratio between the length of the support element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.8, preferably from about 0.4 to about 0.8, more preferably from about 0.5 to about 0.8. In further embodiments, a ratio between the length of the support element and the length of the rod of aerosol-generating substrate is from about 0.3 to about 0.7, preferably from about 0.4 to about 0.7, more preferably from about 0.5 to about 0.7.
  • a ratio between the length of the support element and the length of the rod of aerosol-generating substrate is about 0.66.
  • a ratio between the length of the support element and the overall length of the aerosol-generating article substrate may be from about 0.125 to about 0.375.
  • a ratio between the length of the support element and the overall length of the aerosol-generating article substrate is at least about 0.13, more preferably at least about 0.14, even more preferably at least about 0.15.
  • a ratio between the length of the support element and the overall length of the aerosol-generating article substrate is preferably less than about 0.3, more preferably less than about 0.25, even more preferably less than about 0.20.
  • a ratio between the length of the support element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.3, more preferably from about 0.14 to about 0.3, even more preferably from about 0.15 to about 0.3. In other embodiments, a ratio between the length of the support element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.25, more preferably from about 0.14 to about 0.25, even more preferably from about 0.15 to about 0.25. In further embodiments, a ratio between the length of the support element and the overall length of the aerosol-generating article substrate is preferably from about 0.13 to about 0.2, more preferably from about 0.14 to about 0.2, even more preferably from about 0.15 to about 0.2.
  • a ratio between the length of the support element and the overall length of the aerosol-generating article substrate is about 0.18.
  • the support element has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, even more preferably at least about 90 percent.
  • the support element is therefore able to provide a desirable level of hardness to the aerosol-generating article.
  • the radial hardness of the support element of aerosol-generating articles in accordance with the invention may be further increased by circumscribing the support element by a stiff plug wrap, for example, a plug wrap having a basis weight of at least about 80 grams per square metre (gsm), or at least about 100 gsm, or at least about 110 gsm.
  • a stiff plug wrap for example, a plug wrap having a basis weight of at least about 80 grams per square metre (gsm), or at least about 100 gsm, or at least about 110 gsm.
  • an aerosol-generating article in accordance with the invention into an aerosol-generating device for heating the aerosol-generating substrate
  • a user may be required to apply some force in order to overcome the resistance of the aerosol-generating substrate of the aerosol-generating article to insertion. This may damage one or both of the aerosol-generating article and the aerosol-generating device.
  • the application of force during insertion of the aerosol-generating article into the aerosol-generating device may displace the aerosol-generating substrate within the aerosol-generating article. This may result in the heating element of the aerosol-generating device not being properly aligned with the susceptor element provided within the aerosol-generating substrate, which may lead to uneven and inefficient heating of the aerosol-generating substrate of the aerosol-generating article.
  • the support element is advantageously configured to resist downstream movement of the aerosol-generating substrate during insertion of the article into the aerosol-generating device.
  • the hollow tubular segment of the support element is adapted to generate a RTD between approximately 0 millimetres H 2 O (about 0 Pa) to approximately 20 millimetres H 2 O (about 100 Pa), more preferably between approximately 0 millimetres H 2 O (about 0 Pa) to approximately 10 millimetres H 2 O (about 100 Pa).
  • the support element therefore preferably does not contribute to the overall RTD of the aerosol-generating article.
  • the intermediate hollow section comprises both a support element comprising a first hollow tube segment and an aerosol-cooling element comprising a second hollow tubular segment.
  • the internal diameter (D STS ) of the second hollow tubular segment is preferably greater than the internal diameter (D FTS ) of the first hollow tubular segment.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is preferably at least about 1.25. More preferably, a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is preferably at least about 1.3. Even more preferably, a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is preferably at least about 1.4. In particularly preferred embodiments, a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is at least about 1.5, more preferably at least about 1.6.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is preferably less than or equal to about 2.5. More preferably, a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is preferably less than or equal to about 2.25. Even more preferably, ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is preferably less than or equal to about 2.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.25 to about 2.5.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.3 to about 2.5.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.4 to about 2.5.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.5 to about 2.5.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.25 to about 2.25.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.3 to about 2.25.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.4 to about 2.25.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.5 to about 2.25.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.25 to about 2.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.3 to about 2.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.4 to about 2.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and the internal diameter (D FTS ) of the first hollow tubular segment is from about 1.5 to about 2.
  • a ratio between the internal diameter (D FTS ) of the first hollow tubular segment and a width of the susceptor element is preferably at least about 0.2. More preferably, a ratio between the internal diameter (D FTS ) of the first hollow tubular segment and a width of the susceptor element is at least about 0.3. Even more preferably, a ratio between the internal diameter (D FTS ) of the first hollow tubular segment and a width of the susceptor element is at least about 0.4.
  • a ratio between the internal diameter (D STS ) of the second hollow tubular segment and a width of the susceptor element is preferably at least about 0.2. More preferably, a ratio between the internal diameter (D STS ) of the second hollow tubular segment and a width of the susceptor element is at least about 0.5. Even more preferably, a ratio between the internal diameter (D STS ) of the second hollow tubular segment and a width of the susceptor element is at least about 0.8.
  • a ratio between a volume of the cavity of the first hollow tubular segment and a volume of the cavity of the second hollow tubular segment is at least about 0.1. More preferably, a ratio between a volume of the cavity of the first hollow tubular segment and a volume of the cavity of second hollow tubular segment is at least about 0.2. Even more preferably, a ratio between a volume of the cavity of first hollow tubular segment and a volume of the cavity of second hollow tubular segment is at least about 0.3.
  • a ratio between a volume of the cavity of the first hollow tubular segment and a volume of the cavity of the second hollow tubular segment is preferably less than or equal to about 0.9. More preferably, a ratio between a volume of the cavity of the first hollow tubular segment and a volume of the cavity of the second hollow tubular segment is preferably less than or equal to about 0.7. Even more preferably, a ratio between a volume of the cavity of the first hollow tubular segment and a volume of the cavity of the second hollow tubular segment is preferably less than or equal to about 0.5.
  • the aerosol-generating article of the present invention comprises a rod of an aerosol-generating substrate.
  • the aerosol-generating substrate may be a solid aerosol-generating substrate.
  • the aerosol-generating substrate comprises a gel composition that includes an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound.
  • the aerosol-generating substrate comprises a gel composition that includes nicotine.
  • the gel composition comprises an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound; an aerosol former; and at least one gelling agent.
  • the at least one gelling agent forms a solid medium and the glycerol is dispersed in the solid medium, with the alkaloid or cannabinoid dispersed in the glycerol.
  • the gel composition is a stable gel phase.
  • a stable gel composition comprising nicotine provides predictable composition form upon storage or transit from manufacture to the consumer.
  • the stable gel composition comprising nicotine substantially maintains its shape.
  • the stable gel composition comprising nicotine substantially does not release a liquid phase upon storage or transit from manufacture to the consumer.
  • the stable gel composition comprising nicotine may provide for a simple consumable design. This consumable may not have to be designed to contain a liquid, thus a wider range of materials and container constructions may be contemplated.
  • the gel composition described herein may be combined with an aerosol-generating device to provide a nicotine aerosol to the lungs at inhalation or air flow rates that are within conventional smoking regime inhalation or air flow rates.
  • the aerosol-generating device may continuously heat the gel composition.
  • a consumer may take a plurality of inhalations or "puffs" where each "puff" delivers an amount of nicotine aerosol.
  • the gel composition may be capable of delivering a high nicotine/low total particulate matter (TPM) aerosol to a consumer when heated, preferably in a continuous manner.
  • TPM total particulate matter
  • stable gel phase or “stable gel” refers to gel that substantially maintains its shape and mass when exposed to a variety of environmental conditions.
  • the stable gel may not substantially release (sweat) or absorb water when exposed to a standard temperature and pressure while varying relative humidity from about 10 percent to about 60 percent.
  • the stable gel may substantially maintain its shape and mass when exposed to a standard temperature and pressure while varying relative humidity from about 10 percent to about 60 percent.
  • the gel composition includes an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound.
  • the gel composition may include one or more alkaloids.
  • the gel composition may include one or more cannabinoids.
  • the gel composition may include a combination of one or more alkaloids and one or more cannabinoids.
  • alkaloid compound refers to any one of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Generally, an alkaloid contains at least one nitrogen atom in an amine-type structure. This or another nitrogen atom in the molecule of the alkaloid compound can be active as a base in acid-base reactions. Most alkaloid compounds have one or more of their nitrogen atoms as part of a cyclic system, such as for example a heterocylic ring. In nature, alkaloid compounds are found primarily in plants, and are especially common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and fungi. In this disclosure, the term “alkaloid compound” refers to both naturally derived alkaloid compounds and synthetically manufactured alkaloid compounds.
  • the gel composition may preferably include an alkaloid compound selected from the group consisting of nicotine, anatabine, and combinations thereof.
  • the gel composition includes nicotine.
  • nicotine refers to nicotine and nicotine derivatives such as free-base nicotine, nicotine salts and the like.
  • cannabinoid compound refers to any one of a class of naturally occurring compounds that are found in parts of the cannabis plant - namely the species Cannabis sativa, Cannabis indica, and Cannabis ruderalis. Cannabinoid compounds are especially concentrated in the female flower heads. Cannabinoid compounds naturally occurring in the cannabis plant include cannabidiol (CBD) and tetrahydrocannabinol (THC). In this disclosure, the term “cannabinoid compounds” is used to describe both naturally derived cannabinoid compounds and synthetically manufactured cannabinoid compounds.
  • CBD cannabidiol
  • THC tetrahydrocannabinol
  • the gel may include a cannabinoid compound selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabielsoin (CBE),cannabicitran (CBT), and combinations thereof.
  • CBD cannabidiol
  • THC tetrahydrocannabinol
  • THCA tetrahydrocannabinolic acid
  • CBDA
  • the gel composition may preferably include a cannabinoid compound selected from the group consisting of cannabidiol (CBD), THC (tetrahydrocannabinol) and combinations thereof.
  • CBD cannabidiol
  • THC tetrahydrocannabinol
  • the gel may preferably include cannabidiol (CBD).
  • CBD cannabidiol
  • the gel composition may include nicotine and cannabidiol (CBD).
  • CBD cannabidiol
  • the gel composition may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).
  • the gel composition preferably includes about 0.5 percent by weight to about 10 percent by weight of an alkaloid compound, or about 0.5 percent by weight to about 10 percent by weight. of a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound in a total amount from about 0.5 percent by weight to about 10 percent by weight.
  • the gel composition may include about 0.5 percent by weight to about 5 percent by weight of an alkaloid compound, or about 0.5 percent by weight to about 5 percent by weight of a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound in a total amount from about 0.5 percent by weight to about 5 percent by weight.
  • the gel composition includes about 1 percent by weight to about 3 percent by weight of an alkaloid compound, or about 1 percent by weight to about 3 percent by weight of a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound in a total amount from about 1 percent by weight to about 3 percent by weight.
  • the gel composition may preferably include about 1.5 percent by weight to about 2.5 percent by weight of an alkaloid compound, or about 1.5 percent by weight to about 2.5 percent by weight of a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound in a total amount from about 1.5 percent by weight to about 2.5 percent by weight.
  • the gel composition may preferably include about 2 percent by weight of an alkaloid compound, or about 2 percent by weight of a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound in a total amount of about 2 percent by weight.
  • the alkaloid compound component of the gel formulation may be the most volatile component of the gel formulation.
  • water may be the most volatile component of the gel formulation and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation.
  • the cannabinoid compound component of the gel formulation may be the most volatile component of the gel formulation.
  • water may be the most volatile component of the gel formulation and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation.
  • the nicotine is included in the gel compositions.
  • the nicotine may be added to the composition in a free base form or a salt form.
  • the gel composition includes about 0.5 percent by weight to about 10 percent by weight nicotine, or about 0.5 percent by weight to about 5 percent by weight nicotine.
  • the gel composition includes about 1 percent by weight to about 3 percent by weight nicotine, or about 1.5 percent by weight to about 2.5 percent by weight nicotine, or about 2 percent by weight nicotine.
  • the nicotine component of the gel formulation may be the most volatile component of the gel formulation. In some aspects water may be the most volatile component of the gel formulation and the nicotine component of the gel formulation may be the second most volatile component of the gel formulation.
  • the gel composition additionally includes an aerosol-former.
  • the aerosol-former is substantially resistant to thermal degradation at the operating temperature of the associated aerosol-generating device.
  • Suitable aerosol-formers include, but are not limited to: polyhydric alcohols, such as triethylene glycol, 1, 3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.
  • Polyhydric alcohols or mixtures thereof may be one or more of triethylene glycol, 1, 3-butanediol and, glycerine (glycerol or propane-1,2,3-triol) or polyethylene glycol.
  • the aerosol-former is preferably glycerol.
  • the gel composition may include a majority of an aerosol-former.
  • the gel composition may include a mixture of water and the aerosol-former where the aerosol-former forms a majority (by weight) of the gel composition.
  • the aerosol-former may form at least about 50 percent by weight of the gel composition.
  • the aerosol-former may form at least about 60 percent by weight or at least about 65 percent by weight or at least about 70 percent by weight of the gel composition.
  • the aerosol-former may form about 70 percent by weight to about 80 percent by weight of the gel composition.
  • the aerosol-former may form about 70 percent by weight to about 75 percent by weight of the gel composition.
  • the gel composition may include a majority of glycerol.
  • the gel composition may include a mixture of water and the glycerol where the glycerol forms a majority (by weight) of the gel composition.
  • the glycerol may form at least about 50 percent by weight of the gel composition.
  • the glycerol may form at least about 60 percent by weight or at least about 65 percent by weight or at least about 70 percent by weight of the gel composition.
  • the glycerol may form about 70 percent by weight to about 80 percent by weight of the gel composition.
  • the glycerol may form about 70 percent by weight to about 75 percent by weight of the gel composition.
  • the gel composition additionally includes at least one gelling agent.
  • the gel composition includes a total amount of gelling agents in a range from about 0.4 percent by weight to about 10 percent by weight. More preferably, the composition includes the gelling agents in a range from about 0.5 percent by weight to about 8 percent by weight. More preferably, the composition includes the gelling agents in a range from about 1 percent by weight to about 6 percent by weight. More preferably, the composition includes the gelling agents in a range from about 2 percent by weight to about 4 percent by weight. More preferably, the composition includes the gelling agents in a range from about 2 percent by weight to about 3 percent by weight.
  • gelling agent refers to a compound that homogeneously, when added to a 50 percent by weight water/50 percent by weight glycerol mixture, in an amount of about 0.3 percent by weight, forms a solid medium or support matrix leading to a gel.
  • Gelling agents include, but are not limited to, hydrogen-bond crosslinking gelling agents, and ionic crosslinking gelling agents.
  • the gelling agent may include one or more biopolymers.
  • the biopolymers may be formed of polysaccharides.
  • the gel composition comprises at least about 0.2 percent by weight hydrogen-bond crosslinking gelling agent.
  • the gel composition preferably comprises at least about 0.2 percent by weight ionic crosslinking gelling agent.
  • the gel composition comprises at least about 0.2 percent by weight hydrogen-bond crosslinking gelling agent and at least about 0.2 percent by weight ionic crosslinking gelling agent.
  • the gel composition may comprise about 0.5 percent by weight to about 3 percent by weight hydrogen-bond crosslinking gelling agent and about 0.5 percent by weight to about 3 percent by weight ionic crosslinking gelling agent, or about 1 percent by weight to about 2 percent by weight hydrogen-bond crosslinking gelling agent and about 1 percent by weight to about 2 percent by weight ionic crosslinking gelling agent.
  • the hydrogen-bond crosslinking gelling agent and ionic crosslinking gelling agent may be present in the gel composition in substantially equal amounts by weight.
  • hydrogen-bond crosslinking gelling agent refers to a gelling agent that forms non-covalent crosslinking bonds or physical crosslinking bonds via hydrogen bonding. Hydrogen bonding is a type of electrostatic dipole-dipole attraction between molecules, not a covalent bond to a hydrogen atom. It results from the attractive force between a hydrogen atom covalently bonded to a very electronegative atom such as a N, O, or F atom and another very electronegative atom.
  • the hydrogen-bond crosslinking gelling agent may include one or more of a galactomannan, gelatin, agarose, or konjac gum, or agar.
  • the hydrogen-bond crosslinking gelling agent may preferably include agar.
  • the gel composition preferably includes the hydrogen-bond crosslinking gelling agent in a range from about 0.3 percent by weight to about 5 percent by weight.
  • the composition includes the hydrogen-bond crosslinking gelling agent in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the composition includes the hydrogen-bond crosslinking gelling agent in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include a galactomannan in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the galactomannan may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the galactomannan may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the galactomannan may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include a gelatin in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the gelatin may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the gelatin may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the gelatin may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include agarose in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the agarose may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the agarose may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the agarose may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include konjac gum in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the konjac gum may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the konjac gum may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the konjac gum may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include agar in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the agar may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the agar may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the agar may be in a range from about 1 percent by weight to about 2 percent by weight.
  • ionic crosslinking gelling agent refers to a gelling agent that forms non-covalent crosslinking bonds or physical crosslinking bonds via ionic bonding. Ionic crosslinking involves the association of polymer chains by noncovalent interactions. A crosslinked network is formed when multivalent molecules of opposite charges electrostatically attract each other giving rise to a crosslinked polymeric network.
  • the ionic crosslinking gelling agent may include low acyl gellan, pectin, kappa carrageenan, iota carrageenan or alginate.
  • the ionic crosslinking gelling agent may preferably include low acyl gellan.
  • the gel composition may include the ionic crosslinking gelling agent in a range from about 0.3 percent by weight to about 5 percent by weight.
  • the composition includes the ionic crosslinking gelling agent in a range from about 0.5 percent by weight to about 3 percent by weight by weight.
  • the composition includes the ionic crosslinking gelling agent in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include low acyl gellan in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the low acyl gellan may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the low acyl gellan may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the low acyl gellan may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include pectin in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the pectin may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the pectin may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the pectin may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include kappa carrageenan in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the kappa carrageenan may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the kappa carrageenan may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the kappa carrageenan may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include iota carrageenan in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the iota carrageenan may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the iota carrageenan may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the iota carrageenan may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include alginate in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the alginate may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the alginate may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the alginate may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include the hydrogen-bond crosslinking gelling agent and ionic crosslinking gelling agent in a ratio of about 3:1 to about 1:3.
  • the gel composition may include the hydrogen-bond crosslinking gelling agent and ionic crosslinking gelling agent in a ratio of about 2:1 to about 1:2.
  • the gel composition may include the hydrogen-bond crosslinking gelling agent and ionic crosslinking gelling agent in a ratio of about 1:1.
  • the gel composition may further include a viscosifying agent.
  • the viscosifying agent combined with the hydrogen-bond crosslinking gelling agent and the ionic crosslinking gelling agent appears to surprisingly support the solid medium and maintain the gel composition even when the gel composition comprises a high level of glycerol.
  • viscosifying agent refers to a compound that, when added homogeneously into a 25°C, 50 percent by weight water/50 percent by weight glycerol mixture, in an amount of 0.3 percent by weight., increases the viscosity without leading to the formation of a gel, the mixture staying or remaining fluid.
  • the viscosifying agent refers to a compound that when added homogeneously into a 25°C 50 percent by weight water/50 percent by weight glycerol mixture, in an amount of 0.3 percent by weight, increases the viscosity to at least 50 cPs, preferably at least 200 cPs, preferably at least 500 cPs, preferably at least 1000 cPs at a shear rate of 0.1 s -1 , without leading to the formation of a gel, the mixture staying or remaining fluid.
  • the viscosifying agent refers to a compound that when added homogeneously into a 25°C 50 percent by weight water/50 percent by weight glycerol mixture, in an amount of 0.3 percent by weight, increases the viscosity at least 2 times, or at least 5 times, or at least 10 times, or at least 100 times higher than before addition, at a shear rate of 0.1 s -1 , without leading to the formation of a gel, the mixture staying or remaining fluid.
  • the viscosity values recited herein can be measured using a Brookfield RVT viscometer rotating a disc type RV#2 spindle at 25°C at a speed of 6 revolutions per minute (rpm).
  • the gel composition preferably includes the viscosifying agent in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the composition includes the viscosifying agent in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the composition includes the viscosifying agent in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the composition includes the viscosifying agent in a range from about 1 percent by weight to about 2 percent by weight.
  • the viscosifying agent may include one or more of xanthan gum, carboxymethyl-cellulose, microcrystalline cellulose, methyl cellulose, gum Arabic, guar gum, lambda carrageenan, or starch.
  • the viscosifying agent may preferably include xanthan gum.
  • the gel composition may include xanthan gum in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the xanthan gum may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the xanthan gum may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the xanthan gum may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include carboxymethyl-cellulose in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the carboxymethyl-cellulose may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the carboxymethyl-cellulose may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the carboxymethyl-cellulose may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include microcrystalline cellulose in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the microcrystalline cellulose may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the microcrystalline cellulose may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the microcrystalline cellulose may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include methyl cellulose in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the methyl cellulose may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the methyl cellulose may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the methyl cellulose may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include gum Arabic in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the gum Arabic may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the gum Arabic may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the gum Arabic may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include guar gum in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the guar gum may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the guar gum may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the guar gum may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include lambda carrageenan in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the lambda carrageenan may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the lambda carrageenan may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the lambda carrageenan may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include starch in a range from about 0.2 percent by weight to about 5 percent by weight.
  • the starch may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the starch may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the starch may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may further include a divalent cation.
  • the divalent cation includes calcium ions, such as calcium lactate in solution.
  • Divalent cations (such as calcium ions) may assist in the gel formation of compositions that include gelling agents such as the ionic crosslinking gelling agent, for example. The ion effect may assist in the gel formation.
  • the divalent cation may be present in the gel composition in a range from about 0.1 to about 1 percent by weight, or about 0.5 percent by weight to about 1 percent by weight.
  • the gel composition may further include an acid.
  • the acid may comprise a carboxylic acid.
  • the carboxylic acid may include a ketone group.
  • the carboxylic acid may include a ketone group having less than about 10 carbon atoms, or less than about 6 carbon atoms or less than about 4 carbon atoms, such as levulinic acid or lactic acid.
  • this carboxylic acid has three carbon atoms (such as lactic acid). Lactic acid surprisingly improves the stability of the gel composition even over similar carboxylic acids.
  • the carboxylic acid may assist in the gel formation.
  • the carboxylic acid may reduce variation of the alkaloid compound concentration, or the cannabinoid compound concentration, or both the alkaloid compound concentration and the cannabinoid compound within the gel composition during storage.
  • the carboxylic acid may reduce variation of the nicotine concentration within the gel composition during storage.
  • the gel composition may include a carboxylic acid in a range from about 0.1 percent by weight to about 5 percent by weight.
  • the carboxylic acid may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the carboxylic acid may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the carboxylic acid may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include lactic acid in a range from about 0.1 percent by weight to about 5 percent by weight.
  • the lactic acid may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the lactic acid may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the lactic acid may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition may include levulinic acid in a range from about 0.1 percent by weight to about 5 percent by weight.
  • the levulinic acid may be in a range from about 0.5 percent by weight to about 3 percent by weight.
  • the levulinic acid may be in a range from about 0.5 percent by weight to about 2 percent by weight.
  • the levulinic acid may be in a range from about 1 percent by weight to about 2 percent by weight.
  • the gel composition preferably comprises some water.
  • the gel composition is more stable when the composition comprises some water.
  • the gel composition comprises at least about 1 percent by weight, or at least about 2 percent by weight., or at least about 5 percent by weight of water.
  • the gel composition comprises at least about 10 percent by weight or at least about 15 percent by weight water.
  • the gel composition comprises between about 8 percent by weight to about 32 percent by weight water. Preferably the gel composition comprises from about 15 percent by weight to about 25 percent by weight water. Preferably the gel composition comprises from about 18 percent by weight to about 22 percent by weight water. Preferably the gel composition comprises about 20 percent by weight water.
  • the aerosol-generating substrate comprises between about 150 mg and about 350 mg of the gel composition.
  • the aerosol-generating substrate comprises a porous medium loaded with the gel composition.
  • a porous medium loaded with the gel composition is that the gel composition is retained within the porous medium, and this may aid manufacturing, storage or transport of the gel composition. It may assist in keeping the desired shape of the gel composition, especially during manufacture, transport, or use.
  • porous is used herein to refer to a material that provides a plurality of pores or openings that allow the passage of air through the material.
  • the porous medium may be any suitable porous material able to hold or retain the gel composition. Ideally the porous medium can allow the gel composition to move within it.
  • the porous medium comprises natural materials, synthetic, or semi-synthetic, or a combination thereof.
  • the porous medium comprises sheet material, foam, or fibres, for example loose fibres; or a combination thereof.
  • the porous medium comprises a woven, non-woven, or extruded material, or combinations thereof.
  • the porous medium comprises, cotton, paper, viscose, PLA, or cellulose acetate, of combinations thereof.
  • the porous medium comprises a sheet material, for example, cotton or cellulose acetate.
  • the porous medium comprises a sheet made from cotton fibres.
  • the porous medium used in the present invention may be crimped or shredded.
  • the porous medium is crimped.
  • the porous medium comprises shredded porous medium.
  • the crimping or shredding process can be before or after loading with the gel composition.
  • Crimping of the sheet material has the benefit of improving the structure to allow passageways through the structure.
  • the passageways though the crimped sheet material assist in loading up gel, retaining gel and also for fluid to pass through the crimped sheet material. Therefore there are advantages of using crimped sheet material as the porous medium.
  • Shredding gives a high surface area to volume ratio to the medium thus able to absorb gel easily.
  • the sheet material is a composite material.
  • the sheet material is porous.
  • the sheet material may aid manufacture of the tubular element comprising a gel.
  • the sheet material may aid introducing an active agent to the tubular element comprising a gel.
  • the sheet material may help stabilise the structure of the tubular element comprising a gel.
  • the sheet material may assist transport or storage of the gel. Using a sheet material enables, or aids, adding structure to the porous medium for example by crimping of the sheet material.
  • the porous medium may be a thread.
  • the thread may comprise for example cotton, paper or acetate tow.
  • the thread may also be loaded with gel like any other porous medium.
  • the thread may be loaded with gel by any known means.
  • the thread may be simply coated with gel, or the thread may be impregnated with gel. In the manufacture, the threads may be impregnated with gel and stored ready for use to be included in the assembly of a tubular element.
  • the porous medium loaded with the gel composition is preferably provided within a tubular element that forms a part of the aerosol-generating article.
  • the tubular element may be longer in longitudinal length then in width but not necessarily as it may be one part of a multicomponent item that ideally will be longer in its longitudinal length then its width.
  • the tubular element is cylindrical but not necessarily.
  • the tubular element may have an oval, polygonal like triangular or rectangular or random cross section.
  • the tubular element preferably comprises a first longitudinal passageway.
  • the tubular element is preferably formed of a wrapper that defines the first longitudinal passageway.
  • the wrapper is preferably a water-resistant wrapper. This water-resistant property the wrapper may be achieved by using a water-resistant material, or by treating the material of the wrapper. It may be achieved by treating one side or both sides of the wrapper. Being water- resistant would assist in not losing structure, stiffness or rigidity. It may also assist in preventing leaks of gel or liquid, especially when gels of a fluid structure are used.
  • the plug of porous medium loaded with the gel composition is circumscribed by a water repellent wrapper.
  • an elongate susceptor element is arranged substantially longitudinally within the rod of aerosol-generating substrate and is in thermal contact with the aerosol-generating substrate.
  • the term "susceptor element” refers to a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents induced in the susceptor element cause heating of the susceptor element. As the elongate susceptor element is located in thermal contact with the aerosol-generating substrate, the aerosol-generating substrate is heated by the susceptor element.
  • the term “elongate” means that the susceptor element 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 element is arranged substantially longitudinally within the rod. This means that the length dimension of the elongate susceptor element is arranged to be approximately parallel to the longitudinal direction of the rod, for example within plus or minus 10 degrees of parallel to the longitudinal direction of the rod. In preferred embodiments, the elongate susceptor element may be positioned in a radially central position within the rod, and extends along the longitudinal axis of the rod.
  • the susceptor element extends all the way to a downstream end of the rod of aerosol-generating article.
  • the susceptor element may extend all the way to an upstream end of the rod of aerosol-generating article.
  • the susceptor element has substantially the same length as the rod of aerosol-generating substrate, and extends from the upstream end of the rod to the downstream end of the rod.
  • the susceptor element is preferably in the form of a pin, rod, strip or blade.
  • the susceptor element preferably has a length from about 5 millimetres to about 15 millimetres, for example from about 6 millimetres to about 12 millimetres, or from about 8 millimetres to about 10 millimetres.
  • a ratio between the length of the susceptor element and the overall length of the aerosol-generating article substrate may be from about 0.2 to about 0.35.
  • a ratio between the length of the susceptor element and the overall length of the aerosol-generating article substrate is at least about 0.22, more preferably at least about 0.24, even more preferably at least about 0.26.
  • a ratio between the length of the susceptor element and the overall length of the aerosol-generating article substrate is preferably less than about 0.34, more preferably less than about 0.32, even more preferably less than about 0.3.
  • a ratio between the length of the susceptor element and the overall length of the aerosol-generating article substrate is preferably from about 0.22 to about 0.34, more preferably from about 0.24 to about 0.34, even more preferably from about 0.26 to about 0.34. In other embodiments, a ratio between the length of the susceptor element and the overall length of the aerosol-generating article substrate is preferably from about 0.22 to about 0.32, more preferably from about 0.24 to about 0.32, even more preferably from about 0.26 to about 0.32.
  • a ratio between the length of the susceptor element and the overall length of the aerosol-generating article substrate is preferably from about 0.22 to about 0.3, more preferably from about 0.24 to about 0.3, even more preferably from about 0.26 to about 0.3.
  • a ratio between the length of the susceptor element and the overall length of the aerosol-generating article substrate is about 0.27.
  • the susceptor element preferably has a width from about 1 millimetres to about 5 millimetres.
  • the susceptor element may generally have a thickness from about 0.01 millimetres to about 2 millimetres, for example from about 0.5 millimetres to about 2 millimetres. In some embodiments, the susceptor element preferably has a thickness from about 10 micrometres to about 500 micrometres, more preferably from about 10 micrometres to about 100 micrometres.
  • the susceptor element has a constant cross-section, for example a circular cross-section, it has a preferable width or diameter from about 1 millimetre to about 5 millimetres.
  • the strip or blade preferably has a rectangular shape having a width of preferably from about 2 millimetres to about 8 millimetres, more preferably from about 3 millimetres to about 5 millimetres.
  • a susceptor element in the form of a strip of blade may have a width of about 4 millimetres.
  • the strip or blade preferably has a rectangular shape and a thickness from about 0.03 millimetres to about 0.15 millimetres, more preferably from about 0.05 millimetres to about 0.09 millimetres.
  • a susceptor element in the form of a strip of blade may have a thickness of about 0.07 millimetres.
  • the elongate susceptor element is in the form of a strip or blade, preferably has a rectangular shape, and has a thickness from about 55 micrometres to about 65 micrometres.
  • the elongate susceptor element has a thickness from about 57 micrometres to about 63 micrometres. Even more preferably, the elongate susceptor element has a thickness from about 58 micrometres to about 62 micrometres. In a particularly preferred embodiment, the elongate susceptor element has a thickness of about 60 micrometres.
  • the elongate susceptor element has a length which is the same or shorter than the length of the aerosol-generating substrate.
  • the elongate susceptor element has a same length as the aerosol-generating substrate.
  • the susceptor element may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate.
  • Preferred susceptor elements comprise a metal or carbon.
  • a preferred susceptor element may comprise or consist of a ferromagnetic material, for example a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel.
  • a suitable susceptor element may be, or comprise, aluminium.
  • Preferred susceptor elements may be formed from 400 series stainless steels, for example grade 410, or grade 420, or grade 430 stainless steel. Different materials will dissipate different amounts of energy when positioned within electromagnetic fields having similar values of frequency and field strength.
  • parameters of the susceptor element such as material type, length, width, and thickness may all be altered to provide a desired power dissipation within a known electromagnetic field.
  • Preferred susceptor elements may be heated to a temperature in excess of 250 degrees Celsius.
  • Suitable susceptor elements may comprise a non-metallic core with a metal layer disposed on the non-metallic core, for example metallic tracks formed on a surface of a ceramic core.
  • a susceptor element may have a protective external layer, for example a protective ceramic layer or protective glass layer encapsulating the susceptor element.
  • the susceptor element may comprise a protective coating formed by a glass, a ceramic, or an inert metal, formed over a core of susceptor element material.
  • the susceptor element is arranged in thermal contact with the aerosol-generating substrate.
  • the susceptor element heats up the aerosol-generating substrate is heated up and an aerosol is formed.
  • the susceptor element is arranged in direct physical contact with the aerosol-generating substrate, for example within the aerosol-generating substrate.
  • the susceptor element may be a multi-material susceptor element and may comprise a first susceptor element material and a second susceptor element material.
  • the first susceptor element material is disposed in intimate physical contact with the second susceptor element material.
  • the second susceptor element material preferably has a Curie temperature that is lower than 500 degrees Celsius.
  • the first susceptor element material is preferably used primarily to heat the susceptor element when the susceptor element is placed in a fluctuating electromagnetic field. Any suitable material may be used.
  • the first susceptor element material may be aluminium, or may be a ferrous material such as a stainless steel.
  • the second susceptor element material is preferably used primarily to indicate when the susceptor element has reached a specific temperature, that temperature being the Curie temperature of the second susceptor element material.
  • the Curie temperature of the second susceptor element material can be used to regulate the temperature of the entire susceptor element during operation. Thus, the Curie temperature of the second susceptor element material should be below the ignition point of the aerosol-generating substrate.
  • Suitable materials for the second susceptor element material may include nickel and certain nickel alloys.
  • the heating of the aerosol-generating substrate and the temperature control of the heating may be separated.
  • the first susceptor element material is preferably a magnetic material having a Curie temperature that is above 500 degrees Celsius. It is desirable from the point of view of heating efficiency that the Curie temperature of the first susceptor element material is above any maximum temperature that the susceptor element should be capable of being heated to.
  • the second Curie temperature may preferably be selected to be lower than 400 degrees Celsius, preferably lower than 380 degrees Celsius, or lower than 360 degrees Celsius. It is preferable that the second susceptor element material is a magnetic material selected to have a second Curie temperature that is substantially the same as a desired maximum heating temperature. That is, it is preferable that the second Curie temperature is approximately the same as the temperature that the susceptor element should be heated to in order to generate an aerosol from the aerosol-generating substrate. The second Curie temperature may, for example, be within the range of 200 degrees Celsius to 400 degrees Celsius, or between 250 degrees Celsius and 360 degrees Celsius.
  • the second Curie temperature of the second susceptor element material may, for example, be selected such that, upon being heated by a susceptor element that is at a temperature equal to the second Curie temperature, an overall average temperature of the aerosol-generating substrate does not exceed 240 degrees Celsius.
  • the aerosol-generating articles of the present invention may further comprise an upstream element located upstream of and adjacent to the aerosol-generating substrate, wherein the upstream section comprises at least one upstream element.
  • the upstream element advantageously prevents direct physical contact with the upstream end of the aerosol-generating substrate.
  • the aerosol-generating substrate comprises a susceptor element
  • the upstream element may prevent direct physical contact with the upstream end of the susceptor element. This helps to prevent the displacement or deformation of the susceptor element during handling or transport of the aerosol-generating article. This in turn helps to secure the form and position of the susceptor element.
  • the presence of an upstream element helps to prevent any loss of the substrate.
  • the upstream element can also advantageously compensate for any potential reduction in RTD, for example, due to evaporation of the gel composition upon heating of the rod of aerosol-generating substrate during use.
  • the upstream element may also provide an improved appearance to the upstream end of the aerosol-generating article. Furthermore, if desired, the upstream element may be used to provide information on the aerosol-generating article, such as information on brand, flavour, content, or details of the aerosol-generating device that the article is intended to be used with.
  • the upstream element may be a porous plug element.
  • a porous plug element does not alter the resistance to draw of the aerosol-generating article.
  • the upstream element has a porosity of at least about 50 percent in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has a porosity of between about 50 percent and about 90 percent in the longitudinal direction.
  • the porosity of the upstream element in the longitudinal direction is defined by the ratio of the cross-sectional area of material forming the upstream element and the internal cross-sectional area of the aerosol-generating article at the position of the upstream element.
  • the upstream element may be made of a porous material or may comprise a plurality of openings. This may, for example, be achieved through laser perforation. Preferably, the plurality of openings is distributed homogeneously over the cross-section of the upstream element.
  • the porosity or permeability of the upstream element may advantageously be varied in order to provide a desirable overall resistance to draw of the aerosol-generating article.
  • the RTD of the upstream element is at least about 5 millimetres H 2 O. More preferably, the RTD of the upstream element is at least about 10 millimetres H 2 O. Even more preferably, the RTD of the upstream element is at least about 15 millimetres H 2 O. In particularly preferred embodiments, the RTD of the upstream element is at least about 20 millimetres H 2 O.
  • the RTD of the upstream element is preferably less than or equal to about 80 millimetres H 2 O. More preferably, the RTD of the upstream element is less than or equal to about 60 millimetres H 2 O. Even more preferably, the RTD of the upstream element is less than or equal to about 40 millimetres H 2 O.
  • the RTD of the upstream element is from about 5 millimetres H 2 O to about 80 millimetres H 2 O, preferably from about 10 millimetres H 2 O to about 80 millimetres H 2 O, more preferably from about 15 millimetres H 2 O to about 80 millimetres H 2 O, even more preferably from about 20 millimetres H 2 O to about 80 millimetres H 2 O.
  • the RTD of the upstream element is from about 5 millimetres H 2 O to about 60 millimetres H 2 O, preferably from about 10 millimetres H 2 O to about 60 millimetres H 2 O, more preferably from about 15 millimetres H 2 O to about 60 millimetres H 2 O, even more preferably from about 20 millimetres H 2 O to about 60 millimetres H 2 O.
  • the RTD of the upstream element is from about 5 millimetres H 2 O to about 40 millimetres H 2 O, preferably from about 10 millimetres H 2 O to about 40 millimetres H 2 O, more preferably from about 15 millimetres H 2 O to about 40 millimetres H 2 O, even more preferably from about 20 millimetres H 2 O to about 40 millimetres H 2 O.
  • the RTD of the upstream element is greater than the RTD of the mouthpiece element.
  • the RTD of the upstream element is at least 1.5 times the RTD of the mouthpiece, more preferably at least 2 times the RTD of the mouthpiece and more preferably at least 2.5 times the RTD of the mouthpiece element. This advantageously provides a greater proportion of the overall RTD of the aerosol-generating article upstream of the rod of aerosol-generating substrate. This enables the RTD of the mouthpiece element to be minimised so that the filtration effect on the aerosol can also be minimised if desired.
  • the upstream element may be formed from a material that is impermeable to air.
  • the aerosol-generating article may be configured such that air flows into the rod of aerosol-generating substrate through suitable ventilation means provided in a wrapper.
  • the upstream element may be made of any material suitable for use in an aerosol-generating article.
  • the upstream element may, for example, be made of a same material as used for one of the other components of the aerosol-generating article, such as the mouthpiece, the cooling element or the support element.
  • Suitable materials for forming the upstream element include filter materials, ceramic, polymer material, cellulose acetate, cardboard, zeolite or aerosol-generating substrate.
  • the upstream element is formed from a plug of cellulose acetate.
  • the upstream element is formed of a heat resistant material.
  • the upstream element is formed of a material that resists temperatures of up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating means for heating the aerosol-generating substrate.
  • the upstream element has a diameter that is approximately equal to the diameter of the aerosol-generating article.
  • the upstream element has a length of between about 1 millimetre and about 10 millimetres, more preferably between about 3 millimetres and about 8 millimetres, more preferably between about 4 millimetres and about 6 millimetres. In a particularly preferred embodiment, the upstream element has a length of about 5 millimetres.
  • the length of the upstream element can advantageously be varied in order to provide the desired total length of the aerosol-generating article. For example, where it is desired to reduce the length of one of the other components of the aerosol-generating article, the length of the upstream element may be increased in order to maintain the same overall length of the article.
  • the upstream element preferably has a substantially homogeneous structure.
  • the upstream element may be substantially homogeneous in texture and appearance.
  • the upstream element may, for example, have a continuous, regular surface over its entire cross section.
  • the upstream element may, for example, have no recognisable symmetries.
  • the upstream element is preferably circumscribed by a wrapper.
  • the wrapper circumscribing the upstream element is preferably a stiff plug wrap, for example, a plug wrap having a basis weight of at least about 80 grams per square metre (gsm), or at least about 100 gsm, or at least about 110 gsm. This provides structural rigidity to the upstream element.
  • the aerosol-generating article according to the present invention may have a length from about 35 millimetres to about 100 millimetres.
  • an overall length of an aerosol-generating article in accordance with the invention is at least about 38 millimetres. More preferably, an overall length of an aerosol-generating article in accordance with the invention is at least about 40 millimetres. Even more preferably, an overall length of an aerosol-generating article in accordance with the invention is at least about 42 millimetres.
  • An overall length of an aerosol-generating article in accordance with the invention is preferably less than or equal to 70 millimetres. More preferably, an overall length of an aerosol-generating article in accordance with the invention is preferably less than or equal to 60 millimetres. Even more preferably, an overall length of an aerosol-generating article in accordance with the invention is preferably less than or equal to 50 millimetres.
  • an overall length of the aerosol-generating article is preferably from about 38 millimetres to about 70 millimetres, more preferably from about 40 millimetres to about 70 millimetres, even more preferably from about 42 millimetres to about 70 millimetres. In other embodiments, an overall length of the aerosol-generating article is preferably from about 38 millimetres to about 60 millimetres, more preferably from about 40 millimetres to about 60 millimetres, even more preferably from about 42 millimetres to about 60 millimetres.
  • an overall length of the aerosol-generating article is preferably from about 38 millimetres to about 50 millimetres, more preferably from about 40 millimetres to about 50 millimetres, even more preferably from about 42 millimetres to about 50 millimetres. In an exemplary embodiment, an overall length of the aerosol-generating article is about 45 millimetres.
  • the aerosol-generating article preferably has an external diameter of at least 5 millimetres.
  • the aerosol-generating article has an external diameter of at least 6 millimetres. More preferably, the aerosol-generating article has an external diameter of at least 7 millimetres.
  • the aerosol-generating article has an external diameter of less than or equal to about 12 millimetres. More preferably, the aerosol-generating article has an external diameter of less than or equal to about 10 millimetres. Even more preferably, the aerosol-generating article has an external diameter of less than or equal to about 8 millimetres.
  • the aerosol-generating article has an external diameter from about 5 millimetres to about 12 millimetres, preferably from about 6 millimetres to about 12 millimetres, more preferably from about 7 millimetres to about 12 millimetres. In other embodiments, the aerosol-generating article has an external diameter from about 5 millimetres to about 10 millimetres, preferably from about 6 millimetres to about 10 millimetres, more preferably from about 7 millimetres to about 10 millimetres.
  • the aerosol-generating article has an external diameter from about 5 millimetres to about 8 millimetres, preferably from about 6 millimetres to about 8 millimetres, more preferably from about 7 millimetres to about 8 millimetres.
  • a diameter (D ME ) of the aerosol-generating article at the mouth end is (preferably) greater than a diameter (D DE ) of the aerosol-generating article at the distal end.
  • a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is (preferably) at least about 1.005.
  • a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is (preferably) at least about 1.01. More preferably, a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is at least about 1.02. Even more preferably, a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is at least about 1.05.
  • a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is preferably less than or equal to about 1.30. More preferably, a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is less than or equal to about 1.25. Even more preferably, a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is less than or equal to about 1.20. In particularly preferred embodiments, a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is less than or equal to 1.15 or 1.10.
  • a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is from about 1.01 to 1.30, more preferably from 1.02 to 1.30, even more preferably from 1.05 to 1.30.
  • a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is from about 1.01 to 1.25, more preferably from 1.02 to 1.25, even more preferably from 1.05 to 1.25. In further embodiments, a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is from about 1.01 to 1.20, more preferably from 1.02 to 1.20, even more preferably from 1.05 to 1.20.
  • a ratio (D ME /D DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is from about 1.01 to 1.15, more preferably from 1.02 to 1.15, even more preferably from 1.05 to 1.15.
  • the external diameter of the article may be substantially constant over a distal portion of the article extending from the distal end of the aerosol-generating article for at least about 5 millimetres or at least about 10 millimetres.
  • the external diameter of the article may taper over a distal portion of the article extending from the distal end for at least about 5 millimetres or at least about 10 millimetres.
  • the elements of the aerosol-generating article are arranged such that the centre of mass of the aerosol-generating article is at least about 60 percent of the way along the length of the aerosol-generating article from the downstream end. More preferably, the elements of the aerosol-generating article are arranged such that the centre of mass of the aerosol-generating article is at least about 62 percent of the way along the length of the aerosol-generating article from the downstream end, more preferably at least about 65 percent of the way along the length of the aerosol-generating article from the downstream end.
  • the centre of mass is no more than about 70 percent of the way along the length of the aerosol-generating article from the downstream end.
  • Providing an arrangement of elements that gives a centre of mass that is closer to the upstream end than the downstream end results in an aerosol-generating article having a weight imbalance, with a heavier upstream end.
  • This weight imbalance may advantageously provide haptic feedback to the consumer to enable them to distinguish between the upstream and downstream ends so that the correct end can be inserted into an aerosol-generating device.
  • This may be particularly beneficial where an upstream element is provided such that the upstream and downstream ends of the aerosol-generating article are visually similar to each other.
  • aerosol-generating articles in accordance with the invention wherein both aerosol-cooling element and support element are present, these are preferably wrapped together in a combined wrapper.
  • the combined wrapper circumscribes the aerosol-cooling element and the support element, but does not circumscribe a further downstream, such as a mouthpiece element.
  • the aerosol-cooling element and the support element are combined prior to being circumscribed by the combined wrapper, before they are further combined with the mouthpiece segment.
  • this is advantageous in that it enables shorter aerosol-generating articles to be assembled.
  • an aerosol-cooling element of 10 millimetres can be combined with a pair of support elements of 7 millimetres on each side (and potentially with other elements like the rod of aerosol-generating substrate, etc.) to provide a hollow segment of 24 millimetres, which is subsequently cut into two intermediate hollow sections of 12 millimetres.
  • the other components of the aerosol-generating article are individually circumscribed by their own wrapper.
  • the upstream element, the rod of aerosol-generating substrate, the support element, and the aerosol-cooling element are all individually wrapped.
  • the support element and the aerosol-cooling element are combined to form the intermediate hollow section. This is achieved by wrapping the support element and the aerosol-cooling element by means of a combined wrapper.
  • the upstream element, the rod of aerosol-generating substrate, and the intermediate hollow section are then combined together with an outer wrapper. Subsequently, they are combined with the mouthpiece element - which has a wrapper of its own - by means of tipping paper.
  • At least one of the components of the aerosol-generating article is wrapped in a hydrophobic wrapper.
  • hydrophobic refers to a surface exhibiting water repelling properties.
  • the “water contact angle” is the angle, conventionally measured through the liquid, where a liquid/vapour interface meets a solid surface. It quantifies the wettability of a solid surface by a liquid via the Young equation. Hydrophobicity or water contact angle may be determined by utilizing TAPPI T558 test method and the result is presented as an interfacial contact angle and reported in "degrees" and can range from near zero to near 180 degrees.
  • the hydrophobic wrapper is one including a paper layer having a water contact angle of about 30 degrees or greater, and preferably about 35 degrees or greater, or about 40 degrees or greater, or about 45 degrees or greater.
  • the paper layer may comprise PVOH (polyvinyl alcohol) or silicon.
  • PVOH polyvinyl alcohol
  • the PVOH may be applied to the paper layer as a surface coating, or the the paper layer may comprise a surface treatment comprising PVOH or silicon.
  • an aerosol-generating article in accordance with the present invention comprises, in linear sequential arrangement, an upstream element, a rod of aerosol-generating substrate located immediately downstream of the upstream element, a support element located immediately downstream of the rod of aerosol-generating substrate, an aerosol-cooling element located immediately downstream of the support element, a mouthpiece element located immediately downstream of the aerosol-cooling element, and an outer wrapper circumscribing the upstream element, the support element, the aerosol-cooling element and the mouthpiece element.
  • the rod of aerosol-generating substrate may abut the upstream element.
  • the support element may abut the rod of aerosol-generating substrate.
  • the aerosol-cooling element may abut the support element.
  • the mouthpiece element may abut the aerosol-cooling element.
  • the aerosol-generating article has a substantially cylindrical shape and an outer diameter of about 7.25 millimetres.
  • the upstream element has a length of about 5 millimetres
  • the rod of aerosol-generating article has a length of about 12 millimetres
  • the support element has a length of about 8 millimetres
  • the mouthpiece element has a length of about 12 millimetres.
  • an overall length of the aerosol-generating article is about 45 millimetres.
  • the upstream element is in the form of a plug of cellulose acetate wrapped in stiff plug wrap.
  • the aerosol-generating article comprises an elongate susceptor element arranged substantially longitudinally within the rod of aerosol-generating substrate and is in thermal contact with the aerosol-generating substrate.
  • the susceptor element is in the form of a strip or blade, has a length substantially equal to the length of the rod of aerosol-generating substrate and a thickness of about 60 micrometres.
  • the support element is in the form of a hollow cellulose acetate tube and has an internal diameter of about 1.9 millimetres. Thus, a thickness of a peripheral wall of the support element is about 2.675 millimetres.
  • the aerosol-cooling element is in the form of a finer hollow cellulose acetate tube and has an internal diameter of about 3.25 millimetres. Thus, a thickness of a peripheral wall of the aerosol-cooling element is about 2 millimetres.
  • the mouthpiece is in the form of a low-density cellulose acetate filter segment.
  • the rod of aerosol-generating substrate comprises an aerosol-generating substrate comprising a gel composition.
  • the aerosol-generating article 10 shown in Figure 1 comprises a rod 12 of aerosol-generating substrate and a downstream section 14 at a location downstream of the rod 12 of aerosol-generating substrate. Further, the aerosol-generating article 10 comprises an upstream section 16 at a location upstream of the rod 12 of aerosol-generating substrate. Thus, the aerosol-generating article 10 extends from an upstream or distal end 18 to a downstream or mouth end 20.
  • the aerosol-generating article has an overall length of about 45 millimetres.
  • the downstream section 14 comprises a support element 22 located immediately downstream of the rod 12 of aerosol-generating substrate, the support element 22 being in longitudinal alignment with the rod 12. In the embodiment of Figure 1 , the upstream end of the support element 22 abuts the downstream end of the rod 12 of aerosol-generating substrate. In addition, the downstream section 14 comprises an aerosol-cooling element 24 located immediately downstream of the support element 22, the aerosol-cooling element 24 being in longitudinal alignment with the rod 12 and the support element 22. In the embodiment of Figure 1 , the upstream end of the aerosol-cooling element 24 abuts the downstream end of the support element 22.
  • the support element 22 and the aerosol-cooling element 24 together define an intermediate hollow section 50 of the aerosol-generating article 10.
  • the intermediate hollow section 50 does not substantially contribute to the overall RTD of the aerosol-generating article.
  • An RTD of the intermediate hollow section 50 as a whole is substantially 0 millimetres H 2 O.
  • the support element 22 comprises a first hollow tubular segment 26.
  • the first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made of cellulose acetate.
  • the first hollow tubular segment 26 defines an internal cavity 28 that extends all the way from an upstream end 30 of the first hollow tubular segment to an downstream end 32 of the first hollow tubular segment 26.
  • the internal cavity 28 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 28.
  • the first hollow tubular segment 26 - and, as a consequence, the support element 22 - does not substantially contribute to the overall RTD of the aerosol-generating article 10.
  • the RTD of the first hollow tubular segment 26 (which is essentially the RTD of the support element 22) is substantially 0millimetres H 2 O.
  • the first hollow tubular segment 26 has a length of about 8 millimetres, an external diameter of about 7.25 millimetres, and an internal diameter (D FTS ) of about 1.9 millimetres.
  • a thickness of a peripheral wall of the first hollow tubular segment 26 is about 2.67 millimetres.
  • the aerosol-cooling element 24 comprises a second hollow tubular segment 34.
  • the second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made of cellulose acetate.
  • the second hollow tubular segment 34 defines an internal cavity 36 that extends all the way from an upstream end 38 of the second hollow tubular segment to a downstream end 40 of the second hollow tubular segment 34.
  • the internal cavity 36 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 36.
  • the second hollow tubular segment 34 - and, as a consequence, the aerosol-cooling element 24 - does not substantially contribute to the overall RTD of the aerosol-generating article 10.
  • the RTD of the second hollow tubular segment 34 (which is essentially the RTD of the aerosol-cooling element 24) is substantially 0 millimetres H 2 O.
  • the second hollow tubular segment 34 has a length of about 8 millimetres, an external diameter of about 7.25 millimetres, and an internal diameter (D STS ) of about 3.25 millimetres.
  • a thickness of a peripheral wall of the second hollow tubular segment 34 is about 2 millimetres.
  • a ratio between the internal diameter (D FTS ) of the first hollow tubular segment 26 and the internal diameter (D STS ) of the second hollow tubular segment 34 is about 0.75.
  • the aerosol-generating article 10 comprises a ventilation zone 60 provided at a location along the second hollow tubular segment 34.
  • the ventilation zone is provided at about 2 millimetres from the upstream end 38 of the second hollow tubular segment 34.
  • a ventilation level of the aerosol-generating article 10 is about 25 percent.
  • the downstream section 14 further comprises a mouthpiece element 42 at a location downstream of the intermediate hollow section 50.
  • the mouthpiece element 42 is positioned immediately downstream of the aerosol-cooling element 24. As shown in the drawing of Figure 1 , an upstream end of the mouthpiece element 42 abuts the downstream end 40 of the aerosol-cooling element 24.
  • the mouthpiece element 42 is provided in the form of a cylindrical plug of low-density cellulose acetate.
  • the mouthpiece element 42 has a length of about 12 millimetres and an external diameter of about 7.25 millimetres.
  • the RTD of the mouthpiece element 42 is about 12 millimetres H 2 O.
  • the rod 12 comprises an aerosol-generating substrate comprising a porous medium loaded with a gel composition as defined above.
  • a suitable gel composition is shown below in Table 1: Table 1: Gel composition Component Amount (% by weight) Water 20 Glycerol 73.5 Nicotine 1.5 Gelling agent 3 Lactic acid 1 Divalent cations 1
  • the rod 12 of aerosol-generating substrate has an external diameter of about 7.25 millimetres and a length of about 12 millimetres.
  • the aerosol-generating article 10 further comprises an elongate susceptor element 44 within the rod 12 of aerosol-generating substrate.
  • the susceptor element 44 is arranged substantially longitudinally within the aerosol-generating substrate, such as to be approximately parallel to the longitudinal direction of the rod 12. As shown in the drawing of Figure 1 , the susceptor element 44 is positioned in a radially central position within the rod and extends effectively along the longitudinal axis of the rod 12.
  • the susceptor element 44 extends all the way from an upstream end to a downstream end of the rod 12. In effect, the susceptor element 44 has substantially the same length as the rod 12 of aerosol-generating substrate.
  • the susceptor element 44 is provided in the form of a strip and has a length of about 12 millimetres, a thickness of about 60 micrometres, and a width of about 4 millimetres.
  • the upstream section 16 comprises an upstream element 46 located immediately upstream of the rod 12 of aerosol-generating substrate, the upstream element 46 being in longitudinal alignment with the rod 12.
  • the downstream end of the upstream element 46 abuts the upstream end of the rod 12 of aerosol-generating substrate. This advantageously prevents the susceptor element 44 from being dislodged. Further, this ensures that the consumer cannot accidentally contact the heated susceptor element 44 after use.
  • the upstream element 46 is provided in the form of a cylindrical plug of cellulose acetate circumscribed by a stiff wrapper.
  • the upstream element 46 has a length of about 5 millimetres.
  • the RTD of the upstream element 46 is about 30 millimetres H 2 O.

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  • Chemical & Material Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Botany (AREA)
  • Agronomy & Crop Science (AREA)
  • Medicinal Preparation (AREA)
  • Cosmetics (AREA)
  • Chemical Vapour Deposition (AREA)
  • Cigarettes, Filters, And Manufacturing Of Filters (AREA)
  • Manufacture Of Tobacco Products (AREA)
  • Thermotherapy And Cooling Therapy Devices (AREA)
EP21706317.1A 2020-02-28 2021-02-24 Aerosol-generating article including substrate with gel composition Active EP4110096B1 (en)

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PCT/EP2021/054540 WO2021170642A1 (en) 2020-02-28 2021-02-24 Aerosol-generating article including substrate with gel composition

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KR20260050355A (ko) 2023-08-10 2026-04-14 필립모리스 프로덕츠 에스.에이. 에어로졸 발생 장치에 사용하기 위한 카트리지
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ZA202210613B (en) 2024-09-25
IL295850A (en) 2022-10-01
CA3168541A1 (en) 2021-09-02
ES3008185T3 (en) 2025-03-21
BR112022016677A2 (pt) 2022-10-11
WO2021170642A1 (en) 2021-09-02
MX2022010525A (es) 2022-09-19
HUE069929T2 (hu) 2025-04-28
KR20220146526A (ko) 2022-11-01
CN115243570A (zh) 2022-10-25
US20230090088A1 (en) 2023-03-23
AU2021225347A1 (en) 2022-09-22
PL4110096T3 (pl) 2025-05-12
PH12022552130A1 (en) 2024-01-29
JP2023516958A (ja) 2023-04-21
EP4110096A1 (en) 2023-01-04
JP7769621B2 (ja) 2025-11-13

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