GB2534208A

GB2534208A - Aerosol-generating article

Info

Publication number: GB2534208A
Application number: GB1500804.8A
Authority: GB
Inventors: Reevell Tony
Original assignee: NGIP Research Ltd
Current assignee: NGIP Research Ltd
Priority date: 2015-01-19
Filing date: 2015-01-19
Publication date: 2016-07-20
Anticipated expiration: 2035-01-19
Also published as: GB2534208B; GB201500804D0

Abstract

An aerosol-generating article 2 for use with an aerosol-generating device comprising a heater, the article 2 comprising a first mouthpiece 20 at an article first end 4, a second mouthpiece 22 at an article second end 6 and an aerosol-forming substrate 10 between the mouthpieces. The substrate may be made from tobacco and the mouthpieces may comprise filters. The filters may be identical or alternatively of different densities. The filters may be pierceable by a heating element of the device. The article may be manufactured by forming a continuous rod of alternating tobacco and filter elements, wrapped in an outer paper, and cutting the rod in the middle of each filter element. Each end of the article may be wrapped in tipping paper which may allow a user to differentiate between the filter densities.

Description

Aerosol-Generating Article The present specification relates to an aerosol-generating article. In particular, but not exclusively, the present specification concerns an aerosol-generating article comprising an aerosol-forming substrate, a first mouthpiece and a second mouthpiece.

Heated tobacco articles are -Known alternatives to conventional cigarettes and function by releasing a nicotine-containing aerosol through heating rather than burning. By avoiding the combustion and pyrolytic degradation of tobacco, these heatnot-burn products are thought to reduce harm to the user.

Example commercial products that use a device having an electrical heater to heat tobacco rods include those from Philip Morris International such as Accord®, Heatbar® and more recently IQOS® using Heatsticksg.

An example of an aerosol-generating article for use with an aerosol-generating device is disclosed in WO 2013/098405 A2. This describes a tobacco rod and an electrical heating device. In use, an internal heating element is inserted into the tip end of the rod to heat the tobacco and generate an aerosol. The aerosol can then be inhaled through a mouthpiece.

According to a first aspect, there is provided an aerosol-generating article for use with an aerosol-generating device comprising a heater, the article comprising a first mouthpiece at an article first end, a second mouthpiece at an article second end and an aerosol-forming substrate between the mouthpieces.

In other words, an aerosol-generating article comprises a first 35 end and a second end where the first end may be configured to be used as a mouthpiece and the second end may be also configured to be used as a mouthpiece. Therefore the article has two ends, each of which can be chosen by the user to be used as a mouthpiece.

The article may comprise an airflow outlet, where either article end may be selected as the airflow outlet. The article first end may be an airflow outlet when the article second end is an airflow inlet and the article first end may be an airflow inlet when the article second end is an airflow outlet.

In use, a user can use the aerosol-generating article with an aerosol-generating device and choose to align the article accordingly to use the first mouthpiece or the second mouthpiece. If a user selects the first mouthpiece to inhale the aerosol, the first mouthpiece is used as an airflow outlet and the second mouthpiece is used as an airflow inlet. Alternatively, if a user selects the second mouthpiece to inhale the aerosol, the second mouthpiece is used as an airflow outlet and the first mouthpiece is used as an airflow inlet.

The article may be rod shaped and comprise an outer wrapper circumscribing the article components. The rod may a cylindrical rod. The rod may be elongated and have the first mouthpiece at the first end of the rod, the second mouthpiece at the second end of the rod, and the aerosol-forming substrate between the mouthpieces. The outer wrapper may comprise cigarette paper.

The article may further comprise a first tipping paper circumscribing the first mouthpiece and a second tipping paper circumscribing the second mouthpiece.

Alternatively, the mouthpieces and aerosol-forming substrate may be wrapped separately and joined by additional wrappers. In 35 other words, a first outer wrapper may circumscribe the first mouthpiece, a second outer wrapper may circumscribe the second mouthpiece and a third outer wrapper may circumscribe the aerosol-forming substrate and any other article components. A first tipping paper may then circumscribe the first outer wrapper and part of the third outer wrapper to join the two together. A second tipping paper may circumscribe the second outer wrapper and part of the third outer wrapper join the two together. In this way, tipping papers may be used to join parts and create a single rod.

This provides a single rod with the resemblance of a conventional cigarette, however, having a mouthpiece at both ends rather than just one end.

The outer wrapper may comprise a first design and the article first end and a second design at the article second end. Alternatively, the first tipping paper may comprise a first design and the second tipping paper may comprise a second design.

The first design may be substantially the same as the second design. The outside visual appearance of the aerosol-generating article may appear substantially symmetrical between an article midpoint and article ends. Alternatively, the first design may be different to the second design. Differing designs allow a user to distinguish between article ends and choose an appropriate end. One or both designs may comprise a traditional tipping paper cork effect pattern.

The first mouthpiece may comprise a first end plug at the first 30 end of the article. The second mouthpiece may comprise a second end plug at the second end of the article.

In use, the aerosol-generating device may comprise a heating element configured to penetrate the end of the article such 35 that the heating element is then internally in direct contact with the aerosol-forming substrate.

As such, the first end plug may be penetrable by a heating element in an aerosol-generating device. The second end plug may be penetrable by a heating element in an aerosol-generating device. In other words, each end plug may be penetrable by a heating element in an aerosol-generating device.

Each end plug may be pierceable. Alternatively each end plug may comprise a slit or a hole, configured in use to expand to allow entry for a heating element as the article is pushed onto the heating element. On removing the article from the heating element, the expanded end plug may be configured to substantially contract to its pre-penetrated state. When a heating element is removed from the article, the penetrated end plug may act to prevent the aerosol-forming substrate from being removed along with the heating element. The penetrated end plug essentially acts to wipe the heating element clean as the heating element is removed.

Alternatively, a device may comprise an external heating element configured to heat the outside of the article and thus indirectly heat the aerosol-forming substrate. Each end plug may be substantially non-penetrable by a heating element in an aerosol-generating device.

Each end plug may comprise a hole through the end plug. The hole may be aligned with the article central longitudinal axis. Each end plug may comprise two or more holes through the end plug. Each hole may he sized to prevent the aerosol-forming substrate from leaving the article through the hole. In this way, the hole provides a more efficient means for aerosol to leave the article.

The aerosol-forming substrate may be compressible when pressure 35 is applied to an article outer surface covering the aerosol-forming substrate. The aerosol-forming substrate may be compressible so as to increase the thermal mass of the aerosol-forming substrate. This leads to increased heating efficiency. The aerosol-forming substrate may be compressed by a user's hand. The aerosol-forming substrate may be compressed by an a compressor in an aerosol-generating device.

Each mouthpiece may comprise a filter. The filter material may comprise material used in conventional combustible cigarettes. The filter may comprise cellulose acetate tow. The filter density may be substantially the same as a conventional combustible cigarette. Alternatively the filter density may be lower than that used in a conventional combustible cigarette. This would allow more of the aerosol to exit the article during inhalation.

The first mouthpiece may have substantially the same dimensions as the second mouthpiece. The first mouthpiece may have a different density to the second mouthpiece. This would provide two different inhalation experiences and thereby provide the user with a choice of mouthpiece and experience. Alternatively, the first mouthpiece may be substantially identical to the second mouthpiece. The mouthpieces may be substantially cylindrical.

The aerosol-forming substrate is the material that is heated by a heating element to produce an inhalable aerosol. The aerosol-forming substrate may comprise a solid material. Additionally, the aerosol-forming substrate may comprise a liquid material.

The solid material may he a carrier for the liquid material.

The aerosol-forming substrate may comprise one or more of: nicotine, propylene glycol, glycerine, ethanol or water. Articles containing nicotine provide a user with a means of inhaling a nicotine aerosol as an alternative to smoking combustible cigarettes. Articles not containing nicotine provide a user with a sensory experience that is an alternative to smoking.

The aerosol-forming substrate may comprise tobacco. The tobacco 5 may be shredded tobacco. The tobacco may comprise a sheet of tobacco.

The shredded tobacco may comprise a first cut tobacco of substantially a first size. Additionally, the tobacco may comprise a second cut tobacco of substantially a second size.

The second cut tobacco may be smaller than the first cut tobacco.

The second cut tobacco may have a size approximately between 5% 15 and 50% the size of the first cut tobacco. The second cut tobacco may have a size approximately between 10% and 30% the size of the first cut tobacco.

The first cut tobacco may comprise one or more additives selected from: nicotine, propylene glycol or glycerine. The second cut tobacco may comprise one or more additives selected from: nicotine, propylene glycol or glycerine. The first cut tobacco may comprise a different tobacco material compared to the second cut tobacco. The first cut tobacco may comprise different additives compared to the second cut tobacco.

The sheet of tobacco may be a homogenised sheet of tobacco material. This is formed by agglomerating particulate tobacco into a sheet having a width and length substantially greater that a thickness. The sheet may be gathered into the article by folding or compressing. The sheet may further be processed to increase its surface area by texturing, crimping, embossing or otherwise deforming.

The aerosol-forming substrate may be sealed within the article between the ends of the article.

The aerosol-generating article may further comprise a support element, where the support element may abut the aerosol-forming substrate. The support element may be circumscribed by an outer 5 wrapper. As such, the support element may comprise an outer circumference substantially equal to the aerosol-forming substrate. The support element outer wrapper may be the same outer wrapper as that which circumscribes the aerosol-forming substrate. In this way, both the aerosol-forming substrate and 10 support element are circumscribed by an outer wrapper to hold the parts together.

The support element may be located within the aerosol-forming substrate. The support element may be a divider and divide the aerosol-forming substrate into a first aerosol-forming substrate and a second aerosol-forming substrate on either side of the support element. In other words, the aerosol-generating article comprises a first aerosol-forming substrate, a second aerosol-forming substrate and support element between aerosol-forming substrates.

The first aerosol-forming substrate may be the same as the second aerosol-forming substrate. Alternatively, the first aerosol-forming substrate may be a different composition to the second aerosol-forming substrate.

The support element may be positioned substantially in the middle of the aerosol-generating article between ends.

The support element may act to support the aerosol-forming substrate as a heating element in penetrated into an article end. In other words, the support prevents the aerosol-forming substrate from being pushed out of the way by a penetrating heating element.

The support element may be configured such that it does not substantially restrict the airflow flowing through the article during use. In other words, the support element provides a restriction to airflow that is less than the restriction to airflow provided by at least one other article component, thereby not being the overall restricting element.

The support may comprise a tube shape with a central opening. As such, the central opening reduces restriction to airflow through the article.

The support element may be made from a material selected to give structural support. The support element may be rigid. The support element may be substantially non-compressible. In other words, the support may not easily be compressed when squeezed in the hand of an average typical user.

The support element may comprise conventional filter material such as cellulose acetate tow. The cellulose acetate may be 20 denser that typically used in a filter, to provide suitable support.

Alternatively, the support element may comprise plastics material. The plastics material may be substantially heat resistant at the temperatures subjected to the article in use.

The support element may comprise an extruded shape. The extruded shape may comprise a tube have one more inner holes along the extruded axis thereby forming inner airflow channels.

The aerosol-generating article may further comprise an aerosol-cooling element. In use, an aerosol-generating article is heated using an aerosol-generating device in order to produce aerosol for a user to inhale. Aerosol initially produced may be hot and an aerosol-cooling element acts to cool the aerosol prior to inhalation by a user.

The aerosol-cooling element may comprise a high surface area. In other words, the aerosol-cooling element comprises a high surface over which air and aerosol can flow in use. The high surface area is relative to the outer surface area of the aerosol-forming element. The high surface area provides a means by which the aerosol may condense and cool prior to being inhaled.

The aerosol-cooling element may comprise a plurality of airflow channels to create a high airflow surface area. Alternatively, the aerosol-cooling element may comprise an open pore material to create a high airflow surface area. The plurality of channels or open pore material allows air to flow without significant restriction whilst providing a high surface area aerosol-cooling surface.

The open pore material may be comprise one or more of: a foamed material such as foamed plastics, or foamed metal; porous ceramic; conventional filter material such as cellulose acetate tow; bundled fibres or strands such as metal wool or bunched wire.

The plurality of airflow channels may be created using a folded or gathered sheet of material such as paper or plastics material. Alternatively, the aerosol-cooling element may comprise an extruded form having multiple open channels along the extruded axis. The extruded axis may be aligned with the article length axis. The extruded form may comprise plastics material or metallic material.

The aerosol-cooling element may comprise substantially cylindrical form. The aerosol-cooling element may be substantially rigid. The aerosol-cooling element may be substantially non-compressible.

The aerosol-cooling element may be a first aerosol-cooling element and may be positioned between the first mouthpiece and the aerosol-forming substrate. The first aerosol-cooling element may abut the first mouthpiece. The first aerosol-cooling element may abut the aerosol forming substrate.

The aerosol-generating article may comprise a second aerosol-cooling element. The second aerosol-cooling element may be positioned between the second mouthpiece and the aerosol-forming substrate. The second aerosol-cooling element may abut the second mouthpiece. The second aerosol-cooling element may abut the aerosol-forming substrate.

Each aerosol-cooling element may be circumscribed by an outer wrapper. As such, each aerosol-cooling element may comprise an outer circumference substantially equal to the aerosol-forming substrate. The aerosol-cooling element outer wrapper may be the same outer wrapper as that which circumscribes the aerosol-forming substrate. In this way, both the aerosol-forming substrate and the aerosol-cooling element or elements are circumscribed by an outer wrapper to hold the parts together.

In use, when the article is configured to be used with an aerosol-generating device comprising a penetrating heating element, the aerosol-cooling element may be penetrable by a heating element in an aerosol-generating device in order for the heating element to reach the aerosol-forming substrate. In other words, each aerosol-cooling element may be penetrable by a heating element in an aerosol-generating device.

The aerosol-generating article may further comprise a non-compressible element. In other words, an element that cannot be easily compressed in the hand of an average user.

The non-compressible element may comprise a solid material. The non-compressible element may comprise a rigid material. The non-compressible element may comprise a heat-resistant material. In other words, the non-compressible element may be heat resistant for typical temperatures at which the article will be used.

The non-compressible eleme= may comprise a tubular form.

Alternatively, the non-compressible element may be substantially spherical. Alternatively, the non-compressible element may be substantially disc-shaped. The non-compressible element may comprise one or more airflow channels or open pores to allow air flow. In this way, airflow is not substantially restricted yet the element remains non-compressible.

The non-compressible element may comprise plastics material, 15 ceramic material, metallic material or some other rigid material such as density gathered paper.

In use, the non-compressible element may act to prevent a region of the aerosol-generating article from being compressed by an aerosol-generating device. This ensures that the aerosol-generating article is compressed in the required region and not in the non-compression region.

The non-compressible element may be positioned between the first mouthpiece and the aerosol-forming substrate. Alternatively, the non-compressible element may be positioned between the second mouthpiece and the aerosol forming substrate.

Alternatively, the non-compressible element may comprise a first non-compressible element positioned between the first mouthpiece and the aerosol-forming substrate. The aerosol-generating article may further comprise a second non-compressible element positioned between the second mouthpiece and the aerosol-forming substrate.

Each non-compressible element may be circumscribed by an outer wrapper. As such, each non-compressible element may comprise an outer circumference substantially equal to the aerosol-forming substrate. The non-compressible element outer wrapper may be the same outer wrapper as that which circumscribes the aerosol-forming substrate. In this way, both the aerosol-forming substrate and the non-compressible element or elements are circumscribed by an outer wrapper to hold the parts together.

The aerosol-generating article may be substantially functionally symmetrical between an article midpoint and article ends.

The article may further comprise a capsule, where the capsule 15 may comprise an additive and may be configured tc open under pressure to release the additive into the article.

The capsule may be located within the aerosol-forming substrate. The capsule may be substantially in the middle of the article.

Alternatively, the capsule may be located at the article first end. Alternatively, the capsule is located at the article second end.

The capsule may be a first capsule comprising a first additive and the article may further comprise a second capsule comprising a second additive, where the first capsule is located at the article first end and the second capsule is located at the article second end.

Where an article comprises a first mouthpiece at a first article end and second mouthpiece at a second article end, the first mouthpiece may comprise a first capsule and a second 35 mouthpiece may comprise a second capsule.

The first additive may be different to the second additive. Each additive may be a liquid additive. Each additive may be a flavorant. A flavorant may comprise menthol.

Each additive may be a non-flavorant additive. The nonflavorant additive may comprise nicotine. The non-flavorant additive may comprise propylene glycol. The non-flavorant additive may comprise glycerine.

The capsule may be configured in use to open under pressure of a user squeezing between fingertips. The capsule may be configured in use to open under pressure of a device compressor. The capsule may be configured in use to open under heating. The capsule may be configured in use to open as the aerosol-forming substrate is heated to generate an aerosol.

The aerosol-generating article may comprise a mark on the outer surface to denote the different capsules. The aerosol-generating article may comprise a first mark on the outer surface in the region of the first capsule. The aerosol-generating article may comprise a second mark on the outer surface in the region of the second capsule. The first mark and the second mark may be different. A user is then able to identify and select an article end with a particular capsule.

The aerosol-generating article may further comprise a smell flavorant. In other words, an aroma or scent or fragrance that is sensed by the nose rather than by inhalation through the mouth. The smell flavorant is located on the outside of the aerosol-generating article. The smell flavorant may be impregnated in the outer wrapper. The smell flavorant may be added to the outer surface of the article.

The smell flavorant may be covered by a cover. The cover may 35 provide an airtight seal. As such, the smell flavorant is not available to the user until the cover is broken. The cover may be broken under pressure such as by scratching the cover or by pressing. Alternatively, the cover may be removed by pulling, peeling or unwrapping. Alternatively, the cover may be broken by heat. The cover may comprise a layer configured to disintegrate under heat.

The aerosol-generating article may comprise a first smell flavorant at a first position on the article outer surface. The aerosol-generating article may comprise a second smell flavorant at a second position on the article outer surface. The first smell flavorant and second smell flavorant may be located substantially the same distance between the article ends. Each smell flavorant may be located along the article length at the position of the aerosol-forming substrate.

Where the article is substantially in the form of a rod, the first smell flavorant and second smell flavorant may be spaced apart circumferentially. In other words, the smell flavorants are located substantially the same distance between ends but at different positions around the circumference of the rod shaped article. The first smell flavorant and second smell flavorant may be spaced apart evenly around the article. For example, for two smell flavorants they may be diametrically opposite.

The aerosol-generating article may further comprise a third smell-flavorant. All smell flavorants may be located substantially at the same distance between article ends and spaced apart circumferentially. All smell flavorants may be spaced apart evenly.

The article comprising external smell flavorants may be used with an aerosol-generating device configured to heat the article externally from an outer surface. In use, the article may be placed into the device comprising a heater, bringing the part of the article comprising the aerosol-forming substrate into contact with the heater. The smell flavorant may be located within the heater region and aroma may be liberated on heating of the article. In addition, the article may be orientated such that the smell flavorant is in direct contact with the heater to liberate an aroma. Where an article comprises more than one smell flavorant spaced apart around the article, the article may be configured such that only the smell flavorant in direct contact with the heater is liberated. The article may be marked to show the position of each smell flavorant so that a user can position the article in the device relative to the heater to select the required aroma.

The outer wrapper may comprise a metallic foil section. The metallic foil section may be attached as part of the outer wrapper. Alternative, the metallic foil section may be a separate component.

The metallic foil section may be located on an outer wrapper inner surface. The metallic foil section may be located on an outer wrapper outer surface. The metallic foil section may 20 cover only part of an outer wrapper surface.

The metallic foil section may comprise a strip having a length extending along the length of the article and a width extending around the circumference of the article.

The strip length may be less that the length of the article. The strip length may extend along the length of the aerosol-forming substrate.

The strip width may be the circumference of the article, forming a metallic foil tube. Alternatively, the strip width may be less that the circumference of the article. The strip width may be substantially equal to half the circumference of the article. Alternatively, the strip width may be less than half the circumference of the article.

The metallic foil section may substantially cover the whole of an outer wrapper surface. The outer wrapper may be metallic foil.

The article may be marked on the outer wrapper outer surface to show the location of the metallic foil section. The article may be marked on the outer wrapper outer surface to show the location of a non-foil section.

The article may be configured such that under compression the foil section is deformed and substantially retains the deformed shape once compression is removed. The article may be configured to be pressed against a device surface comprising a surface variation such that the foil section retains the impression of the surface variation after removal from the device.

The metallic foil may comprise aluminium foil. Any non-foil section of the outer wrapper may comprise cigarette paper.

The aerosol-generating article may comprise an outer diameter between approximately 6mm and 12mm. The aerosol-generating article may comprise an outer diameter between approximately 6mm and 10mm. The aerosol-generating article may comprise an outer diameter between approximately 7mm and 9mm. The aerosol-generating article may comprise a diameter of approximately The aerosol-generating article may comprise a length between approximately 30mm and 100mm. The aerosol-generating article may comprise a length between approximately 45mm and 85mm. The aerosol-generating article may comprise a length of approximately 45mm. The aerosol-generating article may comprise a length of approximately 60mm.

Each mouthpiece may comprise an outer diameter substantially the same as the article outer diameter.

Each mouthpiece may comprise a length between approximately 5mm 5 and 20mm. Each mouthpiece may comprise a length between approximately 5mm and 10mm.

Each tipping paper may comprise a length between approximately 5mm and 20mm. Each tipping paper may comprise a length between 10 approximately 10mm and 15mm.

Each support element may comprise an outer diameter substantially the same as the article outer diameter.

Each support element may comprise a length between approximately 2mm and 10mm. Each support element may comprise a length of between approximately 4mm and 8mm.

A support element central opening may have a diameter between 20 approximately 50% and 90% of the outer support diameter. A support element central opening may have a diameter between approximately 70% and 90% of the outer support diameter.

Each non-compression element may comprise an outer diameter substantially the same as the article outer diameter.

Each non-compression element may comprise a length between approximately 2mm and 10mm. Each non-compression element may comprise a length between approximately 4mm and 2mm.

Each aerosol-cooling element may comprise an outer diameter substantially the same as the article outer diameter.

Each aerosol-cooling element may comprise a length between 35 approximately 5mm and 25mm. Each aerosol-cooling element may comprise a length between approximately 10mm and 20mm.

Each aerosol-cooling element may comprise a cooling surface area between approximately 100 square millimetres and 1000 square millimetres for each millimetre of length. Each aerosol-cooling element may comprise a cooling surface area between approximately 400 square millimetres and 600 square millimetres for each millimetre of length.

Each aerosol-forming substrate may comprise an outer diameter substantially the same as the article outer diameter.

The aerosol-forming substrate may comprise a length between approximately 5mm and 50mm. The aerosol-forming substrate may comprise a length between approximately 10mm and 40mm. The aerosol-forming substrate may comprise a length between approximately 10mm and 25mm. The aerosol-forming substrate may comprise a length between approximately 25mm and 40mm.

The article aerosol-forming substrate may be compressed such that the smallest outer diameter is reduced between approximately 10% and 60%. The article may be compressed such that the smallest outer diameter is reduced between approximately 20% and 50%. The article may be compressed such that the smallest outer diameter is reduced between approximately 30% and 400.

For the avoidance of doubt, it should be stated that a plurality of aerosol-generative article configurations are possible based on the above description. Explicit examples that 30 combine parts already described are now given below.

The aerosol-generating article in the form of a rod may comprise a first mouthpiece, an aerosol-forming substrate and a second mouthpiece, all circumscribed by an outer wrapper and arranged sequentially within the wrapper.

The aerosol-generating article in the form of a rod may comprise a first mouthpiece, a first aerosol-forming substrate, a support element, a second aerosol-forming substrate and a second mouthpiece, all circumscribed by an outer wrapper and arranged sequentially within the wrapper.

The aerosol-generating article in the form of a rod may comprise a first mouthpiece, a first aerosol-cooling element, an aerosol-forming substrate, a second aerosol-cooling element and a second mouthpiece, all circumscribed by an outer wrapper and arranged sequentially within the wrapper.

The aerosol-generating article in the form of a rod may comprise a first mouthpiece, a first aerosol-cooling element, an aerosol-forming substrate, a second aerosol-cooling element and a second mouthpiece, where the first mouthpiece is circumscribed by a first outer wrapper, the second mouthpiece is circumscribed by a second outer wrapper, and the first aerosol-cooling element, an aerosol-forming substrate and the second aerosol-cooling element are arranged sequentially and circumscribed by a third outer wrapper, where a first tipping paper circumscribes the first outer wrapper and part of the third outer wrapper to join the two together, a second tipping paper circumscribes the second outer wrapper and part of the third outer wrapper join the two together.

Although not explicitly stated, other example combinations are also possible.

According to a second aspect, there is provided a method of forming an aerosol-generating article comprising the steps of: arranging a mouthpiece element and an aerosol-forming substrate element in a repeated and continuous sequence; wrapping the elements to form a continuous rod; and cutting the rod at the midpoint of each mouthpiece element to create individual rods with a mouthpiece at each end.

When the mouthpiece element is cut at its midpoint, it creates a first and second mouthpiece, each with half the length of the uncut mouthpiece. The term 'uncut mouthpiece element' refers to the fact that the part will become a mouthpiece element after formation rather than used as a mouthpiece during formation.

The method may comprise the step of: wrapping tipping paper around the mouthpiece section prior to cutting. In this way, when the mouthpiece is cut, the tipping paper is also cut to give individual rods with tipping paper covered mouthpieces at either end.

The method may comprise the step of: wrapping the mouthpiece 15 element separately to the other elements and joining the mouthpiece element to the other elements using the wrapped tipping paper.

The method step of arranging elements in a repeated and continuous sequence may comprise: arranging a mouthpiece element, a first aerosol-forming substrate, a support element, and a second aerosol-forming substrate in a repeated and continuous sequence.

The method step of arranging elements in a repeated and continuous sequence may comprise: arranging a mouthpiece element, a first aerosol-cooling element, an aerosol-forming substrate, and a second aerosol-cooling element in a repeated and continuous sequence.

As described above, the aerosol-generating article has a mouthpiece at each end and various alternative configurations are possible for elements between the mouthpiece ends. The method step of arranging the elements in a repeated and continuous sequence may be such that the article is formed in a continuous fashion, with the mouthpiece element to be later cut at a midpoint to form the first and second mouthpiece ends.

According to a third aspect, there is provided an aerosol-generating system comprising an aerosol-generating article, the article as described above, and an aerosol-generating device comprising a heater.

The aerosol-generating system may be configured such that in use the aerosol-generating article protrudes from the aerosol-generating device to expose an article mouthpiece. In other words, an article mouthpiece may be exposed so that a user can inhale on the article using the article mouthpiece.

The aerosol-generating device may comprise a power source such as a cell or battery. The aerosol-generating device may be electrically operated. The heater may be an electrical heater. The device may comprise an airflow inlet and an airflow outlet, where the device is configured in use to channel airflow through the article.

The aerosol-generating device may comprise an internal heater configured to heat the aerosol-generating article internally. The heater may be penetrated into an end of the aerosol-generating article. The heater may be configured to heat the aerosol-forming substrate by direct contact with the aerosol-forming substrate.

Alternatively, the aerosol-generating device may comprise an external heater configured to heat the aerosol-generating article externally. The heater may contact an outer surface of the aerosol-generating article in the region of the aerosol-forming substrate. The heater may be configured to heat the aerosol-forming substrate from an external surface of the aerosol-generating article.

The aerosol-generating device may comprise a compressor. The compressor may be configured in use to compress the aerosol-generating article. The compressor may be configured to compress the aerosol-forming substrate against a heater so as to increase the thermal mass of the aerosol-forming substrate and increase hearing efficiency. In other words, the compressor is a mechanism that pushes against the article tc deform the outer shape of the article and compress the contents.

The compressor may comprise a moveable element, moveable between a first position substantially not compressing the aerosol-generating article after the article has been inserted fully into the device, and a second position compressing the article such that pressure is applied to the article outer surface and the article is deformed and compressed.

The heater may comprise a heater plate. The heater may comprise a heating element configured to heat the heater plate. Alternatively, the heating element may be formed as part of the heater plate. The heater plate is a rigid surface against which the article can be pressed and may for example be planar or curved. The aerosol-generating system is configured such that in use the compressor acts to press the aerosol-generating article in the region of the aerosol-forming substrate against the heater plate. In this way, the surface area of the article in contact with the heater plate may be increased.

The aerosol-generating device may comprise a length between approximately 20mm and 150mm. The aerosol-generating device may comprise a length between approximately 90mm and 120mm. The aerosol-generating device may comprise a length approximately 100mm.

The heater may be configured to heat at a temperature between approximately 100 degrees Celsius and 300 degrees Celsius. The heater may be configured to heat at a temperature between approximately 150 degrees Celsius and 250 degrees Celsius. The heater may be configured to heat at a temperature of approximately 200 degrees Celsius.

According to a fourth aspect, there is provided a method of using the aerosol-generating system, the system as described above, comprising the steps of: selecting an aerosol-generating article mouthpiece to use from either the first mouthpiece or second mouthpiece; inserting the aerosol-generating article into the aerosol-generating device such that the selected mouthpiece protrudes from the device; raising the temperature of the heater in the aerosol-generating device in order to heat the aerosol-forming substrate to generate an aerosol.

The method may further comprise the step of: penetrating the heater into the article when the article is inserted into the device.

Alternatively, the method may further comprise the step of: aligning the aerosol-forming substrate with an external heater.

When the aerosol-generating device comprises a compressor, the method may further comprise the step of: compressing the aerosol-forming substrate after it has been inserted into the aerosol-forming device. Compressing may involve compressing the aerosol-forming substrate in the heater region of the device. Compressing may involve compressing the aerosol-generating article against a heater plate by moving a compressor from a first position to a second position. Tn the first position the compressor may substantially not compress the article. In the second position, the compressor may be in contact with the article such that pressure is applied to the article outer surface and the article is deformed and compressed.

Specific embodiments will now be described. These are examples only and are described in reference to the accompanying drawings in which: Figure 1 is a perspective view of an aerosol-generating article; Figure 2 is a side cross-sectional view the aerosol-generating article of Figure 1; Figure 3 is a perspective view of the aerosol-generating article of Figure 1 engaged with an aerosol-generating device; Figure 4 is a side cross-sectional view of the aerosol-generating article of Figure 1 showing penetration of the article by a device heating element; Figure 5 is a side cross-sectional view of the aerosol-15 generating article of Figure 1 showing a device external heater in contact with the article; Figure 6 is a side cross-sectional view of the aerosol-generating article of Figure 1 showing a device external heater and compression of the article against the heater; Figure 7 is a side cross-sectional view of the aerosol-generating article of Figure 1 showing penetration of the article by a device heating element and compression of the article against the heating element; Figure 8 is a side cross-sectional view of an aerosol-generating article comprising a central divider; Figure 9 is a side cross-sectional view of an aerosol-generating article comprising aerosol-cooling elements; Figure 10 is a side cross-sectional view of an aerosol-generating article comprising end plugs with apertures; Figure 11 is a side cross-sectional view of an aerosol-generating article comprising non-compression elements; Figure 12 is a side cross-sectional view of an aerosol-generating article comprising a capsule; and Figure 13 is a side cross-sectional view of an aerosol-generating article comprising two capsules.

Figure 1 and Figure 2 show an aerosol-generating article 2 comprising an article first end 4 and an article second end 6. The article 2 is cylindrical in shape and has an outer wrapper 8 tightly wrapped around the article components. Inside the article 2 there is an aerosol-forming substrate 10 between a first end plug 12 and a second end plug 14. The outer wrapper 8 circumscribes the first end plug 12, aerosol-forming substrate 10 and second end plug 14.

The article 2 is similar in shape to a conventional combustible cigarette but is shorter than a typical combustible cigarette and has end plugs at both ends. As such, neither end of the article 2 can be ignited and the article cannot be smoked like a conventional cigarette.

In common with conventional cigarettes, the outer wrapper 8 is cigarette paper and the end plugs are filters made from cellulose acetate tow. The aerosol-forming substrate 10 is tobacco and includes glycerine as an aerosol-forming additive.

The outer wrapper 8 has first design 16 printed on the first end 4 and a second design 18 printed on the second end 6. The designs are the same as the tipping paper design used in a conventional cigarette where a cork effect design is used to highlight the mouthpiece of a cigarette. In this way, the article 2 has two such mouthpiece designs at either end. The article 2 has a first mouthpiece 20 at the article first end 4 and a second mouthpiece 22 at the article second end 6. The article 2 is visually symmetrical and looks the same from either end.

In use, the article 2 is used with an aerosol-generating device 24 such as that shown in Figure 3. The device 24 has a power supply, electronics and a heater. The device 24 has an opening 26 to receive the article 2, is activated by a button 28, and has an air inlet 30.

The article 2 is inserted into the device 24 and the device 24 acts to heat the tobacco 10 and produce an aerosol. An article end protrudes from the device and this article end is used as the mouthpiece through which the aerosol is inhaled. A user can insert the article 2 into the device 24 such that either the first mouthpiece 20 or the second mouthpiece 22 protrudes from the device. As such, a user is able to select one of the two available mouthpieces. When a user inhales through the mouthpiece, air is drawn into the device 24 through the air inlet 30, through the article 2 and out through the selected mouthpiece. The selected mouthpiece is therefore an airflow outlet and the other article end is an airflow inlet.

Figure 4 shows a configuration where the device heater is a piercing heating element 32. In this configuration the heating element 32 has a spiked tip and in use the article 2 is pressed onto the heating element 32 so that the second end plug 14 is pierced by the spike and the heating element is pushed inside the article 2. The heating element 32 is then in direct contact with the aerosol-forming substrate 10. In use, the heating element is able to directly heat the aerosol-forming substrate 10 to produce an aerosol. As the article 2 is removed from the device 24, the heating element 32 is drawn out of the article 2 and the second end plug 14 acts to wipe the heating element 32 clean and prevent any aerosol-forming substrate from leaving the article 2.

Figure 5 shows a different device configuration to that of Figure 4, where the device heater is an external heater 34 positioned against the outer surface of the article 2 rather than penetrated into the article 2. The external heater 34 is aligned next to the aerosol-forming substrate 10 and in use acts to heat the aerosol-forming substrate 10 from the outside of the article 2. On heating, an aerosol is produced that can be inhaled by a user.

In Figure 6 a different device configuration is shown where a device compressor 36 is shown acting on the article 2. The device compressor comprises a movable element 38 that is operable to move and press against the article 2. In Figure 3, the movable element 38 is a lid that is able to pivot about a hinge 40. A gap provided between the hinge 40 and the device body provides the device air inlet 30. When the lid 38 is open, the article 2 can be easily added to and removed from the device 2. When the lid 38 is closed, the compressor 36 presses against the article 2. It can be seen in Figure 6 that the compressor 36 compresses the article 2 in the region of the aerosol-forming substrate 10. The compressor 36 presses the article 2 against the external heater 34 such that the density of the aerosol-forming substrate 10 is increased and the contact of the article 2 with the external heater 34 is increased. This acts to increase the thermal nass of the aerosol-forming substrate 10 and increase the heating efficiency. This also acts to increase the resistance to draw through the article 2.

In Figure 7, a different device configuration is shown, a compressor 36 is shown acting on an article 2 where the heater is the internal heating element 32 shown in Figure 4. Again, the compression of the aerosol-forming substrate 10 acts to increase its thermal mass and pressing the aerosol-forming substrate 10 against the heating element leads to increased heating efficiency.

Figure 8 shows another embodiment, similar to that of Figure 2, where the article 2 further comprises a divider 42. The divider 42 is located half way along the article 42 and divides the aerosol-forming substrate 10 into a two parts, a first aerosol-forming substrate 10a and a second aerosol-forming substrate 10b. The divider 42 is contained within the outer wrapper 8 and comprises cellulose acetate like the filters. The divider 42 is a physical divider and separates the aerosol-forming substrates but allows airflow through the article 2.

In this embodiment, the first aerosol-forming substrate 10a is different to the second aerosol-forming substrate. The article 2 can be used from either end, but the user experience will depend on which end is selected. The article 2 is marked at each end with different designs so that a user is able to distinguish between ends and select an end to be used. When the article 2 is used with a device 24, the aerosol-forming substrate furthest from the selected mouthpiece is heated to release an aerosol. Therefore, the device heater acts only on the aerosol-forming substrate furthest from the selected mouthpiece. Likewise, a compressor acts only on the aerosol-forming substrate furthest from the selected mouthpiece.

In use, the aerosol and vapour from heating travels through the unheated and uncompressed aerosol-forming substrate section prior to being inhaled. This acts to condense further aerosol and cool the aerosol prior to inhalation by the user. This also acts to infuse the aerosol with a fresh tobacco taste of unheated tobacco.

Figure 9 shows another embodiment, similar to that of Figure 2, where the article 2 further comprises a first aerosol-cooling element 44 and a second aerosol-cooling element 46. The first aerosol-cooling element 44 is located between the first end plug 12 and the aerosol-forming substrate 10. The second aerosol-cooling element 46 is located between the second end plug 14 and the aerosol-forming substrate 10. All components are tightly wrapped by the outer wrapper 8.

The aerosol-cooling elements provide a large surface area on which the vapour can condense to form aerosol and where aerosol 35 can cool prior to inhalation. The aerosol-cooling elements comprise paper that is folded many times and packed together such that the gaps are aligned with the article length axis. In this way, the aerosol can travel over the significantly increased surface area between the folds in order to condense and cool.

Where the device 24 provides a piercing heating element 32, the aerosol-cooling elements can also be pierced so that the heating element 32 is able to move through the end plug and aerosol-cooling element in order to reach and heat the aerosol-forming substrate 10.

Figure 10 shows another embodiment, similar to that of Figure 2, where the first end plug 12 comprises a first aperture 48 and the second end plug 14 comprises a second aperture 50. The apertures are holes through the central axis of the end plugs and allow a piercing heating element 32 to be easily pushed through the end plug and into the article 2. In use, as the heating element 32 is pushed into the article, the apertures expand to allow access. Once the heating element is removed, the apertures contract to a smaller size. This acts to effectively seal the end of the article once removed from the device.

Figure 11 shows another embodiment, similar to that of Figure 2, where the article 2 further comprises a first non-compressible element 52 and a second non-compressible element 54. The first non-compressible element 52 is located between the first end plug 12 and the aerosol-forming substrate 10. The second non-compressible element 54 is located between the second end plug 14 and the aerosol-forming substrate 10. All components are tightly wrapped by the outer wrapper 8.

The non-compressible elements are rigid such that they cannot be compressed when squeezed between fingertips. In this 35 embodiment the non-compressible elements are spheres of porous ceramic material. These allow airflow through the article 2 whilst providing non-compressible rigidity. The article 2 in this embodiment is for use with a device 24 comprising an external heating element 34 and a compressor 36. The non-compressible elements ensure that the article is not compressed at an incorrect point. In use, the article 2 is aligned with a device 24 such that the aerosol-forming substrate 10 is compressed and heated between the non-compressible elements. If the article 2 is not aligned correctly then the non-compressible elements do not allow compression and a user is able to determine that the article 2 is not aligned correctly.

A user can then align the article 2 correctly in the device 24 so as to compress and heat only the part of the article 2 comprising the aerosol-forming substrate 10.

Figure 12 shows another embodiment, similar to that of Figure 2, where the article 2 further comprises a capsule 56 containing an additive 58. In this embodiment the capsule is located in the centre of the article 2 within the aerosol-forming substrate 10. The capsule 56 comprises a thin wall polymer material and in use can be ruptured under pressure. The capsule 56 can be ruptured by squeezing between fingertips or under the compression force of a device compressor. The additive 58 is a liquid that leaves the capsule 56 once ruptured and mixes with the aerosol-forming substrate 10. In this embodiment, the additive 58 is a menthol flavorant. In use, an aerosol containing menthol is then produced for the user to inhale.

Figure 13 shows another embodiment, similar to that of Figure 12, where the article 2 comprises a first capsule 56a and a second capsule 56b instead of a single capsule. The first capsule 56a is located at the article first end 9 within the first end plug 12. The second capsule 56b is located at the article second end 6 within the second end plug 14. The first capsule contains a first additive 58a and the second capsule contains a second additive 58b. In this embodiment, the first additive 58a is different to the second additive 58b. The first additive 58a is menthol flavourant and the second additive is a tobacco essence flavourant. The article 2 is marked on the outer surface, having a first design at the first article end 5 and a second design at the second article end so that a user can distinguish between ends and additives. In this way, a user is able to select an end according to the preference of additive. In use, a user selects an end to inhale through and breaks the capsule in the selected end to release the additive. 10 The article 2 is used with a device 24 and the aerosol is flavoured with the additive prior to inhalation.

The embodiments described above are examples only and are not limiting. Other embodiments could also be described and will be apparent to those skilled in the art. Features from different embodiments could be combined to form new embodiments. For example, an article could comprise both aerosol-cooling elements and a divider.

Claims

Claims 1. An aerosol-generating article for use with an aerosol-generating device comprising a heater, the article comprising a first mouthpiece at an article first end, a second mouthpiece at an article second end and an aerosol-forming substrate between the mouthpieces.
2. An aerosol-generating article according to claim 1, 10 comprising an airflow outlet, where either article end may be selected as the airflow outlet.
3. An aerosol-generating article according to claim 2, wherein the article first end is an airflow outlet when the article second end is an airflow inlet and the article first end is an airflow inlet when the article second end is an airflow outlet.
4. An aerosol-generating article according to any preceding claim, wherein the article is rod shaped and comprises an outer 20 wrapper circumscribing the article components.
5. An aerosol-generating article according to any preceding claim, further comprising a first tipping paper circumscribing the first mouthpiece and a second tipping paper circumscribing the second mouthpiece.
6. An aerosol-generating article according to any preceding claim, wherein the outer wrapper comprises a first design at the article first end and a second design at the article second 30 end.
7. An aerosol-generating article according to claim 5, wherein the first tipping paper comprises a first design and the second tipping paper comprises a second design.
8. An aerosol-generating article according to claim 6 or claim 7, wherein the first design is substantially the same as the second design.
9. An aerosol-generating article according to any preceding claim, wherein the outside visual appearance of the aerosol-generating article appears substantially symmetrical between an article midpoint and article ends.
10. An aerosol-generating article according to claim 6 or claim 7, wherein the first design is different to the second design.
11. An aerosol-generating article according to any preceding claim, wherein the first mouthpiece comprises a first end plug at the first end of the article.
12. An aerosol-generating article according to claim 11, wherein the second mouthpiece comprises a second end plug at the second end of the article.
13. An aerosol-generating article according to claim 11 or claim 12, wherein each end plug is penetrable by a heating element in an aerosol-generating device.
14. An aerosol-generating article according to claim 13, wherein each end plug is pierceable.
15. An aerosol-generating article according to claim 13, wherein each end plug comprises a slit or a hole, configured in 30 use to expand to allow entry for a heating element as the article is pushed onto the heating element.
16. An aerosol-generating article according to claim 11 or claim 12, wherein each end plug is substantially non-penetrable 35 by a heating element in an aerosol-generating device.
17. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate is compressible when pressure is applied to an article outer surface covering the aerosol-forming substrate.
18. An aerosol-generating article according to any preceding claim, wherein each mouthpiece comprises a filter.
19. An aerosol-generating article according to claim 18, 10 wherein each filter comprises cellulose acetate tow.
20. An aerosol-generating article according to any preceding claim, wherein the first mouthpiece comprises substantially the same dimensions as the second mouthpiece.
21. An aerosol-generating article according to any preceding claim, wherein the first mouthpiece comprises a different density to the second mouthpiece.
22. An aerosol-generating article according to any of claims 1 to 20, wherein the first mouthpiece is substantially identical to the second mouthpiece.
23. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate comprises tobacco.
24. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate is sealed within the article between the ends of the article.
25. An aerosol-generating article according to any preceding claim, further comprising a support element, where the support element abuts the aerosol-forming substrate.
26. An aerosol-generating article according to claim 25, wherein the support element is a divider and divides the aerosol-forming substrate into a first aerosol-forming substrate and a second aerosol-forming substrate on either side of the support element.
27. An aerosol-generating article according to claim 25 or claim 26, wherein the support element is positioned substantially in the middle of the aerosol-generating article between ends.
28. An aerosol-generating article according to any preceding claim, further comprising an aerosol-cooling element.
29. An aerosol-generating article according to any preceding claim, further comprising a first aerosol-cooling element positioned between the first mouthpiece and the aerosol-forming substrate and second aerosol-cooling element positioned between the second mouthpiece and the aerosol-forming substrate.
30. An aerosol-generating article according to claim 28 or claim 29, wherein each aerosol-cooling element is penetrable by a heating element in an aerosol-generating device.
31. An aerosol-generating article according to any preceding claim, further comprising a non-compressible element. 25
32. An aerosol-generating article according to any preceding claim, further comprising a first non-compressible element positioned between the first mouthpiece and the aerosol-forming substrate and a second non-compressible element positioned between the second mouthpiece and the aerosol-forming substrate.
33. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article is substantially 35 functionally symmetrical between an article midpoint and article ends.
34. A method of forming an aerosol-generating article comprising the steps of: arranging a mouthpiece element and an aerosol-forming substrate element in a repeated and continuous sequence; wrapping the elements to form a continuous rod; and cutting the rod at the midpoint of each mouthpiece element to create individual rods with a mouthpiece at each end.
35. A method according to claim 34, further comprising the step 10 of wrapping tipping paper around the mouthpiece section prior to cutting.
36. A method according to claim 34 or claim 35, wherein the method step of arranging elements in a repeated and continuous sequence may comprise: arranging a mouthpiece element, a first aerosol-forming substrate, a support element and a second aerosol-forming substrate in a repeated and continuous sequence.
37. A method according to claim 34 or claim 35, wherein the method step of arranging elements in a repeated and continuous sequence may comprise: arranging a mouthpiece element, a first aerosol-cooling element, an aerosol-forming substrate, and a second aerosol-cooling element in a repeated and continuous sequence.
38. An aerosol-generating system comprising an aerosol-generating article, the article according to any of claims 1 to 33, and an aerosol-generating device comprising a heater.
39. An aerosol-generating system according to claim 38, wherein the aerosol-generating system is configured such that in use the aerosol-generating article protrudes from the aerosol-generating device to expose an article mouthpiece.
40. A method of using the aerosol-generating system, the system according to claim 38 or claim 39, comprising the steps of: selecting an aerosol-generating article mouthpiece to use from either the first mouthpiece or second mouthpiece; inserting the aerosol-generating article into the aerosol-generating device such that the selected mouthpiece protrudes from the device; raising the temperature of the heater in the aerosol-generating device in order to heat the aerosol-forming substrate to generate an aerosol.
41. An aerosol-generating article, substantially as described herein with reference to the accompanying drawings.
42. A method of forming an aerosol-generating article, 15 substantially as described herein with reference to the accompanying drawings.
43. An aerosol-generating system, substantially as described herein with reference to the accompanying drawings.
44. A method of using an aerosol-generating system, substantially as described herein with reference to the accompanying drawings.