KR20190005853A - An aerosol generating article having an insulating heat source - Google Patents

Abstract

The aerosol generating article 2 comprises a layer 5 of an aerosol forming substrate 4, a combustible heat source 3 and at least one fiber reinforced airgel wrapping at least part of the total length of the combustible heat source 3. The aerosol generating article 2 comprises at least one air flow path through which the air sucked through the aerosol generating article 2 can be inhaled so that the user can inhale and an air flow path between the combustible heat source 3 and the aerosol forming substrate 4 But also one or more nonflammable substantially air impermeable barrier.

Description

An aerosol generating article having an insulating heat source

The present invention relates to an aerosol-generating article having an aerosol-forming substrate and a combustible heat source, and a method of forming such an aerosol-generating article.

A number of aerosol-generating articles have been proposed in the art where the cigarettes are heated rather than burned. One goal of such heated aerosol generating articles is to reduce known harmful smoke constituents of the type produced by combustion and pyrolytic degradation of cigarettes in a combustible cigarette. In one known type of heated aerosol-generating article, an aerosol is generated from a combustible heat source by heat transfer from the combustible heat source to an aerosol-forming substrate located adjacent to the combustible heat source. During the generation of the aerosol, the volatile compounds are released from the aerosol-forming substrate by heat transfer from the combustible heat source and are entrained in the air sucked through the aerosol-generating article. The released compound is condensed as it is cooled to form an aerosol that is inhaled by the user.

The combustion temperature of a combustible heat source for use in a heated smoking article should not be high enough to burn or thermally alter the aerosol-forming substrate during use of the heated aerosol-generating article. However, the combustion temperature of the combustible heat source must be high enough to generate sufficient heat to release sufficient volatile compounds from the aerosol-forming substrate, particularly to generate a satisfactory aerosol during the initial puff.

Various combustible heat sources for use in heated aerosol generating articles have been proposed in the art. The combustion temperature of a combustible heat source for use in a heated aerosol generating article is generally about 600 ° C to 800 ° C.

In order to reduce the surface temperature of the heated aerosol-generating article, it is known to wrap the periphery of the combustible heat source of the heated aerosol-generated article with an insulating member. However, it has been found that such insulating members can potentially reduce the efficiency of the heat source in heating the aerosol-forming substrate to generate the aerosol by lowering the temperature of the combustible heat source while the combustible heat source is burning. This effect is evident when the insulating member substantially extends the length of the combustible heat source. In addition, such insulating members can interfere with the continuous burning of the combustible heat source, thereby reducing the burning duration of the combustible heat source.

It would be desirable to provide an aerosol generating article that can be assembled in a simple and reliable manner, with a reduced surface temperature at the proximal end of the heat source, a satisfactory appearance, and the like. It would also be desirable to provide an aerosol generating article that produces satisfactory aerosols both during initial purging and later purging.

According to a first aspect of the present invention there is provided an aerosol-generating article comprising an aerosol-forming substrate, a combustible heat source, and a layer of at least one fiber-reinforced airgel surrounding at least a portion of the length of the combustible heat source. The aerosol generating article also includes one or more air flow paths through which the air sucked through the aerosol generating article for the user to inhale can be followed and one or more incombustible substantially air impermeable barriers between the combustible heat source and the aerosol forming substrate do. One or more incombustible substantially air impervious, non-incendive barriers disposed between the combustible heat source and the aerosol-forming substrate are configured such that during use, the air sucked through the aerosol-generating article along at least one airflow path is not in direct contact with the combustible heat source, From at least one airflow path.

In use, a combustible heat source can be ignited by an external heat source, such as a lighter, to begin combustion. The combustible heat source may heat the aerosol-forming substrate to vaporize the volatile compounds of the aerosol-forming substrate. When the user aspirates on the aerosol generating article, air may be drawn into the aerosol generating article along one or more air flow paths and mixed with the vapor of the heated aerosol forming substrate to form an aerosol. The aerosol is aspirated from the aerosol-generating article and delivered to the user to be inhaled by the user.

A layer of at least one fiber-reinforced airgel wrapping at least a portion of the length of the combustible heat source may insulate the combustible heat source. This can lower the surface temperature of the aerosol-generating article in a combustible heat source. In addition, the layer of at least one fiber-reinforced airgel can allow sufficient air to pass through so that combustion of the combustible heat source is substantially unimpeded.

As used herein, the terms " aerogels " and " unenhanced aerogels " are used interchangeably to describe an open cell foam. Aerogels can be porous. The term " mesoporous " refers to a material comprising pores having a diameter in the range of about 2 nm to about 50 nm. The aerosol may comprise an interconnected network, and the interconnected network may be a nanostructure. Aerogels can exhibit a porosity of about 50% or greater. Aerogels can exhibit porosity of about 90% or greater. Aerogels can be formed by removing liquid components from conventional gels. A conventional gel is understood to mean a semi-solid colloidal suspension of solids dispersed in a liquid.

Aerogels generally have very low thermal conductivity. Without wishing to be bound by theory, the conductive heat transfer in the airgel is suppressed by the high porosity, and convective heat transfer in the airgel is suppressed by the small diameter of the pores. The small diameter of the pore limits the movement of air through the airgel.

As used herein, the term " fiber-reinforced aerogels " refers to a composite material comprising an airgel matrix reinforced with a fibrous material. The fibrous material can be understood as a material containing fibers.

The average width of the pores exhibited by unreinforced aerogels is similar to the mean free path of air molecules at room temperature, although non-reinforced aerogels may have interconnected porous structures. As a result, unreinforced aerogels have low permeability to air. It is understood that this is due to the Knudsen effect.

The average width of the pores represented by fiber-reinforced aerogels is greater than the average free path of air molecules at room temperature. The greater the pore width of the air permeable fiber-reinforced airgel compared to the air permeable unreinforced airgel, the less the effect of the Knuxen effect. As a result, fiber-reinforced aerogels have been found to have higher permeability than unreinforced aerogels.

Fiber-reinforced aerogels were also observed to show superior mechanical properties compared to unreinforced aerogels. For example, fiber-reinforced aerogels may be more flexible and more processable than unreinforced aerogels.

The at least one fiber-reinforced layer surrounds at least a portion of the length of the combustible heat source. The layer of at least one fiber-reinforced airgel of the present invention may substantially cover the entire length of the combustible heat source. This allows the aerosol-generating article to benefit from the insulating properties of the fiber-reinforced aerogels to lower the surface temperature of the proximal heat source of the aerosol-generating article in a combustible heat source and to aid in the permeability of the fiber- Reaching a heat source so that the combustible heat source can be ignited and burned substantially without interruption. It has been observed that a combustible heat source that is substantially circumscribed by at least one fiber-reinforced airgel can be combusted at a higher temperature for a longer period of time, as compared to a combustible heat source that is not circumscribed by any material layer .

The fiber-reinforced aerogels of the present invention also have processability that facilitates the formation of a layer of fiber-reinforced aerogels that wraps at least a portion of the length of the heat source. As used herein, the term " layer " is used to describe a material that generally conforms to the shape of a combustible heat source. The layer of at least one fiber-reinforced airgel can be any suitable type of layer disposed to surround the heat source. Suitable types of layers include, among other things, wrappers and coatings. As used herein, the term "coating" is used to describe a layer of material that covers a heat source and that adheres to a heat source.

The layer of at least one fiber-reinforced airgel may be in direct contact with the combustible heat source. The layer of at least one fiber-reinforced airgel may be spaced apart from the combustible heat source.

As used herein, the term ' length ' is used to describe a dimension in the longitudinal direction of an aerosol-generating article of a part or component of the aerosol-generating article. The layer of at least one fiber-reinforced aerogels surrounds at least a portion of the combustible heat source length. For example, a layer of at least one fiber-reinforced airgel can wrap about half of the combustible heat source length. The layer of at least one fiber-reinforced airgel can cover more than half of the combustible heat source length. The layer of at least one fiber-reinforced airgel can cover about 60% to about 100% of the length of the combustible heat source. The layer of at least one fiber-reinforced airgel can cover at least 70% of the length of the combustible heat source. The layer of at least one fiber-reinforced aerogels may cover at least 80% of the combustible heat source length. The layer of at least one fiber-reinforced airgel may cover at least 90% of the combustible heat source length. The layer of at least one fiber-reinforced airgel can cover the entire length of the combustible heat source. The layer of at least one fiber-reinforced airgel can substantially cover the length of the combustible heat source.

The layer of at least one fiber-reinforced airgel can be sufficiently permeable to air such that the combustible heat source can be burned substantially unimpeded.

The at least one fiber-reinforced aerogel can wrap both halves of the length of the aerosol forming substrate. Advantageously, the fiber-reinforced aerogels wrapping the aerosol-forming substrate can lower the surface temperature of the aerosol-generating article in the aerosol-forming substrate.

The layer of at least one fiber-reinforced airgel can wrap a combustible heat source at the bottom of the combustible heat source. This can advantageously reduce the surface temperature of the aerosol generating article at the site of the combustible heat source closest to the user during normal operation of the aerosol generating article.

The layer of at least one fiber-reinforced airgel can wrap a combustible heat source at the top of the combustible heat source.

The layer of at least one fiber-reinforced airgel can wrap a combustible heat source at the top and bottom of the combustible heat source.

The exposed portion of the combustible heat source may be referred to herein as a " naked portion ". The layer of at least one fiber-reinforced airgel of the present invention may be provided to cover or cover the nib or exposed portion of the combustible heat source.

In some embodiments, a portion of the combustible heat source may be circumscribed by at least one additional layer at the top. The at least one additional layer may be a layer of a cigarette paper. In these embodiments, the top of the combustible heat source is nap. That is, the top of the combustible heat source is not covered by at least one additional layer. In these embodiments, a layer of at least one fiber-reinforced airgel can wrap the top of the combustible heat source. The layer of at least one fiber-reinforced airgel can wrap a combustible heat source from the top of at least one additional layer surrounding the top of the combustible heat source to or near the bottom of the combustible heat source. As such, in these embodiments, the combustible heat source can be substantially circumscribed along its length by a combination of at least one additional layer at the bottom and a layer of at least one fiber-reinforced airgel at the top. In some embodiments, the layer of at least one fiber-reinforced airgel and at least one additional layer may be overlapped along the length of the combustible heat source.

The layer of at least one fiber-reinforced airgel is separated from the at least one airflow path such that during use, the air sucked through the aerosol-generating article along the at least one airflow path is not in direct contact with the layer of the at least one fiber- .

In some embodiments, the at least one layer of fiber-reinforced aerosol comprises one or more air flow paths such that the air that is drawn through the aerosol-generating article along the at least one air flow path is not in direct contact with the layer of the at least one fiber- As shown in FIG.

In some embodiments, at least one portion of the layer of at least one fiber-reinforced airgel can be covered, coated, or encapsulated within the material that is substantially impermeable to fibers or particles. One or more portions of a layer of at least one fiber-reinforced airgel covered, coated, or encapsulated in a material that is substantially impermeable to fibers or particles may pass through the aerosol-generating article along one or more airflow paths Can be positioned adjacent to the air to be sucked. The air sucked through the aerosol-forming article along at least one airflow path is covered by at least one of the fibers of the layer of fiber-reinforced aerogels and / Can be separated from the particles.

In some embodiments, at least one portion of the at least one layer of fiber-reinforced airgel can be covered with a paper layer to separate a layer of at least one fiber-reinforced airgel from the at least one airflow path. The paper layer may be provided on at least one of the inner surface of the layer of at least one fiber-reinforced airgel and the outer surface of the at least one fiber-reinforced airgel. The paper layer may be provided on both the inner and outer surfaces of the layer of at least one fiber-reinforced airgel. The paper layer may comprise a laminated paper. The paper layer may be co-laminated with at least one layer of fiber-reinforced airgel. The paper layer may be provided only in a portion adjacent to the air flow path as part of the layer of at least one fiber-reinforced airgel.

The layer of at least one fiber-reinforced aerogel may be substantially resistant to combustion. As used herein, the term "combustion-resistant" refers to a material that remains substantially intact during ignition and combustion of a combustible heat source. Providing a layer of at least one flame-retardant fiber-reinforced airgel wrapping at least a portion of the length of the combustible heat source may advantageously prevent flame or smoke from being discharged from the layer. This can substantially prevent or inhibit the release of unwanted emissions or odors from the layer while the combustible heat source is burning.

A layer of a combustible heat source, an aerosol forming substrate, and at least one fiber-reinforced airgel can be configured to substantially prevent or inhibit the temperature of the aerosol forming substrate from exceeding about 375 DEG C while the combustible heat source is burning. For example, a layer of a combustible heat source, an aerosol-forming substrate, and at least one fiber-reinforced airgel is shaped to substantially prevent or inhibit the temperature of the aerosol forming substrate from exceeding about 375 DEG C while the combustible heat source is burning, Dimensions, and can be arranged. Whereby the integrity of the aerosol forming base material can be preserved. For example, if the aerosol-forming substrate comprises more than one aerosol forming agent, the aerosol forming agent may undergo pyrolysis above a temperature of about 375 ° C. For example, if the aerosol-forming substrate comprises a cigarette, the cigarette may be burned at a much higher temperature.

A layer of a combustible heat source, an aerosol-forming substrate, and at least one fiber-reinforced airgel is positioned such that the temperature of the aerosol-forming substrate at a location 2 mm from the proximal surface of the aerosol-forming substrate during the combustion of the combustible heat source is at least about 100 ° C . ≪ / RTI >

The fiber-reinforced aerogels may comprise less than about 80% by weight of aerogels. The fiber reinforced aerogels may comprise less than about 70 weight percent aerogels. The fiber reinforced aerogels may comprise less than about 20% by weight of aerogels. The fiber reinforced aerogels may comprise less than about 30% by weight of aerogels. The fiber-reinforced aerogels may comprise from about 20 weight percent to about 80 weight percent airgel, or from about 40 weight percent to about 60 weight percent airgel. Where the fiber-reinforced aerogels comprise silica airgel, the fiber-reinforced aerogels may comprise from about 30 wt% to about 40 wt% synthetic amorphous silica. Where the fiber-reinforced aerogels comprise silica airgel, the fiber-reinforced aerogels may comprise from about 10 weight percent to about 20 weight percent methylsilylated silica.

The fiber reinforced aerogels may comprise at least about 20 weight percent fibrous material. The fiber reinforced aerogels may comprise at least about 30 weight percent fibrous material. The fiber-reinforced aerogels may comprise at least about 70 weight percent fibrous material. The fiber-reinforced aerogels may comprise at least about 60 weight percent fibrous material. The fiber-reinforced aerogels may comprise from about 20% to about 70% fibrous material, or from about 40% to about 50% fibrous material.

The fiber-reinforced aerogels comprise from about 30% to about 40% by weight of synthetic amorphous silica; From about 10% to about 80% methylsilylated silica; And from about 40% to about 50% by weight fibrous material.

The fiber-reinforced aerogels of the present invention may comprise any suitable aerogels. Examples of suitable aerogels include, among other things, silica airgel, metal oxide aerogels, organic and carbon aerogels, nanotube aerogels, metal aerogels or combinations thereof. When the aerogels are silica aerogels, the aerogels may comprise one or more of synthetic amorphous silica and methylsilylated silica.

The fiber-reinforced aerogels of the present invention may comprise any suitable fibrous material. The fibrous material may comprise one or more of any suitable fibers. For example, suitable fibers may include, among other things, glass fibers, silica-based fibers, carbon fibers, polymer fibers, metal fibers and ceramic fibers. The fibers may comprise at least one of an organic material and an inorganic material. The fibers may comprise a combination of organic and inorganic materials. The fibrous material may be a fabric. The fibrous material may be a nonwoven fabric. The fibrous material may include fiber batting or fiber wadding.

The fiber-reinforced aerogels may comprise a binder.

The fibrous material may comprise a binder. Binders are used in some fibrous materials to fix fibrous materials together. Providing a binder can also improve the mechanical properties of the fibrous material. For example, the binder can make the fibrous material less vulnerable and more flexible.

The binder may be a cellulose derivative binder. As used herein, the term " cellulosic derivative binding agent " is used to describe a binding agent comprising a cellulose derivative. In particular, the cellulose derivative binder may comprise a cellulose derivative formed by the addition of a particular side group of cellulose.

Suitable cellulose derivatives include, but are not limited to, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), hydroxyethylmethylcellulose (HEC), hydroxyethylcellulose, cellulose acetate, cellulose esters, and cellulose ethers Do not. Preferably, the cellulose derivative binder comprises carboxymethylcellulose.

The binder may comprise one or more organic binders, such as bitums, syngeneic vegetable adhesives, and polymers. The binder may comprise one or more inorganic binder materials such as lime, cement, gypsum, and liquid glass. When the binder comprises more than one polymer, the polymer may comprise acrylic resins, phenolic resins, polyesters, epoxies, polyethers, PVOH, styrenics, polycarboxyl ethers and polyurethanes. The binder may include one or more of CMC and bentonite. The binder may be an acrylic binder.

The fiber reinforced aerogels may comprise ceramic fibrous materials. The ceramic fiber material may include ceramic fibers.

Where the fiber-reinforced aerogels comprise a ceramic fibrous material, the ceramic fibrous material may comprise a crystalline ceramic material. The ceramic fibrous material may comprise a non-crystalline ceramic material. The ceramic fibrous material may be amorphous. The ceramic fibrous material may be semi-crystalline. The ceramic fibrous material may be crystalline.

As used herein, the term " ceramic fiber material " includes glass. As used herein, the term " glass " is used to describe a material that exhibits glass transition at a glass transition temperature. In general, the term " glass " is used herein to describe an amorphous or amorphous solid material. However, the term " glass " also includes materials comprising a crystalline component and an amorphous component. Glass materials that include both crystalline and amorphous components may be referred to as "glass-ceramic" materials.

The properties of the glass material of the present invention can be determined by the method of forming the glass. As used herein, the term " glass " includes glass formed by any suitable method. Suitable methods of forming the glass include: melt quenching; Physical vapor deposition; Solid phase reactions including thermochemical and mechanochemical reactions; Liquid phase reactions such as the sol-gel method; Irradiation of crystalline solids such as radiation amorphisation; And pressurized amorphization (with high pressure to form the glass).

In some embodiments, the ceramic fibrous material may comprise glass. The ceramic fiber material may comprise glass fibers. The ceramic fiber material may comprise glass-ceramic fibers. The ceramic fiber material may comprise continuous filament glass fibers.

In some embodiments, the ceramic fibrous material may not comprise glass. That is, the ceramic fibrous material may comprise any ceramic material except glass. The ceramic fiber material may not be a glass material. The ceramic fiber material may not include glass fibers. In these embodiments, the ceramic fibrous material generally comprises a crystalline ceramic material.

In some embodiments, the fibrous material may comprise biosoluble fibers. As used herein, the term " bioavailability " is used to describe a material that can be dissolved in a biological system, e.g., a biological system of the human body. The bioavailability of a material in a particular biological system may be significantly different from the solubility of the material in water. As used herein, when at least 0.1 g of a substance is dissolved in 100 ml of a biological system solvent, the substance may be considered to be bio-soluble. Likewise, if less than 0.1 g of a substance is dissolved in 100 ml of a biological system solvent, the substance may be considered to be bio-soluble. Generally, the bio soluble fibers of the present invention can be dissolved in the user's respiratory system when the fibers are inhaled. That is, the bio soluble fibers of the present invention generally dissolve in the user's respiratory system when inhaling fibers. The bio soluble fibers of the present invention can be dissolved in the user's alveolar environment.

The bioerodible material may be any suitable bioerodible material. Suitable bio-soluble materials include alkaline earth silicate wools (AES wool) and high-alumina low-silica wools.

In some embodiments of the present invention, the fiber-reinforced aerogels may comprise about 100 weight percent AES wool.

The fiber reinforced aerogels may comprise any other suitable reinforcing material. For example, the fiber-reinforced aerogels may comprise polymer fibers such as polyamides and polyimides. Fiber reinforced aerogels may be further reinforced by additional means such as particulate strengthening. For example, fiber-reinforced aerogels can be reinforced with carbon black particles. The fiber-reinforced aerogels may further comprise any other suitable component including, but not limited to, titanium dioxide, aluminum trihydrate, and pigments that may include iron and manganese.

Suitable fiber-reinforced aerogels include Pyrogel XT-E and Pyrogel XT-F, both of which are products of Aspen Aerogels® .

The layer of at least one fiber-reinforced airgel can have any suitable thickness. Generally, the layer of at least one fiber-reinforced airgel is a thin layer. The thickness of the at least one fiber-reinforced airgel layer may be at least about 0.25 mm to at least about 0.5 mm. The thickness of the layer of the at least one fiber-reinforced aerogel may be less than about 10 mm, or less than about 5 mm. The layer of the at least one fiber-reinforced aerogel can have a thickness of about 0.25 mm to about 10 mm, or a thickness of about 0.5 mm to about 5 mm.

An aerosol-generating article according to the present invention comprises an aerosol-forming substrate. As used herein, the term " aerosol-forming substrate " is used to describe a substrate capable of releasing volatile compounds upon heating and forming an aerosol. The aerosol generated from the aerosol-forming substrate of the aerosol-generating article according to the present invention may or may not be visible, and may include not only vapors (e.g., fine particles of gaseous material, usually liquid or solid at room temperature) Gaseous and condensed vapor droplets.

The aerosol-forming substrate may be a solid. The aerosol-forming substrate may be liquid at room temperature.

The aerosol-forming substrate may comprise at least one aerosol-forming agent and at least one material capable of releasing volatile compounds in response to heating.

The at least one aerosol forming agent can be any suitable known compound or mixture of compounds which, in use, facilitates the formation of dense and stable aerosols and is substantially resistant to thermal degradation at the operating temperature of the aerosol generating article. Suitable aerosol formers are well known in the art and include, for example, polyhydric alcohols; Esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; And aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyldodecanedioate and tetradecanedioate. Exemplary aerosol formers for use in the aerosol-generating articles according to the invention are: polyhydric alcohols, or mixtures thereof such as triethylene glycol; 1,3-butanediol; And glycerin.

The material capable of releasing volatile compounds in response to heating may be a charge of vegetable material, for example a filling of homogenized vegetable material. For example, the aerosol-forming substrate may be a cigarette; Tea (for example, green tea); Peppermint; Laurel; Eucalyptus; Basil; sage; verbena; And tarragon. ≪ RTI ID = 0.0 > [0040] < / RTI > The botanical materials may include additives including, but not limited to, wetting agents, flavoring agents, binders, and mixtures thereof. The plant-based material may consist essentially of a tobacco material, optionally a homogenized tobacco material.

The aerosol generating article according to the present invention may comprise an aerosol forming base containing nicotine. For example, an aerosol-generating article in accordance with the present invention may comprise an aerosol-forming substrate comprising a cigarette.

The aerosol-forming substrate may be circumscribed by a filter plug wrap.

An aerosol generating article according to the present invention comprises a combustible heat source arranged to heat an aerosol forming substrate and separated from at least one air flow path.

The combustible heat source may comprise a body made of a combustible material. The body of the combustible material may have a substantially constant diameter. The body of the combustible material may have a constant diameter along its length. This can advantageously simplify the process associated with the manufacture of combustible heat sources and aerosol generating articles. In some embodiments, the body of combustible material can form a substantially cylindrical body having a substantially constant diameter along its length.

The combustible heat source may be a carbonaceous heat source. As used herein, the term " carbonaceous " is used to describe a combustible heat source comprising carbon. Preferably, the combustible carbonaceous heat source for use in an aerosol generating article according to the present invention comprises at least about 35%, more preferably at least about 40%, most preferably at least about 45% Of carbon content.

The combustible heat source according to the present invention may be a combustible carbon-based heat source. As used herein, the term 'carbon-based heat source' is used primarily to describe a heat source consisting of carbon.

The combustible carbon-based heat source for use in a smoking article according to the present invention is at least about 50%, preferably at least about 60%, more preferably at least about 70%, most preferably at least about 50% May have a carbon content of at least about 80%.

The combustible heat source of the present invention is separated from one or more air flow paths through the aerosol generation article. As used herein, the term " air flow path " is used to describe a route through which an air can be drawn through an aerosol-generating article so that the user can inhale. As used herein, the terms " top " and " bottom " refer to the relative direction of components of an aerosol-generating article and the position .

Separating the combustible heat source from the at least one airflow path of the aerosol generating article can substantially prevent or inhibit the combustion of the combustible heat source from beginning while the user purges. This can substantially prevent or suppress temperature spikes of the aerosol-forming substrate while the user is pumping on the aerosol-generating article. This can substantially prevent or suppress combustion or pyrolysis of the aerosol-forming substrate in a situation where puffing occurs intensively. This can substantially prevent or inhibit the components of the aerosol generated by the aerosol-generated article from changing due to the user's puffing habit.

Separating the combustible heat source from the at least one airflow path substantially prevents combustion and decomposition products and other materials formed during combustion and combustion of the combustible heat source from entering the aspirated air through the aerosol generating article along one or more airflow paths Or suppression.

The separate combustible heat source of the present invention may comprise a blind heat source. As used herein, the term " blind " is used to describe a combustible heat source in which air that has passed through an aerosol generating article for inhalation by a user does not pass through the air flow channel along the combustible heat source. Thus, the thermal conduction between the blind combustible heat source and the aerosol forming substrate is mostly caused by the conductive heat transfer.

The convective heat transfer between the combustible heat source and the aerosol forming substrate is reduced or minimized if the air flow channel through the combustible heat source is not provided. Reducing the convective heat transfer between the combustible heat source and the aerosol-forming substrate can substantially prevent or suppress abrupt temperature changes of the aerosol-forming substrate during puffing by the user. This can substantially prevent or suppress combustion or pyrolysis of the aerosol-forming substrate in a situation where puffing occurs intensively. This can substantially prevent or inhibit the components of the aerosol generated by the aerosol-generated article from changing due to the user's puffing habit. This can substantially prevent or inhibit combustion and decomposition products and other materials formed during ignition and combustion of the combustible heat source through the aerosol generation article and into the aspirated air along one or more air flow paths.

A separate combustible heat source of the present invention may include a non-blind heat source. As used herein, the term " non-blind " is used to describe a heat source through which one or more air flow channels pass along a heat source, do. As such, heat transfer between the non-blind combustible heat source and the aerosol-forming substrate can occur by both convective heat transfer and convective heat transfer along one or more air flow channels.

As used herein, the term " air flow channel " is used to describe a channel that extends along the length of a combustible heat source where the air can be sucked down to the user for inhalation. As such, the aerosol generating article of the present invention may not include more than one air flow channel.

One or more incombustible substantially air impermeable barriers disposed between the combustible heat source and the aerosol forming substrate may include a first barrier that contacts one or both of the proximal end of the combustible heat source and the distal end of the aerosol forming substrate. The first barrier may facilitate separating the combustible heat source from the at least one airflow path of the aerosol generating article. The first barrier may reduce the maximum temperature at which the aerosol-forming substrate is exposed during ignition or combustion of the combustible heat source and may substantially prevent or inhibit thermal degradation or combustion of the aerosol-forming substrate during use of the aerosol-generating article.

As used herein, the term "non-combustible" is used to describe a material that is substantially non-combustible at the temperatures reached by a combustible heat source during combustion or ignition.

As used herein, the term " air impermeable " is used to describe a material that substantially prevents or inhibits air from passing therethrough.

The first barrier may be attached or otherwise secured to one or both of the proximal end of the combustible heat source and the distal end of the aerosol-forming substrate.

The first barrier may comprise a first barrier coating provided on the proximal side of the combustible heat source. In such embodiments, the first barrier may comprise a first barrier coating provided on at least substantially the entire proximal surface of the combustible heat source. The first barrier may comprise a first barrier coating provided on the entire proximal face of the combustible heat source. The first barrier coating can be formed or applied to the proximal side of the combustible heat source by any suitable method, such as the method described in WO-A1-2013120855.

Depending on the desired properties and performance of the aerosol generating article, the first barrier may have low thermal conductivity or high thermal conductivity. In certain embodiments, the first barrier may have a thermal conductivity of about 0.1 W / mK to about 200 W / mK.

The thickness of the first barrier can be suitably adjusted to achieve good aerosol generation performance. In certain embodiments, the first barrier may have a thickness from about 10 [mu] m to about 500 [mu] m.

The first barrier may be formed of one or more suitable materials that are substantially thermally stable and non-combustible at the temperature achieved by the combustible heat source during ignition and combustion. Suitable materials are well known in the art and include, but are not limited to, clay (e.g., bentonite and kaolinite), glass, minerals, ceramic materials, resins, metals and combinations thereof.

The materials from which the first barrier can be formed include clay and glass. The material from which the first barrier can be formed includes copper, aluminum, stainless steel, an alloy, alumina (Al2O3), a resin, and a mineral adhesive.

When the first barrier comprises a metal or alloy such as copper, aluminum, or stainless steel, the first barrier coating may advantageously serve as a thermal link between the combustible heat source and the aerosol forming substrate. This can improve the conductive heat transfer from the combustible heat source to the aerosol forming substrate.

The aerosol generating article may further include one or more air inlets at the lower end of the proximal end of the combustible heat source. In some embodiments, the at least one air inlet is between the proximal end of the combustible heat source and the proximal end of the aerosol generating article. The one or more air inlets may be arranged such that the air is not drawn through the combustible heat source and may be drawn through one or more air inlets into one or more air flow paths of the aerosol generating article. This can substantially prevent or inhibit temperature spikes of the aerosol-forming substrate during purging by the user.

The one or more air inlets may comprise any suitable air inlets through which the air can be drawn into the aerosol generating article. For example, suitable air inlets include holes, slits, slots, or other apertures. The number, shape, size and arrangement of air inlets can be suitably adjusted to achieve good aerosol generation performance.

One or more air inlets may be disposed at any location between the proximal end of the combustible heat source and the proximal end of the aerosol generating article. One or more air inlets may be disposed in the aerosol forming substrate. One or more air inlets may be disposed between the distal end of the aerosol-forming substrate and the proximal end of the aerosol-forming substrate. Where one or more air inlets are disposed in the aerosol forming substrate and the aerosol forming substrate comprises a filter plug wrap, the filter plug wrap may be provided with one or more openings for introducing air into the aerosol forming substrate. The one or more openings may be slits, slots, or other suitable apertures in which air can be drawn into the aerosol-forming substrate. The number, shape, size and arrangement of openings can be suitably adjusted to achieve good aerosol generation performance.

The combustible heat source may include one or more air flow channels. That is, the combustible heat source may be a non-blind heat source. The one or more airflow channels may extend along the length of the combustible heat source. One or more air flow channels may form part of one or more air flow paths of the aerosol generating material.

One or more incombustible substantially air impermeable barriers disposed between the combustible heat source and the aerosol forming base material may be disposed between the combustible heat source and the at least one air flow channel of the combustible heat source when the combustible heat source comprises one or more air flow channels within the aerosol- 2 barrier. ≪ / RTI >

The second barrier may facilitate separating the combustible heat source from the at least one airflow path of the aerosol generating article. The second barrier may reduce the maximum temperature at which the aerosol-forming substrate is exposed during ignition or combustion of the combustible heat source, thereby helping to prevent or reduce thermal degradation or combustion of the aerosol-forming substrate during use of the aerosol- have.

The second barrier may be attached to or otherwise secured to a combustible heat source.

The second barrier may comprise a second barrier coating provided on an inner surface of the at least one airflow channel. The second barrier may comprise a second barrier coating provided over at least substantially the entire inner surface of the at least one airflow channel. The second barrier may comprise a second barrier coating provided on at least substantially the entire inner surface of the at least one airflow channel.

The second barrier coating may be provided by inserting a liner into one or more air flow channels. For example, where one or more airflow paths include one or more airflow channels extending through the interior of the combustible heat source, a nonflammable substantially air impermeable hollow tube may be inserted into each of the one or more airflow channels.

The second barrier advantageously prevents or inhibits combustion and decomposition products formed during the ignition and combustion of the combustible heat source of the aerosol generating article according to the present invention from entering the air sucked at the bottom through one or more air flow channels have.

Depending on the desired properties and performance of the aerosol-generating article, the second barrier may have a low thermal conductivity or a high thermal conductivity. The second barrier may have low thermal conductivity.

The thickness of the second barrier can be suitably adjusted to achieve good aerosol generation performance. In certain embodiments, the second barrier may have a thickness of from about 30 [mu] to about 200 [mu]. In one embodiment, the second barrier has a thickness of from about 30 [mu] to about 100 [mu].

The second barrier may be formed of one or more suitable materials that are substantially thermally stable and nonflammable at the temperatures achieved by the combustible heat source during ignition and combustion. Suitable materials are known in the art and include, for example, clay; Metal oxides such as iron oxide, alumina, titania, silica, silica-alumina, zirconia and ceria; Zeolite; Zirconium phosphate; And other ceramic materials, or combinations thereof.

Preferred materials from which the second barrier can be formed include clay, glass, aluminum, iron oxides, and combinations thereof. If desired, catalyst components, such as components that promote the oxidation of carbon monoxide to carbon dioxide, can be incorporated into the second barrier. Suitable catalyst components include, but are not limited to, for example, platinum, palladium, transition metals, and oxides thereof.

When the aerosol-generating article according to the invention comprises a first barrier between the lower end of the combustible heat source and the upper end of the aerosol-forming substrate and comprises a second barrier between the combustible heat source and one or more air flow channels along the combustible heat source, The barrier may be formed of the same or different materials / materials as the first barrier.

When the second barrier comprises a second barrier coating provided on the inner surface of the at least one air flow channel, the second barrier coating may be formed by any suitable method such as those described in US-A-5,040,551 and WO-A1-2013120855 Lt; RTI ID = 0.0 > airflow < / RTI > channel.

The aerosol generating article may further comprise at least one proximal portion of the combustible heat source and at least one additional layer surrounding the distal portion of the aerosol forming base. The at least one additional layer comprising: a thermal conduction element for transferring heat from the combustible heat source to the aerosol forming substrate; And a cigarette paper layer.

The heat-conducting element may only wrap the distal portion of the aerosol-forming substrate. The thermal conduction element may substantially cover the length of the aerosol forming substrate. The thermal conduction element may be in direct contact with at least one of a combustible heat source and an aerosol-forming substrate. The thermal conduction element may not be in direct contact with either the combustible heat source or the aerosol forming substrate.

The thermal conduction element may provide a thermal connection between the combustible heat source and the aerosol forming substrate. The thermal conduction element may be substantially flammable.

Suitable heat conduction elements may include metal foil wrappers or metal alloy foil wrappers. The metal foil wrapper may include an aluminum foil wrapper, a steel foil wrapper, an iron foil wrapper, and a copper foil wrapper. The thermal conduction element may comprise an aluminum tube.

The length of the proximal portion of the combustible heat source circumscribed by the thermal conduction element may be from about 2 mm to about 8 mm, or from about 3 mm to about 5 mm.

The length of the distal portion of the combustible heat source where the thermal conduction element is not circumscribed may be about 4 mm to about 15 mm or about 4 mm to about 8 mm.

The layer of cigarette paper may wrap around at least proximal of the combustible heat source, the length of the aerosol-forming substrate, and any other components of the aerosol-generating article disposed proximal to the aerosol-forming substrate. The layer of cigarette paper may substantially cover the length of the combustible heat source. When the layer of cigarette paper substantially encloses the length of the combustible heat source, a layer of cigarette paper at the location of the combustible heat source may be provided with a vent, such as a perforation, hole or slit, to allow air to pass through the layer of cigarette paper to the combustible heat source have. The number, shape, size and location of openings can be suitably adjusted to achieve good aerosol generation performance. The layer of cigarette paper can be meticulously wrapped around the combustible heat source and the aerosol-forming substrate to grasp and secure the combustible heat source and the aerosol-forming substrate of the layer of cigarette paper when the aerosol-generating article is assembled.

The layer of at least one fiber-reinforced aerogel may be a radially outer layer. If the aerosol-generating article comprises one or more additional layers, the radially outer layer of the fiber-reinforced aerogels may be laid over at least a portion of one or more additional layers. That is, one or more additional layers may be disposed between the combustible heat source and the layer of the at least one fiber-reinforced airgel. For example, where the aerosol-generating article comprises an additional layer comprising a thermal conduction element, the thermal conduction element may be a radially inner layer, and the layer of at least one fiber-reinforced aerogel comprises a radially outer layer Lt; / RTI >

As used herein, the terms " radially outer " and " radially inner " are used to denote the relative distance of the components of the aerosol generating article from the longitudinal axis of the aerosol generating article. As used herein, the term " radial " is used to describe a direction perpendicular to the longitudinal axis of the aerosol generating article extending in the direction between the proximal and distal ends of the aerosol generating article.

The at least one additional layer may be a radially outer layer. The at least one additional layer may be laid over at least a portion of the layer of the at least one fiber-reinforced airgel.

The layer of at least one fiber-reinforced aerogel can be fixed or attached to one or more other components or portions of the aerosol-generating article. The layer of at least one fiber-reinforced airgel can be secured to any suitable component of the aerosol-generating article. For example, a layer of at least one fiber-reinforced aerogel can be secured to at least one of a combustible heat source, an aerosol-forming substrate, and one or more additional layers. The layer of at least one fiber-reinforced aerogel can be secured to one or more components of the aerosol-generated article by any suitable means. The layer of at least one fiber-reinforced aerogel can be fixed using an adhesive. Suitable adhesives may exhibit resistance to high temperatures such as silicate glue. If the at least one additional layer is a radially outer layer, the at least one additional layer may be meticulously wrapped around at least a portion of the at least one layer of airgel.

In some embodiments, the layer of at least one fiber-reinforced airgel can be integral with the combustible heat source. As used herein, the term "integral" is used to describe a layer that is in direct contact with a combustible heat source and adheres to a combustible heat source, without the aid of an extraneous adhesive or other intermediate connection material.

In some embodiments, a layer of at least one fiber-reinforced airgel can be formed from a strip of fiber-reinforced aerogels having opposing portions. Strips of fiber-reinforced aerogels may be wrapped around a combustible heat source such that opposite ends of the strip overlap each other. The overlapped opposite ends of the strip may be secured together using an adhesive or any other suitable means. Whereby a layer of at least one fiber-reinforced airgel can be fixed on the combustible heat source.

In some embodiments, an intermediate layer may be provided between a layer of at least one fiber-reinforced airgel and at least one of a combustible heat source, an aerosol-forming substrate, and one or more additional layers. The intermediate layer may be adjacent to a layer of at least one fiber-reinforced airgel. The intermediate layer may be in contact with a layer of at least one fiber-reinforced airgel. The intermediate layer may be disposed radially inward of the layer of at least one fiber-reinforced airgel.

The intermediate layer may be an adhesive layer. The adhesive layer may comprise any suitable adhesive. Suitable adhesives may exhibit resistance to high temperatures such as silicate glue. The adhesive layer can be disposed between the layer of at least one fiber-reinforced airgel and the combustible heat source, and the layer of the at least one fiber-reinforced airgel can be attached to the combustible heat source. The adhesive layer may be disposed between a layer of at least one fiber-reinforced airgel and at least one additional layer, and the layer of at least one fiber-reinforced airgel may be attached to the at least one further layer. The adhesive layer may be disposed between the layer of at least one fiber-reinforced airgel and the aerosol-forming substrate, and the layer of the at least one fiber-reinforced airgel may be attached to the aerosol-forming substrate.

In some embodiments, a layer of at least one fiber-reinforced airgel can be formed from a strip of fiber-reinforced aerogels having opposing portions. Strips of the fiber-reinforced aerogels may be wrapped around a combustible heat source so that the opposite ends of the strip are bordered but not overlapping each other. The adhesive layer may be provided at one end of the strip opposite the flammable heat source, at least at the opposite end of the strip. The adhesive layer may fix the strip of fiber-reinforced airgel at the flammable heat source, at least at the opposite end of the strip.

The aerosol generating article may include a heat conducting member disposed between the combustible heat source and the aerosol forming substrate. The heat conduction member may be the first barrier described above. The aerosol generating article may comprise a heat conducting member and a first barrier. The thermal conduction member may comprise a material similar to the thermal conduction element. The aerosol generating article may comprise a heat conducting element and a heat conducting element. Providing at least one of the thermal conduction element and the thermal conduction member may facilitate conduction heat transfer between the combustible heat source and the aerosol forming substrate.

The aerosol generating article may further comprise any other suitable component. For example, the aerosol-generating article may include a conductive element; Aerosol cooling elements; Spacer elements; And a mouthpiece. One or more additional components may be disposed coaxially with the combustible heat source and the aerosol forming substrate. One or more additional components may be disposed adjacent the aerosol forming substrate. The one or more additional components may be arranged in any suitable order. An aerosol generating article comprises: a transfer element adjacent a proximal end of the aerosol forming substrate; An aerosol cooling element adjacent the proximal end of the transmission element; A spacer element adjacent the proximal end of the aerosol cooling element; And a mouthpiece adjacent the proximal end of the spacer.

As used herein, the terms " proximal " and " distal " are used to describe the relative positions of components or components of an aerosol generating article in accordance with the present invention. The proximal end of the component of the aerosol-generating article is the end of the component closest to the mouth end of the aerosol-generating article and the distal end of the component of the aerosol-generating article is the end of the component furthest from the mouth end of the aerosol- to be. Generally, a combustible heat source is disposed at the distal end of the aerosol generating article.

According to a second aspect of the present invention, there is provided a method of forming an aerosol-generating article according to the first aspect of the present invention. The method comprising: disposing a combustible heat source for heating the aerosol forming substrate; Providing at least one airflow path through which the air can be drawn through the aerosol generating article for the user to inhale; Separating the combustible heat source from the at least one airflow path during use such that air drawn through the aerosol generating article along at least one airflow path is not in direct contact with the combustible heat source; And wrapping at least a portion of the length of the combustible heat source with a layer of at least one fiber-reinforced airgel.

In some embodiments, the step of wrapping at least a portion of the combustible heat source length with a layer of at least one fiber-reinforced airgel comprises: providing a strip of fiber-reinforced airgel having an opposite end; Wrapping the strip around a combustible heat source such that a layer of at least one fiber-reinforced airgel surrounds the combustible heat source; Overlapping the opposite ends of the strip; And fixing the overlapping ends together to secure the layer of the at least one fiber-reinforced airgel to the combustible heat source.

The overlapping ends of the strips of the fiber-reinforced aerogels may be secured together using any suitable means. For example, the overlapping ends of the strips of fiber-reinforced aerogels may be secured together using an adhesive. Suitable adhesives should be resistant to high temperatures and include silica glue.

In some embodiments, the step of wrapping at least a portion of the combustible heat source length with a layer of at least one fiber-reinforced airgel comprises: providing a strip of fiber-reinforced airgel having an opposite end; Applying an adhesive layer to one side of the strip at least at each of the opposite ends; Disposing the strip to which the adhesive layer is applied to face a combustible heat source; Wrapping the strip around the combustible heat source such that at least a portion of the combustible heat source length is circumscribed by a layer of at least one fiber-reinforced airgel; Bending opposite ends of the strip without overlapping opposite ends of the strip; And fixing the strip to the combustible heat source with an adhesive layer.

In some embodiments, a layer of at least one fiber-reinforced airgel can be laminated with an additional layer, such as a cigarette paper layer. The layer of at least one fiber-reinforced airgel can be laminated with the additional layer before the layer of at least one fiber-reinforced airgel is applied to the combustible heat source. Strips of co-piled paper comprising a layer of at least one fiber-reinforced airgel and additional layers can be wrapped around the combustible heat source in the same manner as strips of fiber-reinforced airgel. In some embodiments, the co-paged paper may be arranged such that the layer of at least one fiber-reinforced airgel is opposed to the combustible heat source. That is, a layer of at least one fiber-reinforced airgel can be disposed radially inward of the additional layer. In some embodiments, the co-punched paper may be positioned such that the additional layer faces the combustible heat source.

The invention will be further described, by way of example only, with reference to the accompanying drawings, in which:
1 shows a schematic view of a first embodiment of an aerosol generating article according to the invention comprising a blind combustible heat source;
Figure 2 shows the temperature profile of the aerosol-generated article of Figure 1 in a first position;
Figure 3 shows the temperature profile of the aerosol-generated article of Figure 1 in a second position;
Figure 4 shows the temperature profile of the aerosol generating article of Figure 1 in the third position;
Figure 5 shows a schematic view of a second embodiment of an aerosol generating article according to the present invention comprising a non-blind combustible heat source.

Fig. 1 shows a schematic view of an aerosol-generating article 2. Fig. The aerosol generating article (2) comprises a combustible heat source (3). The combustible heat source 3 comprises a substantially cylindrical body of carbonaceous material having a length of about 10 mm. The combustible heat source 3 is a blind heat source. That is, the combustible heat source 3 does not include any air channels extending through the combustible heat source.

The aerosol-generating article (2) further comprises an aerosol-forming substrate (4). The aerosol-forming substrate 4 is disposed at the proximal end of the combustible heat source 3. The aerosol-forming substrate 4 comprises a substantially cylindrical plug made of a tobacco material 18 circumscribed by a filter plug wrap 19.

The nonflammable substantially air impermeable barrier 6 is disposed between the proximal end of the combustible heat source 3 and the distal end of the aerosol forming base 4. [ The first barrier 6 comprises a disk of aluminum foil. The first barrier 6 also includes a heat conduction member for conducting heat from the proximal surface of the combustible heat source 3 to the distal surface of the aerosol forming substrate 4 between the combustible heat source 3 and the aerosol- .

The heat-conducting element 9 surrounds the proximal portion of the combustible heat source 3 and the distal portion of the aerosol-forming substrate 4. The heat-conducting element 9 comprises an aluminum tube. The thermal conduction element 9 is in direct contact with the proximal portion of the combustible heat source 3 and the filter plug wrap 19 of the aerosol-forming substrate 4. [

The aerosol-generating article 2 comprises various other components arranged adjacent to the aerosol-forming substrate 4, including: a transfer element 11 disposed at the proximal end of the aerosol-forming substrate 4; An aerosol cooling element (12) disposed at the proximal end of the transfer element (11); A spacer element (13) disposed at the proximal end of the aerosol cooling element (11); And a mouthpiece 10 disposed at the proximal end of the spacer element 13.

The components of the aerosol generating article 2 are wrapped in a layer 7 of a cigarette paper. The layer 7 of cigarette paper is wrapped around the thermal conduction element 9 and does not extend beyond the distal end of the heat conduction element 9 and over the distal portion of the combustible heat source 3. [

According to the invention, the aerosol-generating article (2) further comprises a layer (5) of fiber-reinforced airgel. The layer 5 of the fiber-reinforced aerosol substantially envelops the length of the combustible heat source 3 and the layer 7 of the cigarette paper, the heat-conducting element 9 and the distal portion of the aerosol-forming substrate 4. That is, the layer 5 of fiber-reinforced aerogels is a radially outer layer at the distal end of the aerosol-generating article 2.

The layer 5 of the fiber-reinforced aerogels comprises a fibrous material comprising silica airgel, and continuous filament glass fibers. The fiber reinforced aerogels comprise about 35 weight percent synthetic amorphous silica, about 15 weight percent methylsilylated silica, and about 45 weight percent continuous filament glass fibers.

A plurality of air inlets (8) for sucking outside air into the aerosol forming article (2) are arranged in the aerosol forming base material (4). The air inlet 8 comprises a plurality of perforations through the layer 7 of the cigarette paper and the lower layer of the plug wrap 19 surrounding the aerosol-forming substrate 4. The air inlet 8 is disposed between the distal surface and the proximal surface of the aerosol-forming substrate 4.

When the user sucks on the mouthpiece 10 of the aerosol generating article 2, the outside air can be sucked into the aerosol generating article 2 through the air inlet 8. The air sucked into the aerosol generating article 2 flows from the air inlet 8 along the air flow path of the aerosol generating article 2 to the aerosol forming substrate 4, the transfer element 11, the cooling element 12, (13) and flows to the mouthpiece (10), and the user can escape the mouthpiece (10) so that the user can inhale and flow to the user. The general direction of the air flow through the aerosol generating article 2 is indicated by the arrows.

In use, the user can ignite the combustible heat source 3 by exposing the combustible heat source 3 to an external heat source such as a lighter. The combustible heat source 3 can be ignited and burned and the heat can be transferred from the combustible heat source 3 to the aerosol forming base 4 through conduction through the heat conduction element 6 and the heat conduction element 9 . The volatile compound of the heated aerosol-forming base material 4 can be vaporized. The user may suck on the dental mouthpiece 10 of the aerosol generating article 2 and draw the outside air into the air flow path of the aerosol generating article 2 through the air inlet 8. [ The vapor from the heated aerosol forming substrate 4 can be entrained in the sucked air through the aerosol forming substrate 4 and can be drawn toward the mouthpiece 10 with air. As the vapor is drawn towards the mouthpiece 10, the vapor may cool down to form an aerosol. The aerosol can be drawn out of the mouthpiece 10 and delivered to the user for inhalation.

It will be appreciated that the first barrier 6, which is substantially air impermeable, inhibits air from passing through the combustible heat source 3 and being drawn into the aerosol-forming substrate 4. [ As such, the first barrier 6 substantially separates the air flow path of the aerosol-generating article 2 from the combustible heat source 3.

In this embodiment, the layer 5 of the fiber-reinforced aerosol extends slightly over the distal end of the aerosol-forming substrate 4. [ As such, the layer 5 of fiber-reinforced aerogels is spaced from the air inlet 8. This spacing allows the air drawn through the air flow path of the aerosol generating article 2 to come into contact with the layer 5 of the fiber-reinforced airgel 5 by substantially separating the layer 5 of the fiber-reinforced airgel from the air inlet 8 .

It will be appreciated that in some embodiments, it may be closely proximal to the bed air inlet of the fiber-reinforced aerogels. In these embodiments, a portion of the fiber-reinforced aerogels closely proximal to the air inlet may be coated with a material that is substantially impermeable to fibers or particles. Thereby, by substantially separating a portion of the layer of fiber-reinforced aerosol closely proximal to the air inlet, the air drawn through the air flow path of the aerosol-generating article may not come into contact with the layer of fiber-reinforced airgel.

During the combustion period of the combustible heat source, experimental data were collected to determine the temperature of the combustible heat source and the aerosol forming base material of various aerosol generating articles similar to the aerosol generating article 2 shown in Fig. Each of the aerosol generating articles tested contained a layer of different material that substantially enveloped the length of the combustible heat source. In particular, wrapping a length of the combustible heat source is substantially non-reinforced airgel (Blueshift Materials International, ^® an aero agent (produced by AeroZero Inc.)) layer, a fiber-reinforced substantially surrounding the length of the combustible heat source of the airgel (Aspen Aerogels Experimental data was collected for an aerosol generating article comprising a layer of pyrogel XT-F (Pyrogel ^® XT-F) produced by the Company, Inc., and no material layer substantially surrounding the length of the combustible heat source Figures 2 to 4 show graphs of experimental measurements of temperature over time at three different locations of various aerosol generating articles.

Figure 2 shows the measured temperature at a location 2 mm from the distal end of the combustible heat source, corresponding to the T ₁ position shown in Figure 1. That is, Figure 2 shows the temperature at the distal end of the combustible heat source.

Figure 3 shows the measured temperature at a location 5 mm from the distal end of the combustible heat source, corresponding to the T ₂ position shown in Figure 1. That is, Figure 3 shows the temperature at approximately half a point along the length of the combustible heat source.

Figure 4 shows the temperature measured at a location 11 mm from the distal end of the combustible heat source, corresponding to the T ₃ position in Figure 1. That is, Figure 4 shows the temperature at the distal end of the aerosol-forming substrate.

All of the temperature profiles were measured using an electronic temperature probe inserted approximately 2 mm deep into the relevant component of the aerosol generating article.

In Figures 2, 3 and 4, the " AeroZero " line labeled 20 shows the temperature profile of an aerosol generating article having a layer of unenhanced aerogels substantially circumscribing the length of the combustible heat source.

In Figures 2, 3 and 4, the " Pyrogel XTF " line labeled 21 indicates the temperature profile of the aerosol-generating article with the layer of fiber-reinforced airgel according to the present invention substantially covering the length of the combustible heat source Lt; / RTI >

In Figures 2, 3 and 4, the " SMAR " line labeled 22 shows the temperature profile of the aerosol-generating article without the layer of material substantially surrounding the length of the combustible heat source.

An aerosol-generating article having a layer of material that substantially surrounds the length of the aerosol-generating article is substantially similar to or exceeds the temperature profile of the aerosol-generating article without the layer of material substantially surrounding the length of the combustible heat source labeled 22 And the like. This indicates that the layer of material does not substantially inhibit combustion of the combustible heat source.

As shown in Figures 2, 3 and 4, at all three positions of the aerosol-generating article during the entire combustion time of the combustible heat source, the temperature of the aerosol-generating article having a layer of unreinforced aerogels substantially covering the length of the combustible heat source 20 is lower than the temperature 22 of the aerosol-generating article without the layer of material that substantially surrounds the length of the combustible heat source.

Surprisingly, as shown in FIGS. 2, 3 and 4, in all three positions of the aerosol generating article during the most of the burning time of the combustible heat source, the aerosol generating article having a layer of fiber reinforced airgel that substantially surrounds the length of the combustible heat source The temperature 21 of the aerosol generating article is substantially similar to the temperature 22 of the aerosol generating article without the layer of material substantially surrounding the length of the combustible heat source. In addition, at all three positions of the aerosol generating article when the experience of aerosol generation ends, the temperature 21 of the aerosol generating article having a layer of fiber-reinforced airgel that substantially encloses the length of the combustible heat source substantially reduces the length of the combustible heat source It actually exceeds the temperature 22 of the aerosol-generating article without the layer of wrapping material.

This surprising result indicates that providing a layer of at least one fiber-reinforced airgel that substantially envelopes the length of the combustible heat source advantageously does not substantially interfere with combustion of the combustible heat source. Indeed, providing a layer of fiber-reinforced aerogels may result in an increase in the temperature of the combustible heat source at the end of the burning time of the combustible heat source, which may prolong the time for the aerosol generating article to generate an aerosol, .

After the heat source was ignited, the aerosol generating article according to the invention was tested by placing the aerosol generating article on Whatman papers and observing its effect. For example, if the aerosol generating article is heated to about 23 ° C * 3 ° C? And 55% ± 5% relative humidity for 24 hours. The conditioned aerosol-generating article was lighted with an electric lighter and allowed to burn for 3 minutes. After 3 minutes, the aerosol-generating article was placed on a laminated watt-mache for 8 minutes. Eight minutes later, Watmanji was examined. Observations showed that the aerosol-generating article with a layer of fiber-reinforced airgel that substantially enveloped the length of the combustible heat source did not puncture anywhere in the watt-mange, creating a small browning zone on the topmost paper. This result indicates that the surface temperature at the proximal end of the heat source is lowered if it has a layer of fiber-reinforced airgel that substantially encloses the length of the combustible heat source.

A schematic diagram of a second embodiment of an aerosol generating article according to the present invention is shown in Fig. The aerosol generating article 102 is substantially similar to the aerosol generating article 2 shown in Fig. The aerosol generating article 102 is disposed in a manner similar to the combustible heat source 103, the aerosol forming substrate 104, the layer 105 of fiber reinforced airgel and the corresponding components of the aerosol generating article 102 shown in FIG. 1 And a layer 107 of cigarettes. However, the combustible heat source 103 is a non-blind heat source. The non-blind heat source 103 includes a tubular body 115 of carbonaceous material having a passageway 116 extending between the distal end face and the proximal end face. Passage 116 forms part of the air flow path through the aerosol generating article 102 and air flows from the proximal end of the aerosol generating article 102 through the combustible heat source 103 to the aerosol forming substrate 104 So that it can be sucked. The layer 105 of fiber-reinforced aerosol is spaced from the airflow path through the aerosol-generating article 102 such that the aspirated air through the airflow path is not in contact with the layer 105 of fiber-

The nonflammable substantially air impermeable first barrier 106 is disposed between the proximal end of the combustible heat source 103 and the distal end of the aerosol forming substrate 104 similar to the first barrier 6 described above with respect to Figure 1 . Unlike the first barrier 6 described above, however, the first barrier 106 has apertures 120 aligned with the passages 116 so that air can pass from the passages 116 to the aerosol- .

A nonflammable substantially air impermeable second barrier (117) is coated on the inner surface of the passageway (116). The second barrier 117 separates the air passing through the passage 116 from the combustible heat source 103 and separates it from the combustion products of the combustible heat source.

Because the combustible heat source 103 is a non-blind heat source, the aerosol generating article 102 does not include an air inlet disposed at the site of the aerosol forming base 104. When the user aspirates on the mouthpiece of the aerosol generating article 102, the outside air may pass through the passage 116 and pass through the heat source 103 and be drawn into the aerosol generating article 102. The air sucked into the aerosol generating article 102 passes through the passage 116 along the air flow path of the aerosol generating article 102 and through the aerosol forming substrate 104, the transfer element, the cooling element and the spacer element, And the user can escape the mouthpiece so that the user can inhale and flow to the user. The general direction of air flow through the aerosol generating article 102 is indicated by the arrows.

It will be appreciated that, in some embodiments, other air inlets may be provided to the aerosol generating article in addition to the air passageway passing through the combustible heat source.

The specific embodiments described above are intended to illustrate the invention. It should be understood, however, that other embodiments may be made without departing from the scope of the invention as defined in the claims, and that the specific embodiments described above are not intended to limit the invention.

Claims (15)

As an aerosol-generating article,
An aerosol-forming substrate;
Combustible heat source;
A layer of at least one fiber-reinforced airgel wrapped around at least a portion of the combustible heat source;
One or more air flow paths through which the air sucked through the aerosol generating article can follow, so that the user can inhale; And
And at least one incombustible substantially air impermeable barrier disposed between the combustible heat source and the aerosol forming substrate. 2. The method of claim 1, wherein the at least one layer of fiber-reinforced airgel is formed such that, during use, air sucked along the at least one airflow path through the aerosol- Wherein said at least one air flow path is separated from said at least one air flow path. 3. A method according to claim 1 or 2, wherein the layer of combustible heat source, the aerosol forming substrate, and the at least one fiber-reinforced airgel is heated such that the temperature of the aerosol forming substrate does not exceed 375 DEG C Wherein the aerosol-generating article is an aerosol-generating article. 4. An aerosol-generating article as claimed in any one of claims 1 to 3, wherein the fiber-reinforced aerogels comprise less than about 80% by weight of aerogels. 5. The aerosol-generating article of any one of claims 1 to 4 wherein the fiber-reinforced aerogels comprise at least about 20 weight percent fibrous material. 9. The aerosol generating article of claim 8, wherein the fiber-reinforced aerogels comprise from about 20% to about 70% fibrous material by weight. 7. An aerosol generating article according to any one of claims 1 to 6, wherein the fiber-reinforced aerogels comprise at least one of a ceramic fiber material and a glass fiber material. 8. An article according to any one of claims 1 to 7, wherein the layer of the at least one fiber-reinforced airgel has a thickness of from about 0.5 mm to about 5 mm. 9. A method according to any one of claims 1 to 8, wherein the nonflammable substantially air impermeable barrier disposed between the combustible heat source of the aerosol-generating article and the aerosol-forming substrate comprises a proximal end of the combustible heat source and a non- And a first barrier bordering one or both of the distal ends. 10. A method according to any one of claims 1 to 9, wherein said at least one airflow path is configured such that air can be drawn into said one or more airflow paths of said aerosol- generating article without penetrating said combustible heat source, And at least one air inlet between the proximal end of the heat source and the proximal end of the aerosol generating article. 11. A method according to any preceding claim, wherein the at least one airflow path includes at least one airflow channel along the combustible heat source, and wherein the at least one airflow path is disposed between the combustible heat source and the at least one airflow channel Wherein the non-combustible substantially air impermeable barrier further comprises a second barrier between the combustible heat source and the at least one air flow channel of the combustible heat source. 12. An aerosol generating article according to any one of claims 1 to 11, wherein the aerosol generating article comprises at least one additional layer surrounding at least a proximal portion of the combustible heat source and a distal portion of the aerosol forming substrate,
A heat conduction element for transferring heat from the combustible heat source to the aerosol forming substrate; And
At least one of the layers of a cigarette paper. 13. The article of claim 12, wherein the at least one layer of fiber-reinforced airgel is a radially outer layer overlying at least a portion of the at least one additional layer. A method of forming an aerosol-generating article according to any one of claims 1 to 13, the method comprising:
Disposing a combustible heat source for heating the aerosol-forming substrate;
Providing at least one airflow path through which the air sucked through the aerosol generating article can follow, so that the user can inhale,
Separating the combustible heat source from the at least one airflow path such that during use the air drawn along the at least one airflow path through the aerosol generating article is not in direct contact with the combustible heat source; And
Encompassing at least a portion of said combustible heat source field with a layer of at least one fiber-reinforced airgel. 15. The method of claim 14, wherein said step of wrapping at least a portion of said combustible heat source field with a layer of at least one fiber-
Providing a strip of fiber-reinforced aerogels having opposite ends;
Wrapping the strip around the combustible heat source such that the combustible heat source is circumscribed by a layer of at least one fiber-reinforced airgel;
Overlapping the opposite end of the strip; And
Further comprising securing the overlapped end to secure the at least one fiber-reinforced airgel to the combustible heat source.

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