WO2024074840A1

WO2024074840A1 - Element for an aerosol generating article or smoking article

Info

Publication number: WO2024074840A1
Application number: PCT/GB2023/052595
Authority: WO
Inventors: Sulistyo WIDODO; Giyanto "-"; Ilham Fadila RAMADHAN; Rosi Ana QOLBI; Agus FAHRONI
Original assignee: Filtrona Development Co. Pte. Ltd.; Filtrona Filters Limited
Priority date: 2022-10-07
Filing date: 2023-10-06
Publication date: 2024-04-11
Also published as: GB202214783D0

Abstract

There is disclosed an element (100) for an aerosol generating article or a smoking article comprising a longitudinally extending hollow tube (101); a layer (102) comprising filler material, wherein the layer (102) is engaged around the hollow tube (101); and a wrapper (103) engaged around the layer (102); wherein the hollow tube (101) comprises a helically wound sheet of material (304) and wherein the helically wound sheet of material (304) has partially overlapping helical turns.

Description

Element for an aerosol generating article or smoking article

The present invention relates to an element for an aerosol generating article, such as a heated tobacco product, or for a smoking article, such as a cigarette.

The use of tube elements in aerosol generating articles and smoking articles is well known in the art. Typically, a tube element includes a cylindrical core of filtering material which includes a channel that extends longitudinally from an end of the cylindrical core. In such articles a tube element is usually included with a plug of modified tobacco and other elements, such as a wrapped plug of filtering material.

The tube element may be positioned at the mouth end of the aerosol generating article to provide a distinctive end appearance and concentrate the aerosol into a stream directed at the tongue of the user. Alternatively, the tube element can be used as a middle segment or at the tobacco end of an aerosol generating article to facilitate passage of the aerosol from the tobacco segment into other elements and/or to cool the aerosol before it reaches the mouth piece. In smoking articles, the tube element may be positioned at the mouth end to provide a distinctive end appearance and reduce the appearance of staining. Alternatively, the tube element can be used as a middle segment or at the tobacco end of a smoking article where it may facilitate passage of the tobacco smoke from the tobacco segment into other elements, act as a reservoir to concentrate the tobacco smoke and enhance nicotine delivery to the user.

In the past, cellulose acetate filamentary tow has been used as the filtering material of tube elements because it can be manufactured into a tube which exhibits desirable hardness, structural integrity and channel definition. Manufacture of such tube elements can take place in a single continuous process. However, cellulose acetate filamentary tow does not readily biodegrade, and as a result aerosol generating article elements and smoking article elements comprising cellulose acetate filamentary tow may persist in the environment for many years.

Elements for aerosol generating articles and smoking articles have been manufactured from materials that readily biodegrade, for example paper. However, it has previously been challenging to manufacture tube elements from paper or other materials that readily biodegrade while retaining the hardness and structural integrity associated with aerosol generating article elements and smoking article elements that are made from cellulose acetate filamentary tow.

There is a need for a tube element for an aerosol generating article or smoking article that has improved biodegradability compared to tube elements comprising cellulose acetate filamentary tow, and which has desirable hardness and structural integrity, for example, similar hardness and structural integrity to existing elements for aerosol generating articles and smoking articles that are formed from cellulose acetate filamentary tow. There is also a need for a method of manufacturing such tube elements.

In an aspect of the present invention, there is provided an element for an aerosol generating article or a smoking article comprising a longitudinally extending hollow tube; a layer comprising filler material, wherein the layer is engaged around the hollow tube; and a wrapper engaged around the layer; wherein the hollow tube comprises a helically wound sheet of material and wherein the helically wound sheet of material has partially overlapping helical turns.

The aerosol generating article may be a heated tobacco product, such as a heat not burn device, tobacco heating device or the like, or an electronic cigarette.

The smoking article may be a cigarette, cigar, cigarillo, roll your own cigarette or the like.

The element may be a mouth piece, for example a mouth piece for an aerosol generating article or a smoking article.

The element may be a cooling element, for example an element for an aerosol generating article that provides a cooling effect on aerosol (e.g., vapour) or tobacco smoke.

The element may be a filter element, for example an element for an aerosol generating article or smoking article that provides a filtration effect on aerosol (e.g., vapour) or tobacco smoke. Alternatively, the element may not provide a filtration effect on aerosol (e.g., vapour) or tobacco smoke, for example the element may have zero, or substantially zero, aerosol (e.g., vapour) or tobacco smoke filtering effect.

The element may function as both a cooling element and a filter element for an aerosol generating article. The element may facilitate the passage of aerosol or tobacco smoke from the tobacco segment into other elements of an aerosol generating article or smoking article (i.e. , the aerosol or tobacco smoke may pass through the channel of the hollow tube into other elements). It will be appreciated that if the element is facilitating the passage of aerosol or tobacco smoke from the tobacco segment into other elements of an aerosol generating article or smoking article, the channel of the hollow tube may not contain any object which may substantially restrict the aerosol or tobacco smoke, for example restrict aerosol or tobacco smoke. In other words, the channel of the hollow tube may be empty. Thus, there may be substantially no retention of the aerosol or tobacco smoke by the element, for example no retention of the aerosol or tobacco smoke by the element. It will further be appreciated that, when assembled with further elements into a multi-segment product, the element may contribute substantially zero, for example zero, to the pressure drop of the multi-segment product due to the lack of or minimal retention of aerosol or tobacco smoke by the element.

The element may act as a reservoir wherein tobacco smoke from a tobacco segment is concentrated, for example tobacco smoke is concentrated within the channel of the hollow tube. The applicant has found that by concentrating the tobacco smoke within the element, the user may receive highly concentrated smoke and accordingly, enhanced nicotine delivery.

The element may be substantially cylindrical, for example cylindrical.

The transverse cross section of the element may be substantially annular, for example annular.

The hollow tube may be a spiral wound tube.

The hollow tube comprises an outer surface and an inner surface. The inner surface of the hollow tube defines a channel which extends longitudinally along the length of the hollow tube, for example the channel may extend longitudinally along the entire length of the hollow tube.

Herein, the phrase “engaged around the hollow tube” means engaged around the outer surface of the hollow tube. The helically wound sheet of material may be a sheet of material that extends helically about the longitudinal axis of the element, such that the helically wound sheet of material partially overlaps with itself at successive points along the longitudinal length of the element.

The helically wound sheet of material may be wound about the longitudinal axis of the element, for example wound about the longitudinal axis of the element in a spiral at an oblique angle to the longitudinal axis of the element.

A portion of the helically wound sheet of material overlaps with itself on each successive helical turn, such that there are no gaps between the turns. It will be appreciated that, without gaps between successive helical turns, the helically wound sheet of material is substantially tubular (e.g., tubular) in shape (i.e., the helically wound sheet of material forms the hollow tube). Therefore, the helically wound sheet of material overlaps with itself at successive points along the longitudinal length of the hollow tube.

The applicant has found that the hollow tube, comprising a helically wound sheet of material with partially overlapping helical turns, will not buckle or deform under the weight of the layer comprising filler material and the wrapper engaged around the layer. The applicant has also found that the hollow tube has a consistent wall thickness and uniform end appearance which may help to prevent counterfeiting.

The average wall thickness of the hollow tube may be from 0.2 to 3.0 mm, for example from 0.5 to 2.5 mm, for example from 1 .0 to 2.0 mm, for example from 1 .3 to 1 .5 mm. The wall thickness is defined herein as the distance between the outer surface and the inner surface of the hollow tube.

The internal diameter of the hollow tube may be from 1.5 to 10 mm, for example from 2.0 to 9.0 mm, for example from 3.0 to 8.0 mm, for example from 4.0 to 7.0 mm, for example 5.0 mm, or 6.0 mm. The internal diameter is defined herein as the distance between diametrically opposed points on the inner surfaces of the channel at its widest point.

The hollow tube may comprise 1-10 sheets of material, for example 1 , 2, 3, 4, 5, 6, 7, 9, or 10 sheet(s) of material. The hollow tube may comprise at least 2 sheets of material, for example at least 3 sheets of material, for example, at least 4 sheets of material. Preferably, the sheet of material of the hollow tube is paper. The paper may comprise plant based fibres, for example one or more of flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch or wood pulp. The paper may be formed from plant based fibres, for example one or more of flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch or wood pulp. The paper may be a filter paper or a cellulose/lyocell/viscose based paper.

Preferably, the sheet of material of the hollow tube is a plug wrap.

The sheet of material of the hollow tube may have a thickness from 0.02 to 1 .5 mm, for example from 0.1 to 1 .2 mm, example from 0.2 to 1 .0 mm, example from 0.3 to 0.8 mm, for example 0.5 mm or 0.6 mm.

The sheet of material of the hollow tube may have a basis weight from 24 to 200 grams per square metre (g/m²), for example from 45 to 180 g/m², for example from 60 to 160 g/m², for example from 100 to 120 g/m².

The hollow tube may be coloured. The sheet of material of the hollow tube may be coloured.

Preferably, the sheet of material of the hollow tube is a strip of material. The sheet of material (e.g. strip of material) of the hollow tube may have a width of from 10 to 20 mm, for example from 12 to 18 mm, for example from 14 to 16 mm, for example 15 mm.

The applicant has found that a plug wrap of basis weight from 24 to 200 grams per square metre (g/m²) can be helically wound and manufactured into a hollow tube that will not buckle or deform under the weight of the layer comprising filler material and the wrapper engaged around the layer.

The sheet of material of the hollow tube may be air permeable. The air permeability of the sheet of material of the hollow tube of paper (or the wrapper) is measured in the CORESTA air permeability unit (CU). A CORESTA Unit is defined as the volumetric flow rate of air (cm³ min^-1) passing through a 1 cm² sample of substrate at an applied pressure difference of 1 kPa. The air permeability of the sheet of material of the hollow tube may be from 20 to 6000 CORESTA, for example from 1000 to 5000 CORESTA, for example from 2000 to 4000 CORESTA. The sheet of material of the hollow tube may comprise a layer of adhesive disposed on a surface of the sheet of material. The layer of adhesive may be disposed on portions of the sheet of material that overlap with itself on each successive helical turn, when helically wound. The layer of adhesive may be used to secure a first portion of the helically wound sheet of material to a second portion of the helically wound sheet of material of successive helical turns. The layer of adhesive may be used to secure the hollow tube together. The layer of adhesive may comprise a strip of adhesive, for example a continuous strip of adhesive, disposed at an edge of the sheet of material. The layer of adhesive may comprise dots of adhesive, disposed at an edge of the sheet of material. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate) as is known in the art.

The hollow tube may comprise a layer of adhesive disposed on the outer surface of the hollow tube. The layer of adhesive may be used to secure the layer comprising filler material to the hollow tube. The layer of adhesive may comprise a strip of adhesive, for example a continuous strip of adhesive, disposed along the longitudinal length of the hollow tube. Alternatively, the adhesive may comprise dots of adhesive disposed along the longitudinal length of the hollow tube. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate) as is known in the art.

The layer comprising filler material may be engaged around the hollow tube along the longitudinal length of the hollow tube, for example along the full longitudinal length of the hollow tube. The layer comprising filler material may be engaged concentrically around the hollow tube. The layer comprising filler material may be the same length as the hollow tube.

The filler material may be gathered (e.g., wrapped, e.g., helically wound) around the hollow tube.

The layer comprising filler material may comprise from 1 to 10 sheets of filler material, for example 1 , 2, 3, 4, 5, 6, 7, 9, or 10 sheet(s). The layer comprising filler material may comprise at least 2 sheets of filler material, for example at least 3 sheets of filler material, for example at least 4 sheets of filler material.

The sheet of filler material may be gathered (e.g., wrapped, e.g., helically wound) around the hollow tube. In an embodiment, the layer comprising filler material may comprise a sheet of filler material engaged concentrically around the hollow tube. The sheet of filler material may be wrapped around the hollow tube, about the longitudinal axis of the hollow tube. The sheet of filler material may be wrapped at a 90-degree angle to the longitudinal axis of the hollow tube. The sheet of filler material may be wrapped once around the hollow tube, about the longitudinal axis of the hollow tube, such that the sheet of filler material circumscribes the hollow tube once and forms a single continuous layer of filler material around the hollow tube. In such examples it will be appreciated that, the width of the sheet of filler material will be approximately the same as the circumference of the hollow tube, such that the sheet of filler material does not overlap or substantially overlap with itself when wrapped around the hollow tube.

In embodiments where the layer comprising filler material comprises two or more sheets of filler material, each sheet of filler material may be successively wrapped once around the hollow tube, about the longitudinal axis of the hollow tube, such that each sheet of filler material circumscribes the hollow tube once and forms multiple layers of filler material around the hollow tube. Each sheet of filler material may be wrapped at a 90-degree angle to the longitudinal axis of the hollow tube. The multiple layers of filler material may be engaged concentrically around the hollow tube.

Alternatively, the sheet of filler material may be wrapped more than once around the hollow tube, such that the sheet of filler material circumscribes the hollow tube more than once (i.e. , overlapping with itself) and forms multiple layers of filler material around the hollow tube.

In a further embodiment, the sheet of filler material may be helically wound around the hollow tube, for example wound about the longitudinal axis of the hollow tube in a spiral at an oblique angle to the longitudinal axis of the hollow tube.

The helically wound sheet of filler material may have partially overlapping helical turns whereby a portion of the helically wound sheet of filler material overlaps with itself on each successive helical turn, such that there are no gaps between the turns. It will be appreciated that, without gaps between successive helical turns, the helically wound sheet of filler material forms a continuous layer of filler material around the hollow tube. The helically wound sheet of filler material may have abutting non-overlapping helical turns whereby opposing edges of the helically wound sheet of filler material abut along the length of successive helical turns, such that successive helical turns are abutted and there are no gaps between the turns.

The sheet of filler material may have a basis weight from 16 to 200 grams per square metre (g/m²), for example from 20 to 160 g/m², for example from 40 to 120 g/m², for example from 60 to 100 g/m², for example from 80 to 90 g/m².

The sheet of filler material may have a width of from 10 to 90 mm, for example from 20 to 80 mm, for example from 50 to 60 mm, for example from 20 to 30 mm, for example 25 mm.

The sheet of filler material may comprise a layer of adhesive disposed on a surface thereof. The layer of adhesive may be used to secure the sheet of filler material around the hollow tube. The layer of adhesive may comprise a strip of adhesive, for example a continuous strip of adhesive, disposed at an edge of the sheet of filler material. Alternatively, the layer of adhesive may comprise dots of adhesive, disposed at an edge of the sheet of filler material. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate) as is known in the art.

The layer comprising filler material may be of average thickness from 0.2 to 3.0 mm, for example from 0.3 to 2.5 mm, for example from 0.4 to 2.0 mm, for example from 0.5 to 1 .5 mm, for example from 0.8 to 1 .4 mm, for example 0.9 mm, 1 .0 mm, 1.1 mm, 1 .2 mm, 1 .3 mm. The thickness is defined herein as the shortest distance between a point on the outer surface of the hollow tube and a point on the wrapper engaged around the layer comprising the filler material. It will be appreciated that the thickness of the layer comprising filler material may not be constant because of overlap of the filler material when gathered (e.g., wrapped, e.g., helically wound) around the hollow tube, therefore the thickness of the layer comprising filler material is an average.

The filler material may exhibit a filtration effect on the aerosol (e.g., vapour) or tobacco smoke as the aerosol (e.g., vapour) or tobacco smoke is drawn through the element. The filler material may comprise a filtering material. The filler material may be a filtering material. The phrase “filtering material” herein means any material that has a filtration effect on the aerosol (e.g., vapour) or tobacco smoke as it is drawn through the element. In some examples, the element of the invention has zero, or substantially zero, aerosol (e.g., vapour) or tobacco smoke filtering effect. In such a case, the element of the invention may facilitate the passage of the aerosol or tobacco smoke from the tobacco segment into other elements of an aerosol generating article or smoking article with substantially no retention of aerosol or tobacco smoke by the element. In other examples, the element of the invention may have an aerosol (e.g., vapour) or tobacco smoke filtering effect.

The filler material may be a paper or a non-woven material. The paper or a non-woven material may comprise plant based fibres, for example one or more of flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch or wood pulp. The paper or a non-woven material may be formed from plant based fibres, for example one or more of flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch or wood pulp. The paper or non-woven material may be an airlaid material, a filter paper or a cellulose/lyocell/viscose based paper.

Preferably, the layer comprising filler material does not comprise cellulose acetate. Preferably, the filler material is not cellulose acetate.

The applicant has found that airlaid materials are straightforward to assemble into a layer engaged around the hollow tube as well as having desirable filtration and/or cooling properties on aerosol (e.g., vapour) or tobacco smoke. The applicant has also found that airlaid materials may provide a layer with consistent thickness and a uniform end appearance which may help to prevent counterfeiting.

The filler material may be embossed. Alternatively, the filler material may not be embossed.

The wrapper may be engaged around the layer comprising filler material along the longitudinal length of the layer comprising filler material, for example along the full longitudinal length of the layer comprising filler material. The wrapper may be engaged concentrically around the layer comprising filler material. The wrapper may be the same length as the layer comprising filler material, which in turn may be the same length as the hollow tube. Therefore, the hollow tube, layer comprising filler material and wrapper may all be the same length.

The wrapper may have a basis weight from 24 to 200 grams per square metre (g/m²), for example from 45 to 180 g/m², for example from 60 to 160 g/m², for example from 100 to 120g/m². The air permeability of the wrapper may be from 20 to 6000 CORESTA, for example from 1000 to 5000 CORESTA, for example from 2000 to 4000 CORESTA.

The wrapper may be paper, for example an air permeable paper. Preferably the wrapper is a plug wrap. The wrapper may be coated, for example coated with a starch, guar gum and/or a hydrophobic coating. The wrapper may function to hold the layer of filler material in place around the hollow tube.

The wrapper may be secured around the layer comprising filler material with adhesive, for example by a lapped and stuck seam as is known in the art.

The applicant has found that a plug wrap of basis weight from 100 to 160 g/m² can be assembled around the layer comprising filler material and will not buckle or deform when combined with other elements for aerosol generating articles or smoking articles, such as filter elements, or when further processed into an aerosol generating article such as a heated tobacco product or an electronic cigarette or into a smoking article, such as a cigarette.

The length of the element is from 5 to 150 mm, for example from 10 to 100 mm, for example from 50 to 90 mm, for example from 12 to 23 mm, for example from 18 mm to 22 mm.

The element may have a circumference from 14 to 30 mm, for example from 16 to 25 mm, for example from 17 to 24 mm, for example from 18 mm to 22 mm, for example 19.8 mm, for example 24.25 mm.

The element may have a hardness of from 90% to 97%, for example 91% to 97%, for example from 92% to 97%, for example 94%, 95% or 96%.

Herein hardness is a measurement of the extent to which the element deforms following application of a given pressure for a given time. Hardness is measured using a Cerulean QTM module 7 device. A preload is applied to the element and the point of contact diameter (DP) is measured. A higher load is then applied and the depressed diameter (DL) is measured after a given time or once a slope threshold is reached. The hardness is calculated as: %H = (DL/DP) x 100. The load cell used with the QTM module 7 device is 290 grams. The applicant has found that elements of the present invention will not buckle or deform when combined with other elements for aerosol generating articles or smoking articles, such as filter elements, or when further processed into an aerosol generating article such as a heated tobacco product or an electronic cigarette or into a smoking article, such as a cigarette. The applicant has also found that the structural integrity the element may match that of other elements for aerosol generating articles or smoking articles, for example formed from cellulose acetate filamentary tow; therefore, the element of the present invention may be easily assembled with further elements into a multi-segment product, for example a multi-segment filter.

The element may comprise biodegradable materials. Preferably, the element comprises solely biodegradable materials. The element may be biodegradable. Preferably, the element does not comprise cellulose acetate.

Herein, biodegradable means being capable of being broken down by living organisms such as bacteria and fungi.

The element or materials of the element may have a biodegradation of at least 90% after 6 months under controlled composting conditions as determined according to ISO14855 Determination of the ultimate aerobic biodegradability of plastic materials under controlled composting conditions - Method by analysis of evolved carbon dioxide.

The element or materials of the element may be readily biodegradable. Herein, the phrase readily biodegradable means the element has ‘Ready Biodegradability’ level of biodegradability as measured according to OECD Test No. 301 B: Ready Biodegradability (CO₂ Evolution (Modified Sturm Test)).

The applicant has found that by manufacturing the element from paper or other materials that readily biodegrade, the element may provide desirable cooling and/or filtration properties on aerosol (e.g., vapour) or tobacco smoke, while also being readily biodegradable.

In a further aspect of the present invention there is provided a multi-segment product, for example a multi-segment filter, for an aerosol generating article or smoking article comprising an element according to any preceding statement and one or more discrete further elements.

In a further aspect of the present invention there is provided an aerosol generating article or smoking article comprising an element as described above or comprising multi-segment product comprising an element as described above.

Herein an aerosol generating article may include heated tobacco products such as heat not burn devices, tobacco heating devices and the like; and electronic cigarettes. Herein a smoking article may include cigarettes, cigars, cigarillos, roll your own cigarettes and the like.

The aerosol generating article or smoking article may include a multi-segment product or element as set out above, that is joined to a wrapped rod of smoking material such as tobacco smoking material. The aerosol generating article or smoking article may further comprise a tipping wrapper, for example a tipping paper. The tipping wrapper joins the wrapped rod of smoking material to the multi-segment product or element by engaging around the adjacent ends of the multi-segment product or element and the wrapped rod of smoking material. The tipping wrapper may be configured to leave some of the outer surface of the multi-segment product or element exposed. The multi-segment product or element may be joined to the wrapped rod of smoking material by a full tipping wrapper which engages around the full length of the multi-segment product or element and the adjacent end of the rod of smoking material.

The applicant has found that an aerosol generating article or a smoking article comprising an element according to the present invention may exhibit a reduction in the appearance of staining at the mouth end (i.e. , the user’s mouth end) in comparison to a conventional (e.g., non-annular) element or mouth piece. The element according to the present invention may also concentrate aerosol, such as vapour, or tobacco smoke into a stream directed at the user’s tongue. The applicant has also found that the element according to the present invention may provide cooling of the aerosol (e.g., vapour) or tobacco smoke. The applicant has also found that the element according to the present invention may facilitate the passage of the aerosol (e.g., vapour) or tobacco smoke from the tobacco segment into other elements of the aerosol generating article with substantially no retention of the aerosol (e.g., vapour) or tobacco smoke by the element. The applicant has also found that the element according to the present invention may act as a reservoir wherein the aerosol or tobacco smoke from the tobacco segment is concentrated, for example concentrated within the channel of the hollow tube. The applicant has also found that the element according to the present invention may also enhance nicotine delivery to the user. The applicant has also found that the element according to the present invention may provide a filtration effect on aerosol (e.g., vapour) or tobacco smoke.

The multi-segment product, element, aerosol generating article or smoking article according to the invention may be unventilated, or may be ventilated by methods well known in the art, e.g., by use of a pre-perforated or air-permeable wrapper or tipping wrapper (tipping paper), and/or laser perforation of the wrapper and/or tipping wrapper. A ventilating full tipping wrapper (tipping paper) may likewise be inherently air-permeable or may be provided with ventilation holes, and for ventilated products where both wrapper and tipping wrapper (tipping paper) are present, ventilation through the tipping wrapper (tipping paper) will usually be in register with that through the wrapper. Ventilation holes through a wrapper, or through a tipping wrapper (tipping paper), or through both simultaneously, may be made by laser perforation during element production.

In a further aspect of the present invention, there is provided a multiple rod comprising a plurality of elements according to the invention, for example arranged end-to-end in a mirror image relationship.

In a further aspect of the present invention, there is provided a method of making an element for an aerosol generating article or smoking article comprising the steps of: advancing a sheet of material in a longitudinal direction; helically winding the sheet of material around a shaping rod, such that the sheet of material partially overlaps with itself on successive helical turns, thereby forming a longitudinally extending hollow tube; advancing filler material in a longitudinal direction; gathering (e.g., wrapping, e.g., helically winding) the filler material around the hollow tube to form a layer comprising filler material engaged around the hollow tube; gathering (e.g., wrapping) and securing a wrapper around the layer comprising filler material to form a continuous rod; and cutting the continuously rod to form individual elements.

The sheet of material may advance continuously.

The sheet of material may be drawn from a source (e.g., a roll of material) before being advanced towards the shaping rod. The method may comprise advancing 1-10 sheets of material, for example 1 , 2, 3, 4, 5, 6, 7, 9, or 10 sheet(s) of material. The method may comprise advancing at least 2 sheets of material, for example at least 3 sheets of material, at least 4 sheets of material. In the case of there being two or more sheets of filler material, this may be drawn from two or more sources, such as two rolls of material.

The method may comprise applying adhesive to the advancing sheet of material. The adhesive may be applied to a surface of the advancing sheet of material. The adhesive may be applied to the advancing sheet of material before the advancing sheet of material is helically wound around the shaping rod. For example, the adhesive may be applied to the sheet of material at a gluing station before the advancing sheet of material is helically wound around the shaping rod. The adhesive may be sprayed onto the sheet of material, for example sprayed on to a surface of the sheet of material, for example along a longitudinal edge of the sheet of material. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate) as is known in the art.

The adhesive may be applied to portions of the sheet of material that will overlap with itself (e.g., at successive helical turns) when the sheet of material is helically wound around the shaping rod.

The shaping rod may also be referred to as a mandrel.

The shaping rod may be substantially cylindrical, for example cylindrical.

The shaping rod may comprise an outer surface which defines the internal diameter of the hollow tube.

The shaping rod may have a diameter from 1 .5 to 10 mm, for example from 2.0 to 9.0 mm, for example from 3.0 to 8.0 mm, for example from 4.0 to 7.0 mm, for example 5.0 mm or 6.0 mm.

The internal diameter of the hollow tube may be from 1 .5 to 10 mm, for example from 2.0 to 9.0 mm, for example from 3.0 to 8.0 mm, for example from 4.0 to 7.0 mm, for example 5.0 mm or 6.0 mm. The sheet of material may have a width of from 10 to 20 mm, for example from 12 to 18 mm, for example from 14 to 16 mm, for example 15 mm.

The sheet of material is helically wound around the outer surface of the shaping rod, for example wound about the longitudinal axis of the shaping rod in a spiral at an oblique angle to the longitudinal axis of the shaping rod. On each successive helical turn around the shaping rod, a first portion of the sheet of material will partially overlap with a second portion of the sheet of material, such that there are no gaps between successive turns of the sheet of material. The overlapping portions of the sheet of material may be secured to each other by adhesive.

Preferably, the sheet of material is paper. The paper may comprise plant based fibres, for example one or more of flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch or wood pulp. The paper may be formed from plant based fibres, for example one or more of flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch or wood pulp. The paper may be a filter paper or a cellulose/lyocell/viscose based paper.

Preferably, the sheet of material is a plug wrap.

The filler material may advance continuously.

The filler material may be drawn from a source before being advanced towards the longitudinally extending hollow tube.

The filler material is gathered (e.g., wrapped, e.g., helically wound) around the hollow tube along the longitudinal length of the hollow tube, for example along the full longitudinal length of the hollow tube.

The filler material may be a sheet of filler material.

The method may comprise advancing 1-10 sheets of filler material, for example 1 , 2, 3, 4, 5, 6, 7, 9, or 10 sheet(s) of filler material. The method may comprise advancing at least 2 sheets of filler material, for example at least 3 sheets of filler material, at least 4 sheets of filler material. In the case of there being two or more sheets of filler material, this may be drawn from two or more sources, such as two rolls of filler material. The sheet of filler material may have a width of 10 to 90 mm, for example 20 to 80 mm, for example 50 to 60 mm, for example 20 to 30 mm, for example 25 mm. The sheet of filler material may be cut to a width of 60 to 90 mm.

The method may comprise a step of cutting the sheet of filler material longitudinally to thereby form two or more sheets of longitudinally extending filler material. For example, the cutting may occur at a cutting station before the sheet of filler material is advanced in a longitudinal direction and then gathered around the hollow tube. The two or more sheets of longitudinally extending filler material may be stacked on top of each other following the cutting. The two or more sheets of longitudinally extending filler material may continue to advance in a longitudinal direction following the cutting. The sheet of filler material may be cut to form two, three, four or more sheets of longitudinally extending filler material. Alternatively, the filler material may be cut by a separate process and wound on to a reel for use in the methods of the invention.

In an embodiment, the sheet of filler material may be wrapped around the hollow tube, about the longitudinal axis of the hollow tube. The sheet of filler material may be wrapped at a 90-degree angle to the longitudinal axis of the hollow tube. The sheet of filler material may be wrapped once around the hollow tube, about the longitudinal axis of the hollow tube, such that the sheet of filler material circumscribes the hollow tube once and forms a single continuous layer of filler material around the hollow tube. Alternatively, the sheet of filler material may be wrapped more than once around the hollow tube about the longitudinal axis of the hollow tube, such that the sheet of filler material circumscribes the hollow tube more than once (i.e. , overlapping with itself) and forms multiple layers around the hollow tube.

The sheet of filler material may be wrapped around the hollow tube in a gathering chamber for gathering (or configured to gather) the sheet of filler material around the hollow tube. The sheet of filler material may be drawn into the gathering chamber having an inlet for receiving the sheet of filler material and the hollow tube and an outlet through which the hollow tube (and the layer of filler material engaged around the hollow tube) exit the gathering chamber. The gathering chamber may be a tapered chamber wherein the diameter of the inlet is larger than the diameter of the outlet.

In embodiments where the method comprises advancing two or more sheets of filler material, the sheets of filler material may be stacked on top of each other to form a stack of two or more sheets of filler material. The stack of two or more sheets of filler material may be successively wrapped once around the hollow tube, about the longitudinal axis of the hollow tube, such that each sheet of filler material circumscribes the hollow tube once and forms multiple layers of filler material around the hollow tube. Each sheet of filler material may be wrapped at a 90-degree angle to the longitudinal axis of the hollow tube. The multiple layers of filler material may be engaged concentrically around the hollow tube. The sheets of filler material may be wrapped around the hollow tube in a gathering chamber for gathering (or configured to gather) the sheets of filler material around the hollow tube.

Herein, the phrase “wound around the hollow tube” means wound around the outer surface of the hollow tube.

The sheet of filler material may be helically wound around the hollow tube in a shaping chamber, the shaping chamber for (or configured to) helically wind the sheet of filler material around the hollow tube. In some examples, the shaping chamber may comprise the shaping rod around which the sheet of material of the hollow tube may be helically wound to thereby form the longitudinally extending hollow tube, before the sheet of filler material is helically wound around the hollow tube. The sheet of filler material (and the sheet of material of the hollow tube) may be drawn into the shaping chamber having an inlet for receiving the sheet of filler material (and the sheet of material of the hollow tube) and an outlet through which the hollow tube (and the layer of filler material engaged around the hollow tube) exit the shaping chamber.

The sheet of filler material may be helically wound such that the sheet of filler material has partially overlapping helical turns whereby a portion of the helically wound sheet of filler material overlaps with itself on each successive helical turn, such that there are no gaps between the turns, thereby forming a continuous layer of filler material around the hollow tube. Alternatively, the sheet of filler material may be helically wound such that the sheet of filler material has abutting non-overlapping helical turns whereby opposing edges of the helically wound sheet of filler material abut along the length of successive helical turns, such that successive helical turns are abutted and there are no gaps between the turns, thereby forming a continuous layer of filler material around the hollow tube. The applicant has found that helically winding the filler material around the hollow tube provides a uniform layer comprising filler material with substantially consistent wall thickness.

The method may further comprise applying adhesive to the advancing sheet of filler material before the advancing sheet of filler material is helically wound around the longitudinally extending hollow tube. The adhesive may be applied to the sheet of filler material at a gluing station before the advancing sheet of filler material is helically wound around the hollow tube. The adhesive may be sprayed onto the sheet of filler material, for example sprayed on to a surface of the sheet of filler material, for example at an edge of the sheet of filler material. The adhesive may be used to secure the sheet of filler material around the hollow tube. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate) as is known in the art.

A wrapper is wrapped around the layer comprising filler material. The wrapper may be wrapped using standard methods known in the art, such as a garniture unit. The wrapper may be secured around the layer comprising filler material with adhesive, for example by a lapped and stuck seam as is known in the art.

The continuous rod may be cut through the transverse cross section to form individual elements. The continuous extending rod may be cut using standard cutting methods known in the art, such as a rotating drum cutter. The continuous rod may be cut at a further cutting station.

In a further aspect of the present invention, there is provided an element for an aerosol generating article formed by the method according to any statement set out above. In a further aspect of the present invention, there is provided an element for a smoking article formed by the method according to any statement set out above.

Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a perspective view of an element for an aerosol generating article or smoking article according to the invention.

Figure 2 is a sectional view of the element shown in figure 1 .

Figure 3 is a perspective view of an element for an aerosol generating article or smoking article according to the invention.

Figure 4 is a schematic overview of a method of the present invention.

Figure 5 is a perspective view of an element for an aerosol generating article or smoking article according to the invention.

Figure 6 is a schematic overview of a method of the present invention.

Figure 1 shows a perspective view of an element 100 for an aerosol generating article, such as a heated tobacco product or an electronic cigarette or for a smoking article, such as a cigarette, according to an embodiment of the present invention.

The element 100 comprises a longitudinally extending hollow tube 101 , a layer comprising filler material 102 engaged around the hollow tube 101 and a wrapper 103 engaged around the layer 102. The hollow tube 101 comprises a helically wound strip of sheet material which may be a strip of plug wrap of width 15 mm and basis weight 120 g/m², although it will be appreciated that other materials are also suitable. The helically wound sheet of material has partially overlapping helical turns (not shown) and forms the hollow tube 101. The helically wound sheet of material extends helically about the longitudinal axis of the element 100, such that the sheet of material partially overlaps with itself at successive points along the longitudinal length of the hollow tube 101 . Successive turns of the helically wound sheet of material may be secured to each other by a layer of adhesive disposed on a surface of the helically wound sheet of material (not shown) thereby securing the hollow tube 101 together. The layer comprising filler material may comprise a sheet of airlaid nonwoven material of width 15 mm, although it will be appreciated that other filler materials are also suitable. The sheet of filler material is wrapped once around the hollow tube 101 and secured to the hollow tube 101 and wrapper 103 by a line of adhesive (not shown) on the hollow tube 101 and on the wrapper 103. The filler material may be embossed. The wrapper 103 is a plug wrap of basis weight 100 g/m² with air permeability from 20 to 6000 CORESTA. The element 100 is of length 108 mm and circumference 24.5 mm.

Figure 2 shows a sectional view cross-sectional profile of the element 100 along line A-A, as shown in figure 1. The transverse cross-section of element 100 is annular. The internal diameter of the hollow tube 101 is shown by d and the average thickness of the layer comprising filler material 102 is shown by t. The layer of filler material 102 is of average thickness 1 .3 mm. The internal diameter of hollow tube 101 is 6 mm and the average wall thickness of the hollow tube 101 is 0.6 mm.

Figure 3 shows a perspective view of a element 300 for an aerosol generating article or a smoking article according to an embodiment of the present invention. The element 300 comprises a longitudinally extending hollow tube 301 , a layer 302 comprising filler material engaged around the hollow tube 301 and a wrapper 303 engaged around the layer 302. The hollow tube 301 comprises a helically wound sheet of material 304 which may be a strip of plug wrap of width 15 mm and basis weight 100 g/m² although it will be appreciated that other materials are also suitable. A portion of the helically wound sheet of material 304 overlaps with itself on each successive turn, such that there are no gaps between the turns. The helically wound sheet of material 304 forms the hollow tube 301 . Successive turns of the helically wound sheet of material 304 may be secured to each other using a layer of adhesive (not shown) disposed on a surface of the sheet of material 304. The adhesive is applied to portions of the sheet of material 304 that overlap with itself (e.g., at successive helical turns) thereby securing the hollow tube 301 together. The layer comprising filler material 302 may comprise a sheet of airlaid non-woven material 305 of width 15 mm, although it will be appreciated that other filler materials are also suitable. The sheet of filler material 305 is helically wound around the hollow tube 301 with abutting non-overlapping helical turns, whereby opposing edges of the helically wound sheet of filler material 305 are abutted along the length of successive turns, such that there are no gaps between the turns. Therefore, the helically wound sheet of filler material 305 forms a continuous layer of filler material 302 around the hollow tube 301 . The helically wound sheet of filler material 305 is secured to the hollow tube 301 and wrapper 303 by a line of adhesive (not shown) on the hollow tube 301 and a line of adhesive (not shown) on the wrapper 303. The wrapper 303 is a plug wrap of basis weight 100 g/m², secured around the layer comprising filler material 302 with a line of adhesive (not shown).

Figure 4 shows a schematic overview of the process of the present invention. The element 300 may be made by the process shown in figure 4.

A sheet of plug wrap 306 of width 15 mm and basis weight 100 g/m² is drawn from a roll 307 and advanced continuously in longitudinal direction L. At a gluing station 308, adhesive is sprayed to a surface of the advancing plug wrap 306 along a longitudinal edge. The plug wrap 306 continues to advance towards shaping chamber 309 comprising a cylindrical shaping rod (mandrel) of diameter 5.0 mm (not shown). The sheet of plug wrap 306 is drawn into the shaping chamber 309 through an inlet and helically wound around the shaping rod, such that the sheet of plug wrap 306 partially overlaps with itself on successive helical turns and the overlapping portions of the sheet of plug wrap are secured to each other by the adhesive, thereby forming a longitudinally extending hollow tube with an internal diameter of about 5.0 mm. A sheet of airlaid non-woven filler material 310 of width 15 mm is drawn from a roll 311 and advanced continuously in longitudinal direction L. The sheet of filler material 310 is drawn into the shaping chamber 309 through an inlet and helically wound around the hollow tube with abutting non-overlapping helical turns, whereby opposing edges of the helically wound sheet of filler material are abutted along the length of successive turns to form a continuous layer around the hollow tube. The hollow tube (and the layer of filler material engaged around the hollow tube) 312 exit the shaping chamber 309 through an outlet. At a garniture unit 313, a plug wrap 315 of basis weight 100 g/m² is drawn from a roll 311 and wrapped around the layer comprising filler material (and the hollow tube) 312 and secured using adhesive form a continuous rod 316. The continuous rod 316 is cut at a cutting station 317 to form the individual element 300.

Figure 5 shows a perspective view of an element 400 for an aerosol generating article or for a smoking article according to an embodiment of the present invention. The element 400 comprises a longitudinally extending hollow tube 401 , a layer 402 comprising filler material engaged around the hollow tube 401 and a wrapper 403 engaged around the layer 402. The hollow tube 401 comprises a helically wound sheet of material 404 which may be a strip of plug wrap of width 15 mm and basis weight 100 g/m² although it will be appreciated that other materials are also suitable. A portion of the helically wound sheet of material 404 overlaps with itself on each successive turn, such that there are no gaps between the turns. The helically wound sheet of material 404 forms the hollow tube 401 . Successive turns of the helically wound sheet of material 404 may be secured to each other using a layer of adhesive (not shown) disposed on a surface of the sheet of material 404. The adhesive is applied to portions of the sheet of material 404 that overlap with itself (e.g., at successive helical turns) thereby securing the hollow tube 401 together. The layer comprising filler material 402 comprises four sheets of airlaid non-woven material, although it will be appreciated that other filler materials are also suitable. Each sheet of filler material is wrapped once around the hollow tube 401 , at a 90-degree angle to the longitudinal axis of the hollow tube, thereby forming multiple layers of filler material engaged concentrically around the hollow tube 401 . The layer comprising filler material 402 is secured to the hollow tube 401 and wrapper 403 by a line of adhesive (not shown) on the hollow tube 401 and on the wrapper 403. The wrapper 403 is a plug wrap of basis weight 100 g/m², secured around the layer comprising filler material 402 with a line of adhesive (not shown).

Figure 6 shows a schematic overview of the process of the present invention. The element 400 according to figure 5 may be made by the process shown in figure 6.

A sheet of plug wrap 406 of width 15 mm and basis weight 100 g/m² is drawn from a roll 405 and advanced in longitudinal direction L. At a gluing station 407, adhesive is sprayed onto a surface of the advancing plug wrap 406 along a longitudinal edge. The sheet of plug wrap 406 continues to advance towards a cylindrical shaping rod (mandrel) 408 of diameter 5.0 mm. The sheet of plug wrap 406 is helically wound around the shaping rod 408, such that the sheet of plug wrap 406 partially overlaps with itself on successive helical turns and the overlapping portions of the sheet of plug wrap 406 are secured to each other by the adhesive, thereby forming a longitudinally extending hollow tube 409 with an internal diameter of about 5.0 mm. The hollow tube 409 is advanced towards a gathering chamber 410 and drawn into the gathering chamber 410 through an inlet. A sheet of airlaid nonwoven filler material 411 of width 60 mm is drawn from a roll 412. At a cutting station 413, the sheet of airlaid non-woven filler material 411 is cut longitudinally to form four sheets 415 of longitudinally extending filler material of width 15 mm. The four sheets of filler material 415 are stacked on top of each other and advanced in a longitudinal direction L towards the gathering chamber 410. The stack of four sheets of filler material 415 is drawn into the gathering chamber 410 through an inlet and wrapped once around the hollow tube 409, at a 90-degree angle to the longitudinal axis of the hollow tube, such that each sheet of filler material circumscribes the hollow tube 409 once and forms multiple layers of filler material engaged concentrically around the hollow tube 409. The hollow tube (and the layer of filler material engaged around the hollow tube) 416 exit the gathering chamber 410 through an outlet. The gathering chamber 410 is a tapered chamber wherein the diameter of the inlet is larger than the diameter of the outlet. The tapered chamber assists with condensing the filler material around the hollow tube. At a garniture unit 419, a plug wrap 418 of basis weight 100 g/m² is drawn from a roll 417 and wrapped around the layer comprising filler material (and the hollow tube) 416 and secured using adhesive to form a continuous rod 420. The continuous rod 420 is cut at a cutting station 421 to form the individual element 400.

Any of the elements illustrated in figures 1 to 3 and 5 may form part of a multi-segment product which is included in an aerosol generating article such as a heated tobacco product or an electronic cigarette or in a smoking article such as a cigarette. The elements according to figures 1 to 3 and 5 may be assembled into a multi-segment product, an aerosol generating article or a smoking article according to methods known in the art.

The aerosol generating article such as a heated tobacco product includes a rod of tobacco material, a heating element, a power source, one or more further filter segments and any element illustrated in figures 1 to 3 and 5 above. The element may be positioned at the mouth end of the aerosol generating article (i.e. , functioning as a mouth piece) and the one or more further filter segments may be positioned downstream from the heating element and tobacco rod.

During use, the heating element of the heated tobacco product heats the rod of tobacco to form aerosol. The aerosol then passes through one or more elements, which may have the function of cooling the aerosol or filtering the aerosol, before it passes through any of the elements illustrated in figures 1 to 3 and 5 above and into the user’s mouth. The aerosol may also be filtered by the element, so the levels of certain compounds in the aerosol are reduced. The aerosol may also be cooled by the element i.e., the temperature of the aerosol is reduced as it passes along the length of the element.

Claims

1 . An element for an aerosol generating article or a smoking article comprising a longitudinally extending hollow tube; a layer comprising filler material, wherein the layer is engaged around the hollow tube; and a wrapper engaged around the layer; wherein the hollow tube comprises a helically wound sheet of material and wherein the helically wound sheet of material has partially overlapping helical turns.

2. An element for an aerosol generating article or a smoking article according to claim

1 wherein the layer comprises a sheet of filler material wrapped around the hollow tube.

3. An element for an aerosol generating article or a smoking article according to claim

2 wherein the sheet of filler material is wrapped at a 90-degree angle to the longitudinal axis of the hollow tube.

4. An element for an aerosol generating article or a smoking article according to claim

3 wherein the sheet of filler material is wrapped once around the hollow tube.

5. An element for an aerosol generating article or a smoking article according to claim 1 wherein the layer comprises a sheet of filler material helically wound around the hollow tube.

6. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the layer comprises from 1 -10 sheets of filler material.

7. An element for an aerosol generating article or a smoking article according to any one of claims 2 to 6 wherein the sheet of filler material is of basis weight from 16 to 200 grams per square meter (g/m²).

8. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the layer comprising filler material is of average thickness from 0.2 to 3.0 mm.

9. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the filler material is a filtering material.

10. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the filler material is a paper or a non-woven material.

11. An element for an aerosol generating article or a smoking article according to claim 10 wherein the paper or non-woven material comprises plant based fibres.

12. An element for an aerosol generating article or a smoking article according to claim 10 or 11 wherein the paper or non-woven material is an airlaid material, a filter paper or a cellulose/lyocell/viscose based paper.

13. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the filler material is embossed.

14. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the average wall thickness of the hollow tube is from 0.2 to 3.0 mm.

15. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the internal diameter of the hollow tube is from 1 .5 to 10 mm.

16. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the sheet of material of the hollow tube is paper.

17. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the sheet of material of the hollow tube has a thickness from 0.02 to 1 .5 mm.

18. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the sheet of material of the hollow tube has a basis weight from 24 to 200 grams per square meter (g/m²).

19. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the sheet of material of the hollow tube is a plug wrap.

20. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the sheet of material of the hollow tube comprises a layer of adhesive disposed on a surface of the sheet of material.

21 . An element for an aerosol generating article or a smoking article according to any preceding claim wherein the wrapper is a plug wrap of basis weight from 24 to 200 grams per square meter (g/m²).

22. An element for an aerosol generating article or a smoking article according to any preceding claim wherein the length of the element is from 5 to 150 mm.

23. An element for an aerosol generating article or smoking article according to any preceding claim wherein the circumference of the element is from 14 to 30 mm.

24. An multi-segment product for an aerosol generating article or a smoking article comprising an element according to any preceding claim and one or more discrete further segments.

25. An aerosol generating article or a smoking article comprising an element according to any preceding claim, or comprising a multi-segment product according to claim 24.

26. A method of making an element for an aerosol generating article or a smoking article comprising the steps of: advancing a sheet of material in a longitudinal direction; helically winding the sheet of material around a shaping rod, such that the sheet of material partially overlaps with itself on successive helical turns, thereby forming a longitudinally extending hollow tube; advancing filler material in a longitudinal direction; gathering the filler material around the hollow tube to form a layer comprising filler material engaged around the hollow tube; gathering and securing a wrapper around the layer comprising filler material to form a continuous rod; and cutting the continuously rod to form individual elements.

27. The method according to claim 26 comprising a step of applying adhesive to the advancing sheet of material.

28. The method according to claim 27 wherein the overlapping portions of the sheet of material are secured to each other by adhesive.

29. The method according to any claim of claims 26 to 28 wherein the filler material is a sheet of filler material.

30. The method according to claim 26 comprising a step of cutting the sheet of filler material longitudinally to thereby form two or more sheets of longitudinally extending filler material.

31 . The method according to claims 29 or 30 wherein the sheet of filler material is wrapped around the hollow tube.

32. The method according to claim 31 wherein the sheet of filler material is wrapped at a 90-degree angle to the longitudinal axis of the hollow tube.

33. The method according to any one of claims 26 to 30 wherein the sheet of filler material is helically wound around the outer surface of the hollow tube.

34. The method according to claim 33 wherein the helically wound sheet of filler material partially overlaps with itself on successive helical turns.

35. The method according to claim 34 wherein the helically wound sheet of filler material has abutting non-overlapping helical turns.