阅读说明：本技术 具有高气溶胶形成剂含量的气溶胶生成制品 (Aerosol-generating article with high aerosol former content ) 是由 F·拉万奇 M·加里奥尔特 C·沙勒 C·莱萨弗劳尔 于 2019-12-04 设计创作，主要内容包括：本发明涉及一种包括含有气溶胶形成基质的基质部分的气溶胶生成制品。基质部分具有在20毫米至60毫米之间的长度以及在4毫米至7毫米之间的直径。气溶胶形成基质包括气溶胶形成剂。气溶胶形成剂的量基于气溶胶形成基质的干重在6重量％至20重量％之间的范围。气溶胶生成制品包括连接部分,所述连接部分设在气溶胶生成制品的一端处、与基质部分直接邻接。连接部分具有管状空芯结构。(The present invention relates to an aerosol-generating article comprising a substrate portion comprising an aerosol-forming substrate. The matrix portion has a length of between 20 mm and 60 mm and a diameter of between 4 mm and 7 mm. The aerosol-forming substrate comprises an aerosol former. The amount of aerosol-former ranges between 6 wt% and 20 wt% based on the dry weight of the aerosol-forming substrate. The aerosol-generating article comprises a connecting portion provided at one end of the aerosol-generating article, directly adjacent to the substrate portion. The connecting portion has a tubular hollow structure.)

1. An aerosol-generating article comprising a substrate portion comprising an aerosol-forming substrate, wherein the substrate portion has a length of between 20 mm and 60 mm and a diameter of between 4 mm and 7 mm, wherein the aerosol-forming substrate comprises an aerosol former, wherein the amount of aerosol former ranges between 6 wt.% and 20 wt.%, based on the dry weight of the aerosol-forming substrate, wherein the aerosol-generating article comprises a connecting portion provided at one end of the aerosol-generating article, directly adjacent to the substrate portion, and wherein the connecting portion has a tubular hollow core structure.

2. An aerosol-generating article comprising a substrate portion comprising an aerosol-forming substrate, wherein the substrate portion has a length of between 20 mm and 60 mm and a diameter of between 4 mm and 7 mm, wherein the aerosol-forming substrate comprises an aerosol former, wherein the amount of aerosol former ranges between 6 wt.% and 20 wt.% based on the dry weight of the aerosol-forming substrate, and wherein the aerosol-generating article comprises a connecting portion having an outer diameter of between 5mm and 6mm, an inner diameter of between 3.5 and 4.5mm, and a length of between 10 and 25 mm.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the amount of aerosol-former ranges between 8 wt% and 15 wt% based on the dry weight of the aerosol-forming substrate.

4. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article has a length of between 30 mm and 60 mm, preferably between 40 mm and 50 mm, more preferably 45 mm.

5. An aerosol-generating article according to any preceding claim, wherein the substrate portion has a diameter of between 5mm and 6mm, preferably between about 5.2 mm and about 5.4 mm.

6. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article further comprises a connecting portion, preferably a hollow acetate tube, downstream of the substrate portion, wherein the connecting portion preferably has a length of between 10 mm and 25 mm.

7. An aerosol-generating article according to claim 6, wherein the aerosol-generating article further comprises a tipping paper arranged to be wrapped at least partially around the connective portion and the substrate portion to overlap therewith, and wherein the tipping paper has a length of from 15 mm to 30 mm.

8. An aerosol-generating article according to claim 6 or claim 7, wherein the connecting portion is provided as a hollow acetate tube having an inner diameter of between 3 mm and 5mm, preferably between 3.5 mm and 4.5mm, more preferably 4 mm.

9. An aerosol-generating article according to any one of claims 6 to 8, wherein the connecting portion is provided as a hollow acetate tube having a wall thickness of between 0.4 mm and 0.8 mm, preferably between 0.5 mm and 0.7 mm, more preferably 0.6 mm.

10. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate is a cut filler comprising strips of plant material, preferably at least 25% by weight of plant leaf.

11. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substrate has a weight of between 80 mg and 400 mg, preferably between 200 mg and 300 mg, more preferably between 245 mg and 270 mg.

12. An aerosol-generating article according to any preceding claim, wherein the aerosol-former consists of glycerol or propylene glycol or any mixture thereof.

13. An aerosol-generating article according to any preceding claim, wherein a dense region of aerosol-forming substrate is provided at one or more of the upstream and downstream ends of the substrate portion.

14. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article consists of a substrate portion according to one of claims 5 to 8 and a connecting portion, and wherein the substrate portion is directly attached to the connecting portion.

15. An aerosol-generating system, the aerosol-generating system comprising:

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

-an aerosol-generating device, wherein the aerosol-generating device comprises

A heating chamber, and

-an external heating member arranged outside the heating chamber, or an internal heating member arranged inside the heating chamber, or both an external heating member and an internal heating member,

-a control unit controlling a temperature profile of the heating member to heat an aerosol-forming substrate of the aerosol-generating article in the heating chamber to a temperature between 150 ℃ and 200 ℃, and

-a power source for powering the heating member.

16. A method for manufacturing an aerosol-generating article, wherein the method comprises the steps of:

i. an aerosol-forming substrate is provided,

applying an aerosol-forming agent to the aerosol-forming substrate, wherein the amount of aerosol-forming agent ranges between 6 wt% and 20 wt% based on the dry weight of the aerosol-forming substrate, and

forming the aerosol-forming substrate into a substrate portion, wherein the substrate portion has a length of between 20 mm and 45 mm and a diameter of between 4 mm and 8 mm.

Technical Field

The present invention relates to an aerosol-generating article and a method for manufacturing an aerosol-generating article.

Background

It is known to provide aerosol-generating devices for generating an inhalable aerosol. Such devices may heat the aerosol-forming substrate contained in the aerosol-generating article without combusting the aerosol-forming substrate. The aerosol-generating article may have an elongate shape for insertion of the aerosol-generating article into a heating chamber of an aerosol-generating device. The heating element may be arranged inside the heating chamber, for example a needle or a sheet, or around the heating chamber, for heating the aerosol-forming substrate when the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device.

While such devices release relevant amounts of material to allow the temperature required to form an acceptable aerosol to be significantly below combustion, not all substrates are suitable for releasing sufficient amounts of material to form a sufficient aerosol at a predetermined temperature below the combustion temperature of the aerosol-forming substrate. Thus, complex but aerosol-forming substrates have been developed to allow release of materials at low temperatures. Today this is achieved by converting tobacco leaves into artificial reconstituted tobacco sheets, for example using paper making or casting processes.

Disclosure of Invention

It is desirable to provide aerosol-generating articles that have a simple construction and allow aerosol generation at low temperatures. In addition, it is desirable to provide so-called "non-burning on heating" articles that have a more natural appearance and taste.

According to a first aspect of the present invention, there is provided an aerosol-generating article comprising a substrate portion comprising an aerosol-forming substrate. The matrix portion has a length of between 20 mm and 60 mm and a diameter of between 4 mm and 7 mm. The aerosol-forming substrate comprises an aerosol former. The amount of aerosol-former may range between 6 wt% and 20 wt% based on the dry weight of the aerosol-forming substrate. The aerosol-generating article may comprise a connecting portion provided at one end of the aerosol-generating article, directly adjacent to the substrate portion. The connecting portion may have a tubular hollow core structure.

According to one aspect of the present invention, there is provided an aerosol-generating article comprising a substrate portion comprising an aerosol-forming substrate. The matrix portion has a length of between 20 mm and 60 mm and a diameter of between 4 mm and 7 mm. The aerosol-forming substrate comprises an aerosol former. The amount of aerosol-former ranges between 6 wt% and 20 wt% based on the dry weight of the aerosol-forming substrate. The aerosol-generating article comprises a connecting portion having an outer diameter of between 5mm and 6mm, an inner diameter of between 3.5 and 4.5mm and a length of between 10 and 25 mm.

Preferably, the matrix portion has a diameter in the range between 5mm and 6mm, more preferably the matrix portion has a diameter between 5.2 mm and 5.5 mm, most preferably the matrix portion has a diameter of about 5.3 mm. The smaller the diameter of the substrate, the lower the temperature required to raise the core temperature of the aerosol-generating article such that a sufficient amount of material is released to form the desired amount of aerosol. At the same time, the small diameter allows rapid penetration of heat into the entire volume of the aerosol-forming substrate. However, where the diameter is too small, the volume to surface ratio of the aerosol-forming substrate becomes less attractive as the amount of available aerosol-forming substrate decreases. According to the invention, a preferred diameter range between 5mm and 6mm is particularly advantageous in terms of the balance between energy consumption and aerosol delivery.

It is particularly advantageous to use an aerosol-generating article having a reduced diameter in combination with an external heating system arranged around the periphery of the aerosol-generating article. When used with such external heating systems, less thermal energy is required to achieve a sufficiently high temperature in the centre of the aerosol-generating article. Thus, when operating at a lower temperature, a desired target temperature in the centre of the aerosol-generating article can be achieved within a desired time frame and energy consumption.

Preferably, the aerosol-forming substrate comprises a cut filler. In this document, "cut filler" is used to refer to chopped plant material, in particular to a mixture of leaves, processed stems and veins, homogenized plant material, for example made into sheets by a casting or paper making process. The cut filler may also include other post-cut filler tobacco or sleeves. According to a preferred embodiment of the invention, the cut filler comprises at least 25% of plant leaves, more preferably at least 50% of plant leaves, still more preferably at least 75% of plant leaves and most preferably at least 90% of plant leaves. Preferably, the plant material is one of tobacco, mint, tea and clove, however the invention is equally applicable to other plant materials that have the ability to release a substance that can subsequently form an aerosol upon application of heat.

Preferably, the tobacco plant material comprises a lamina of one or more of flue-cured tobacco, sun-cured tobacco, aromatic tobacco and filler tobacco. Flue-cured tobacco is tobacco with generally large, light-colored leaves. Throughout this specification, the term "flue-cured tobacco" is used for tobacco that has been smoked. Examples of flue-cured tobacco are chinese, brazilian, usa, such as virginia, indian, tamsannia or other african flue-cured tobacco. The flue-cured tobacco is characterized by high sugar-nitrogen ratio. From a sensory point of view, flue-cured tobacco is a type of tobacco that is accompanied by a pungent and refreshing sensation after curing. According to the invention, flue-cured tobacco is tobacco having a reducing sugar content of between about 2.5% and about 20% by dry weight of tobacco leaves and a total ammonia content of less than about 0.12% by dry weight of tobacco leaves. Reducing sugars include, for example, glucose or fructose. Total ammonia includes, for example, ammonia and ammonia salts. Sun-cured tobacco is tobacco with generally large dark leaves. Throughout this specification, the term "sun-cured tobacco" is used for tobacco that has been air cured. In addition, sun-cured tobacco can be fermented. Tobacco used primarily for chewing, snuff, cigar, and pipe blends is also included in this category. Typically, these sun-cured tobaccos are air-cured and may be fermented. From a sensory point of view, sun-cured tobacco is a type of tobacco that is accompanied by a dark cigar-type sensation of smoky flavor after baking. Sun-cured tobacco is characterized by a low sugar nitrogen ratio. Examples of sun-cured tobacco are malavist or other african burley, dark-baked Brazil papao, sun-cured or air-cured Indonesian spider orchid (Indonesian Kasturi). According to the invention, sun-cured tobacco is tobacco having a reducing sugar content of less than about 5% by dry weight of tobacco leaves and a total ammonia content of at most about 0.5% by dry weight of tobacco leaves. Oriental tobaccos are tobaccos that often have small, light-colored leaves. Throughout this specification, the term "flavourant tobacco" is used for other tobaccos having a high content of aromatic substances (e.g. of essential oils). From an organoleptic point of view, aromatic tobacco is a type of tobacco that is accompanied by a sensation of pungency and aroma after curing. Examples of oriental tobaccos are greece oriental, oriental turkey, semioriental tobaccos, and cured burley, such as perlix (pereque), yellow tobacco (Rustica), american burley, or moriland (Meriland). Filler tobacco is not a specific tobacco type, but it comprises tobacco types that are primarily used to supplement other tobacco types used in the blend and do not impart a specific characteristic aroma to the final product. Examples of filler tobacco are stems, midribs or stalks of other tobacco types. A specific example may be a smoked stem of the lower stem of smoked Brazil (fluid Cure Brazil).

Cut filler suitable for use with the present invention may be substantially similar to cut filler used in conventional smoking articles. The cut width of the cut filler is preferably between 0.3 mm and 2.0 mm, more preferably, the cut width of the cut filler is between 0.5 mm and 1.2 mm, and most preferably, the cut width of the cut filler is between 0.6 mm and 0.9 mm. The cut width may play a role in the thermal distribution within the matrix portion of the article. In addition, the cut width may play a role in the resistance to draw of the article. In addition, the cut width may affect the overall density of the matrix portion.

The strand length of cut filler is somewhat random in value, as the length of a strand will depend on the overall size of the object from which the strand is cut. However, by conditioning the material prior to cutting, for example by controlling the moisture content and overall fineness of the material, longer strands can be cut. Preferably, the bundle has a length of between about 10 mm to about 40 mm before forming the bundle into the matrix section. Obviously, if the bundles are arranged in a matrix section in the longitudinal extension, wherein the longitudinal extension of the section is below 40 mm, the final matrix section may comprise bundles which on average are shorter than the initial bundle length. Preferably, the length of the bundles of cut filler is such that between about 20% and 60% of the bundles extend along the entire length of the matrix portion. This prevents the beam from easily escaping from the matrix section.

In a preferred embodiment, the weight of the aerosol-forming substrate is between 80 mg and 400 mg, preferably between 150 mg and 250 mg, more preferably between 170 mg and 220 mg. This amount of aerosol formation generally allows sufficient material for forming the aerosol. In addition, in view of the above limitations on diameter and size, this allows for a balanced density of aerosol-forming substrate between energy absorption, resistance to draw and fluid passage within the substrate section (where the substrate comprises plant material).

According to the invention, the aerosol-forming substrate is impregnated with the aerosol-forming agent. Soaking the aerosol-forming substrate may be done by spraying or by other suitable application methods. The aerosol former may be applied to the mixture during preparation of the cut filler. For example, the aerosol former may be applied to the mixture in a direct conditioning sleeve (DCCC). Conventional machinery may be used to apply the aerosol former to the cut filler. The aerosol former may be any suitable known compound or mixture of compounds which in use promotes the formation of a dense and stable aerosol. The aerosol-former may facilitate substantial thermal degradation resistance of the aerosol at temperatures applied during normal use of the aerosol-generating article. Suitable aerosol-formers are, for example: polyhydric alcohols such as, for example, triethylene glycol, 1, 3-butanediol, propylene glycol, and glycerin; esters of polyhydric alcohols, such as, for example, glycerol monoacetate, glycerol diacetate, or glycerol triacetate; aliphatic esters of mono-, di-or polycarboxylic acids, such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

Preferably, the aerosol former comprises one or more of glycerol and propylene glycol. The aerosol former may consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

Preferably, the amount of aerosol-former is between 6 and 20 wt% based on the dry weight of the aerosol-forming substrate, more preferably the amount of aerosol-former is between 8 and 18 wt% based on the dry weight of the aerosol-forming substrate, most preferably the amount of aerosol-former is between 10 and 15 wt% based on the dry weight of the aerosol-forming substrate. For some embodiments, the target value for the amount of aerosol-forming agent is about 13% wt% based on the dry weight of the aerosol-forming substrate. The most effective amount of aerosol-former will also depend on the aerosol-forming substrate, whether the aerosol-forming substrate comprises a thin layer of plant material or homogenised plant material. For example, the type of substrate will determine, amongst other factors, to what extent the aerosol-forming agent can facilitate release of a substance from the aerosol-forming substrate.

For these reasons, the aerosol-forming substrate of the invention is capable of efficiently producing a sufficient amount of aerosol at relatively low temperatures. Temperatures in the heating chamber between 150 degrees celsius and 200 degrees celsius are sufficient for the aerosol-forming substrate of the invention to generate a sufficient amount of aerosol, whereas in aerosol-generating devices using cast tobacco blades temperatures of around 250 degrees celsius are typically employed.

Another advantage of the present invention associated with operating at lower temperatures is that the requirement for not cooling the aerosol is reduced. A simpler cooling function may be sufficient when using substantially lower temperatures. This in turn allows for a simpler and less complex structure of the aerosol-generating article to be used.

Thus, advantageously, the aerosol-generating article of the present invention comprises only the substrate portion in which the aerosol-forming substrate is provided, without any additional segments or sections. Such an embodiment would have a particularly simple structure.

The aerosol-generating article may further comprise a connecting portion provided at one end of the aerosol-generating article, directly adjacent to the substrate portion. Preferably, the linking moiety may be located downstream of the matrix moiety.

As used herein, the terms "upstream" and "downstream" are used to describe the relative position of a component or part of a component of an aerosol-generating article according to the invention with respect to the direction of air drawn through the aerosol-generating article during use of the aerosol-generating article.

The connecting portion may have a tubular hollow core structure. The connecting portion may be, for example, a Hollow Acetate Tube (HAT), a Fine Hollow Acetate Tube (FHAT), or a plug wrapped around a central paperboard tube, all of which are known from the manufacture of filter elements.

The connecting portion may be provided as a hollow acetate tube having an inner diameter of between 3 mm and 5mm, preferably between 3.5 mm and 4.5mm, more preferably about 4 mm.

The connecting portion may be provided as a fine hollow acetate tube with a wall thickness of between 0.4 mm and 0.9 mm, preferably between 0.5 mm and 0.7 mm, more preferably 0.6 mm.

Preferably, the length of the connecting portion is between 5mm and 30 mm, preferably the length of the connecting portion is between 10 mm and 25 mm.

If the aerosol-generating article is used in combination with a reusable mouthpiece, the connecting portion may advantageously be used in order to provide a secure and airtight connection with such a mouthpiece. The length of the connecting portion can be easily varied so that the overall length of the aerosol-generating article can be easily adapted to the needs of the aerosol-generating system in which the aerosol-generating article is used.

The aerosol-generating article may have an overall length of between 20 to 60 millimetres, preferably between 40 to 50 millimetres and more preferably about 45 millimetres.

The aerosol-generating article may further comprise a tipping paper arranged to be at least partially wrapped around the connecting portion and the substrate portion to overlap the connecting portion and the substrate portion. The tipping paper may have a length of 10 mm to 30 mm. The tipping paper may be used to attach components of the aerosol-generating article to one another.

Preferably, the aerosol-generating article comprises only two sections, namely a substrate portion and a connecting portion. Such an embodiment would still have a very simple structure and could therefore be produced at a significantly reduced cost.

If desired or required, for example to achieve a sufficiently high resistance to draw of the aerosol-generating article, additional filtering sections may be included in the aerosol-generating article. Preferably, such additional filtration sections may be included between the substrate portion and the connecting portion. Preferably, such additional filter sections comprise a filter material, such as cellulose acetate. Preferably, such additional filter sections comprise a filter material, such as cellulose acetate. Preferably, the length of the additional filter section is between about 4 mm and about 8 mm, between about 5mm and about 7 mm. Preferably, the combined length of the additional filter section and the connecting portion is between about 10 mm and about 18 mm, preferably 13 mm.

The aerosol-generating article may further comprise means for preventing accidental or intentional burning of the aerosol-forming substrate. Such devices may comprise a package of non-flammable material, such as a metal foil or a co-laminated paper, such as an aluminium co-laminated paper. The aerosol-forming substrate of the present device is not intended and is not suitable for smoking in a conventional manner by burning one end with a lighter. The use of additional non-combustible packaging can effectively increase the safety of use of the aerosol-generating article.

A dense end region of the aerosol-forming substrate may be provided at one or more of the upstream and downstream ends of the substrate portion of the aerosol-generating article. The dense end region may have a density up to 10% higher than the density of the remaining section of the matrix portion. Increasing the density of the substrate at the end of the substrate portion can help prevent tobacco from falling off the end of the substrate portion. The increased density of matrix on the downstream end of the matrix portion may further help to ensure that the matrix portion is well and securely attached to the connection portion or to any other component to which the downstream end of the matrix portion is attached. The increased density at the end of the matrix portion may be obtained by providing an increased amount of cut filler at the end of the matrix portion. In addition, the dense end may improve the release of material from the aerosol-forming substrate. In a preferred embodiment, the application of thermal energy is limited to the aerosol-forming substrate to prevent exposure of adjacent sections of the aerosol-generating article to heat. For example, excessive heat can degrade other sections of the article, such as the aforementioned components. In addition, for aerosol droplet formation, the material needs to be coagulated and the application of heat extending along the downstream end of the aerosol-forming substrate is detrimental to aerosol formation. Thus, in this case, the end portions of the aerosol-forming substrate may receive less heat than the central portion of the aerosol-forming substrate. An increase in density, i.e. the presence of material in this region, may allow the end portion of the aerosol-forming section to effectively contribute to the release of material in such a non-uniform heating arrangement.

The downstream end of the connecting portion of the aerosol-generating article may be further configured to connect to a mouthpiece. The mouthpiece may be a reusable mouthpiece and may also be provided with a connecting portion. In use, the connection portion of the aerosol-generating article is connected to the connection portion of the mouthpiece. In one embodiment, the mouthpiece may define an internal passage for allowing an inhalable aerosol to pass therethrough. The internal passageway of the mouthpiece may have an internal diameter that varies along the longitudinal length of the mouthpiece.

The inner diameter of the internal passageway of the mouthpiece may gradually increase towards the downstream end of the mouthpiece. Air channels with increased diameter may suitably act as cooling elements. The inhalable aerosol drawn through such channels expands and thus cools according to the so-called venturi effect.

In another aspect of the invention, an aerosol-generating device is provided comprising a housing, control circuitry and a power source. The housing defines a heating chamber within which the heating element is disposed. The heating chamber is configured to define a cavity for receiving an aerosol-generating article comprising an aerosol-forming substrate. The aerosol-generating article may be inserted into the heating chamber and heated by the heating element.

The heating element is configured to heat the aerosol-forming substrate to generate an aerosol. The control circuit is configured to maintain the temperature of the heating element at a target temperature during use, or alternatively, maintain the temperature of the heating element at a predetermined target temperature profile.

The heating element may be configured as an external heating element. The external heating element may take any suitable form. For example, the external heating element may take the form of one or more flexible heating foils on a dielectric substrate (e.g., polyimide). Such flexible heating foils may be shaped to conform to the perimeter of the substrate receiving cavity. Alternatively, the external heating element may take the form of one or more metal meshes, flexible printed circuit boards, Molded Interconnect Devices (MIDs), ceramic heaters, flexible carbon fiber heaters, or may be formed on a suitable shaped substrate using coating techniques (e.g., plasma vapor deposition). The external heating element may also be formed using a metal having a defined relationship between temperature and resistivity. In such an exemplary device, the metal may be formed as a trace between two layers of suitable insulating material. An external heating element formed in this manner may be used to heat and monitor the temperature of the external heating element during operation. Alternatively or additionally, an internal heating element may be provided, for example a needle or a sheet which is at least partially inserted into the aerosol-forming substrate for use.

The aerosol-generating device may further comprise a mouthpiece to be connected to the aerosol-generating article at use. The mouthpiece may be a separate part or may be part of the aerosol-generating device. For example, the mouthpiece may be hingedly connected to the housing of the aerosol-generating device.

The mouthpiece may help to centre the aerosol-generating article inside the heating chamber. By centering the aerosol-generating article in the heating chamber, a homogeneous heat transfer to the aerosol-generating article may be obtained. This may further reduce the maximum temperature required in order to obtain maximum aerosol generation efficiency, and may help improve the consistency of the user experience. In another aspect of the invention, there is provided an aerosol-generating system comprising an aerosol-generating device having a heating element, and an aerosol-generating article as described above.

The aerosol-generating system is preferably configured such that the aerosol-forming substrate of the aerosol-generating article in use is heated to a temperature of between 150 degrees celsius and 250 degrees celsius, preferably to a temperature of between 170 degrees celsius and 220 degrees celsius, and more preferably to a temperature of between 180 degrees celsius and 200 degrees celsius.

In another aspect of the invention, there is provided an aerosol-generating system comprising an aerosol-generating article as described above; an aerosol-generating device, wherein the aerosol-generating device comprises a heating chamber and an external heating member disposed outside the heating chamber, or an internal heating member disposed inside the heating chamber, or both an external heating member and an internal heating member; a control unit that controls a temperature profile of the heating member; and a power source for supplying power to the heating member. The control unit may control the temperature profile of the heating member to heat the aerosol-forming substrate of the aerosol-generating article in the heating chamber to a temperature of between 150 ℃ and 200 ℃.

The invention further relates to a method for manufacturing an aerosol-generating article, wherein the method comprises the steps of:

i. an aerosol-forming substrate is provided,

applying an aerosol-forming agent to the aerosol-forming substrate, wherein the amount of aerosol-forming agent ranges between 6 wt% and 20 wt% based on the dry weight of the aerosol-forming substrate, and

forming the aerosol-forming substrate into a substrate portion, wherein the substrate portion has a length of between 20 mm and 45 mm and a diameter of between 4 mm and 7 mm.

According to this aspect of the invention, the matrix portion according to the method preferably has a diameter in the range between 5mm and 6mm, more preferably between 5.2 mm and 5.5 mm. The matrix portion may have a diameter of about 5.3 millimeters. The smaller the diameter of the substrate, the lower the temperature required to raise the core temperature of the aerosol-generating article such that a sufficient amount of material is released to form the desired amount of aerosol.

The aerosol-forming substrate may comprise cut filler. The cut filler suitable for use with the present invention may generally correspond to cut filler used in conventional smoking articles. The cut width of the cut filler may range between 0.3 mm to 2.0 mm, between 0.5 mm to 1.2 mm, and between 0.6 mm to 0.9 mm.

The strand length of the cut filler can be freely selected as deemed appropriate. The length of the strands of cut filler may be such that 20% to 60% of the strands extend along the entire length of the substrate portion.

The weight of the aerosol-forming substrate may be between 80 mg and 400 mg, preferably between 200 mg and 300 mg, more preferably between 245 mg and 270 mg.

The method may further comprise the step of impregnating the cut filler with an aerosol former. Impregnation may be accomplished by spraying or by other suitable application methods. The aerosol former may be applied to the mixture during preparation of the cut filler. For example, the aerosol former may be applied to the mixture in a direct conditioning sleeve (DCCC). Conventional machinery may be used to apply the aerosol former to the cut filler. The aerosol-former may be any suitable known compound or mixture of compounds which, in use, facilitates the formation of a dense and stable aerosol and which is substantially resistant to thermal degradation at the temperatures applied during normal use of the aerosol-generating article. Suitable aerosol-forming agents are well known in the art and include, but are not limited to: polyhydric alcohols such as, for example, triethylene glycol, 1, 3-butanediol, propylene glycol, and glycerin; esters of polyhydric alcohols, such as, for example, glycerol monoacetate, glycerol diacetate, or glycerol triacetate; aliphatic esters of mono-, di-or polycarboxylic acids, such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

The aerosol former may comprise one or more of glycerol and propylene glycol. The aerosol former may consist of glycerol or propylene glycol or a combination of glycerol and propylene glycol.

The amount of aerosol-former may range between 6 wt% and 20 wt% based on the dry weight of the aerosol-forming substrate.

The aerosol-generating article of the present invention may comprise substantially only the substrate portion in which the aerosol-forming substrate is provided. Such an embodiment would have the simplest possible structure.

The method may further comprise the step of providing a connecting portion which may be attached at one end of the aerosol-generating article, directly adjacent to the substrate portion. The linking moiety may be located downstream of the matrix moiety.

The connecting portion may have a tubular hollow core structure. The attachment portion may be a Hollow Acetate Tube (HAT), a Fine Hollow Acetate Tube (FHAT), or a plug wrapped around a central paperboard tube, all of which are known from the manufacture of filter elements for electronic vaping devices. The connecting portion may be formed of any suitable material or combination of materials. For example, the filter portion may be formed from one or more materials selected from the group consisting of: cellulose acetate; a cardboard; paper, such as crimped heat-resistant paper or crimped parchment paper; cotton; fiber glue; glass fibers; and other polymeric materials such as Low Density Polyethylene (LDPE). In a preferred embodiment, the filter portion is formed from cellulose acetate.

The connecting portion may be provided as a hollow acetate tube having an inner diameter of between 3 mm and 5mm, preferably between 3.5 mm and 4.5mm, more preferably about 4 mm.

The connecting portion may be provided as a fine hollow acetate tube with a wall thickness of between 0.4 mm and 0.9 mm, preferably between 0.5 mm and 0.7 mm, more preferably 0.6 mm.

The length of the connecting portion may range between 5mm and 30 mm, preferably the length of the connecting portion is between 10 mm and 25 mm.

The aerosol-generating article may have an overall length of between 20 to 60 millimetres, preferably between 40 to 50 millimetres and more preferably about 45 millimetres.

The method may further comprise the step of providing a tipping paper arranged to be wrapped at least partially around the web portion and the substrate portion to overlap the web portion and the substrate portion. The tipping paper may have a length of 10 mm to 30 mm. The tipping paper may be used to attach components of the aerosol-generating article to one another.

Preferably, the aerosol-generating article comprises only two sections, namely a substrate portion and a connecting portion. Such an embodiment would still have a very simple structure and could therefore be produced at a significantly reduced cost.

The method may further comprise the step of providing a filter section to be included in the aerosol-generating article. Preferably, such additional filtration sections may be included between the substrate portion and the connecting portion.

The method may further comprise the step of providing means for preventing accidental or intentional burning of the aerosol-forming substrate. Such devices may comprise a package of non-flammable material, such as a metal foil or a co-laminated paper, such as an aluminium co-laminated paper.

The method may further comprise the steps of: a dense end region of the aerosol-forming substrate is provided at one or more of the upstream and downstream ends of the substrate portion of the aerosol-generating article. The dense end region may have a density up to 10% higher than the density of the remaining section of the matrix portion.

The downstream end of the connecting portion of the aerosol-generating article may be further configured to connect to a mouthpiece. The mouthpiece may be a reusable mouthpiece and may also be provided with a connecting portion. In use, the connection portion of the aerosol-generating article is connected to the connection portion of the mouthpiece. In one embodiment, the mouthpiece may define an internal passage for allowing an inhalable aerosol to pass therethrough. The internal passageway of the mouthpiece may have an internal diameter that varies along the longitudinal length of the mouthpiece.

The inner diameter of the internal passageway of the mouthpiece may gradually increase towards the downstream end of the mouthpiece. Air channels with increased diameter may suitably act as cooling elements. The inhalable aerosol drawn through such channels expands and thus cools according to the so-called venturi effect.

Features described in relation to one aspect may equally be applied to other aspects of the invention.

Drawings

The invention will be further described, by way of example only, with reference to the accompanying drawings, in which:

figure 1 shows a side view of an aerosol-generating article according to the invention,

figure 2 shows a cross-section through an aerosol-generating article comprising a mouthpiece, an

Figure 3 shows a cross-section through an aerosol-generating system of the invention.

Detailed Description

An aerosol-generating article 10 according to the present invention is shown in figure 1. The aerosol-generating article 10 comprises a substrate portion 12 and a connecting portion 14 in the form of a hollow acetate tube. The hollow acetate tube is directly adjacent to the substrate portion 12. The two portions are joined together by tipping paper 16 which extends over the entire connecting portion 14 and a portion of the substrate portion 12.

The matrix portion 12 has a length of 32 mm and a diameter of 5.3 mm. The connecting portion 14 has a length of 15 mm and an outer diameter of 5.3 mm. The inner diameter of the hollow acetate tube of the connecting portion 14 was 4 mm.

The tipping paper 16 has a length of 20 mm. The two-part aerosol-generating article 10 has a total length of 45 mm. To prevent the end from loosening, the aerosol-forming substrate is provided with an increased substrate density at both ends of the substrate portion 12. The dense end 20 at the upstream end of the aerosol-generating article 10 prevents the aerosol-forming substrate from falling off the upstream end portion of the substrate portion 12. The dense end 22 at the downstream end of the matrix portion 12 provides sufficient rigidity to that portion of the matrix portion 12, which helps to ensure that the matrix portion 12 is well and securely attached to the connecting portion 14.

The connecting portion 14 is configured to connect to the mouthpiece 24 when the aerosol-generating article 10 is in use, as can be seen in the cross-sectional view depicted in figure 2. Again, the aerosol-generating article 10 comprises two portions, a substrate portion 12 and a connecting portion 14, which are securely attached to each other. The mouthpiece 24 further comprises a connection portion 26 having an outer diameter corresponding to the inner diameter of the connection portion 14 of the aerosol-generating article 10. When attached together, an airtight connection is established between the mouthpiece 24 and the aerosol-generating article 10.

The mouthpiece 24 has a central channel 28 defining an airflow path for the generated aerosol. The diameter of the central passage 28 gradually increases along the airflow path. The mouthpiece 24 effectively supports cooling of the aerosol due to the venturi effect caused by this configuration.

In fig. 3, a schematic cross-section of an aerosol-generating system 30 of the present invention is depicted. The aerosol-generating system 30 comprises an aerosol-generating device 32 and an aerosol-generating article 10.

The aerosol-generating device 32 comprises a housing 34 in which a power source 36 and electronic circuitry 38 are located. The aerosol-generating device 32 further comprises a heating chamber 40 in which a heating element 42 is arranged.

As depicted in fig. 3, the heating chamber 40 defines a cavity configured to receive the aerosol-generating article 10. When inserted into the heating chamber 40, the heating element 42 defines the outer perimeter of the aerosol-generating article 10. In the embodiment of fig. 3, the heating element 42 is provided as an external heating element.