AEROSOL-GENERATING ARTICLE COMPRISING AN AEROSOL-GENERATING FILM

Abstract

An aerosol-generating article is provided, including: a tubular carrier element defining a longitudinally extending internal cavity; and a layer of an aerosol-generating film applied to a portion of an inner surface of the tubular carrier element, such that an outer surface of the aerosol-generating film is exposed to the internal cavity of the tubular carrier element, the aerosol-generating film including at least 25 percent by weight of a polyhydric alcohol, and a thickness of the layer of the aerosol-generating film being between 0.05 millimeter and 1.0 millimeter. An aerosol-generating substrate for an aerosol-generating article, a method of making an aerosol-generating article, and an aerosol-generating system are also provided.

Claims

1.-15. (canceled)

16. An aerosol-generating article, comprising: a tubular carrier element defining a longitudinally extending internal cavity; and a layer of an aerosol-generating film applied to a portion of an inner surface of the tubular carrier element, such that an outer surface of the aerosol-generating film is exposed to the internal cavity of the tubular carrier element, wherein the aerosol-generating film comprises at least 25 percent by weight of a polyhydric alcohol, and wherein a thickness of the layer of the aerosol-generating film is between 0.05 millimeter and 1.0 millimeter.

17. The aerosol-generating article according to claim 16, wherein the aerosol-generating film further comprises at least 10 percent by weight of a cellulose based film-forming agent.

18. The aerosol-generating article according to claim 16, wherein the aerosol-generating film extends longitudinally from an upstream end of the tubular carrier element for less than about 50 percent of a length of the tubular carrier element.

19. The aerosol-generating article according to claim 16, wherein a surface area of the outer surface of the aerosol-generating film exposed to the internal cavity is at least about 1 square centimeter.

20. The aerosol-generating article according to claim 16, wherein the aerosol-generating film is crimped.

21. The aerosol-generating article according to claim 16, further comprising a flow restriction element within the internal cavity of the tubular carrier element and downstream of the aerosol-generating film.

22. The aerosol-generating article according to claim 21, wherein the flow restriction element is configured to provide the aerosol-generating article with an RTD of at least about 80 mm WG.

23. The aerosol-generating article according to claim 21, wherein a longitudinal spacing between the flow restriction element and a downstream end of the aerosol-generating film is at least about 10 percent of a length of the tubular carrier element.

24. The aerosol-generating article according to claim 16, wherein the tubular carrier element further comprises a coating layer comprising aluminum, the coating layer extending over at least a portion of the inner surface of the tubular carrier element, and wherein the layer of the aerosol-generating film is provided over the coating layer.

25. The aerosol-generating article according to claim 16, wherein at least one end of the tubular carrier element is sealed by a sealing element.

26. The aerosol-generating article according to claim 25, further comprising a frangible sealing element at the upstream end of the tubular carrier element, the frangible sealing element being configured to obstruct airflow into and out of the cavity.

27. An aerosol-generating substrate for an aerosol-generating article, the aerosol-generating substrate comprising: a tubular carrier element defining a longitudinally extending internal cavity; and a layer of an aerosol-generating film applied to a portion of an inner surface of the tubular carrier element, such that an outer surface of the aerosol-generating film is exposed to the internal cavity of the tubular carrier element, wherein the aerosol-generating film comprises at least 25 percent by weight glycerin, and wherein a thickness of the layer of the aerosol-generating film is between 0.05 millimeter and 1.0 millimeter.

28. A method of making an aerosol-generating article, the method comprising the steps of: providing an aqueous film-forming composition comprising glycerin; providing a sheet material; applying the aqueous film-forming composition onto a surface of the sheet material to form a film layer; drying the film layer to form a layer of an aerosol-generating film comprising at least 25 percent by weight glycerin, wherein a thickness of the layer of the aerosol-generating film is between 0.05 millimeter and 1.0 millimeter; and rolling the sheet material to form a tubular carrier element defining a longitudinally extending internal cavity and having the layer of the aerosol-generating film applied to a portion of the inner surface of the tubular carrier element.

29. An aerosol-generating system, comprising: an aerosol-generating article, comprising: a tubular carrier element defining a longitudinally extending internal cavity, and a layer of an aerosol-generating film applied to a portion of an inner surface of the tubular carrier element, such that an outer surface of the aerosol-generating film is exposed to the internal cavity of the tubular carrier element, the aerosol-generating film comprising at least 25 percent by weight glycerin and a thickness of the layer of the aerosol-generating film being between 0.05 millimeter and 1.0 millimeter; and an electrically operated aerosol-generating device comprising a heater and an elongate heating chamber configured to receive the aerosol-generating article so that the aerosol-generating article is heated in the heating chamber.

30. An aerosol-generating system, comprising: an aerosol aerosol-generating article, comprising: an aerosol-generating substrate comprising a tubular carrier element defining a longitudinally extending internal cavity, and a layer of an aerosol-generating film applied to a portion of an inner surface of the tubular carrier element, such that an outer surface of the aerosol-generating film is exposed to the internal cavity of the tubular carrier element, the aerosol-generating film comprising at least 25 percent by weight polyhydric alcohol and a thickness of the layer of the aerosol-generating film being between 0.05 millimeter and 1.0 millimeter; and an electrically operated aerosol-generating device comprising a heater element configured to heat the aerosol-generating substrate of the aerosol-generating article, the heater element being a heater blade or a heater pin configured to be inserted into the cavity such that the heater blade or the heater pin faces the outer surface of the aerosol-generating film.

Description

[0133] The invention will now be further described with reference to the figures in which:

[0134] FIG. 1 shows a schematic longitudinal cross-sectional view of an aerosol-generating article according to a first embodiment of the invention;

[0135] FIG. 2 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of FIG. 1 in combination with an internal heater element of an aerosol-generating device;

[0136] FIG. 3 shows a schematic longitudinal cross-sectional view of the aerosol-generating article of FIG. 1 in combination with an external heater element of an aerosol-generating device; and

[0137] FIG. 4 shows a schematic longitudinal cross-sectional view of an aerosol-generating article according to a second embodiment of the invention in combination with an internal heater element of an aerosol-generating device.

[0138] The aerosol-generating article 10 shown in FIG. 1 comprises a tubular carrier element 12, an aerosol-generating film 14 and a flow restriction element 16.

[0139] The tubular carrier element 12 is in the form of a paper tube having a length of approximately 12 millimetres and an external diameter of approximately 7 millimetres. The tubular carrier element 12 is cylindrical in shape and defines a longitudinally extending internal cavity 18 extending from an upstream end 20 of the tubular carrier element 12 to a downstream end 22.

[0140] The aerosol-generating film 14 is provided as a single layer over the inner surface of the tubular carrier element 12. The aerosol-generating film 14 has a thickness of approximately 0.25 millimetres and extends from the upstream end 20 of the tubular carrier element 12 downstream along the internal cavity 18 to a distance of approximately 10 millimetres from the upstream end 20. The aerosol-generating film 14 therefore covers an area of approximately 2 square centimetres on the inner surface of the tubular carrier element 12.

[0141] The aerosol-generating film 14 has the following composition:

TABLE-US-00001 Aerosol-generating film composition (w/w) 19.3% HPMC 4.8% Agar 1.4% Nicotine 48% Glycerin 2.1% Levulinic Acid 24.4% Water

[0142] The flow restriction element 16 comprises a single segment of cellulose acetate tow which is provided within the internal cavity 18 of the tubular carrier element 12, at the downstream end 22. The flow restriction element 16 has a length of approximately 20 millimetres and an external diameter corresponding to the diameter of the internal cavity 18 of the tubular carrier element 12. The flow restriction element 16 is downstream of the aerosol-generating film 14 and spaced apart from the aerosol-generating film 14 such that an empty space is defined inside the tubular carrier element 12, between the downstream end of the aerosol-generating film 14 and the upstream end of the flow restriction element 16.

[0143] The upstream end 20 of the tubular carrier element 12 is sealed by means of upstream sealing element 24 which comprises a sheet of aluminium provided over the end of the tubular carrier element 12 to seal the upstream end of the internal cavity 18.

[0144] The downstream end 22 of the tubular carrier element 12 is sealed by means of downstream sealing element 26 which comprises a sheet of paper provided over the downstream end of the flow restriction element 16 at the downstream end of the tubular carrier element 12.

[0145] The aerosol-generating article 10 shown in FIG. 1 is suitable for use with an electrically operated aerosol-generating device comprising a heater for heating the aerosol-generating film 14.

[0146] FIG. 2 shows a schematic view of the aerosol-generating article 10 being heated in an aerosol-generating device 50 having a heater blade 52. The aerosol-generating article 10 is inserted into the aerosol-generating device 50 such that the heater blade 52 pierces through the upstream sealing element 24 and is inserted into the internal cavity 18 of the tubular carrier element 12. The heater blade 52 faces the outer surface of the aerosol-generating film 14 within the tubular carrier element 12. As can be seen from FIG. 2, the aerosol-generating film 14 is provided such that it extends approximately as far along the tubular carrier element 12 as the heater blade 52.

[0147] During use, the heater blade 52 heats the aerosol-generating film 14 to a temperature sufficient to generated an aerosol from the aerosol-generating film 14. The aerosol is drawn through the flow restriction element 16 and out through the downstream end 22 of the tubular carrier element.

[0148] FIG. 3 shows a schematic view of the aerosol-generating article 10 being heated in an alternative aerosol-generating device 60 having a heating chamber 62 into which the upstream end of the aerosol-generating article is inserted such that an external heater element 64 surrounds the upstream part of the tubular carrier element 12 incorporating the aerosol-generating film 14. The heater element 64 heats the aerosol-generating film 14 circumferentially from outside the tubular carrier element 12. As can be seen from FIG. 3, the aerosol-generating film 14 extends approximately as far along the tubular carrier element 12 as the heater element 64.

[0149] The aerosol-generating device 60 further comprises a piercing element 66 which pierces the upstream sealing element 24 as the aerosol-generating article 10 is inserted into the heating chamber 62.

[0150] FIG. 4 shows an aerosol-generating article 70 according to a second embodiment of the present invention, which is similar in construction to the aerosol-generating article 10 shown in FIG. 1 but comprises a modified upstream sealing element 74. The aerosol-generating article 70 is adapted for use with an aerosol-generating device 50 having a heater blade 52, as described above with reference to FIG. 2.

[0151] The upstream sealing element 74 of the aerosol-generating article 70 comprises a aluminium membrane which has been pre-folded in a concertina arrangement. Prior to use, the aluminium membrane is pre-folded and gathered so that the membrane lies substantially flat with the folds inside the internal cavity of the tubular carrier element 12. As the aerosol-generating article 70 is inserted into the aerosol-generating device 50, the heater blade 52 pushes against the folded aluminium membrane, which unfolds and extends as the heater blade 52 is pushed inwards into the tubular carrier element 12. The aluminium membrane surrounds the heater blade 52 so that the heater blade 52 remains covered during use.