SYSTEM, APPARATUS AND METHOD OF MANUFACTURING A TUBULAR ELEMENT FOR USE WITH AN AEROSOL GENERATING ARTICLE

Abstract

A system, apparatus and method of manufacturing a tubular element (500) for use in an aerosol generating article. The tubular element (500) may comprise gel (124), or comprise a porous medium (125) loaded with gel (124), or comprise thread loaded with gel (214), or comprise a combination thereof.

Claims

1-20. (canceled)

21. A tubular element manufacturing system, for manufacturing tubular elements comprising gel; the tubular element manufacturing system comprising: a first continuous feed means configured to continuously feed a first web of wrapping material along a feed path; a nozzle configured to dispense gel directly onto the first web of wrapping material; wherein the gel comprises water; a second continuous feed means to feed a second component onto the first web of wrapping material; a wrapping means configured to wrap the first web of wrapping material around the gel and second component, to form a continuous length of tubular element.

22. The tubular element manufacturing system according to claim 21 in which the second component is a porous medium.

23. The tubular element manufacturing system according to claim 21, wherein a nozzle is configured to dispense gel onto a second component on the first web of wrapping material.

24. The tubular element manufacturing system according to claim 21 in which the second component is a second web of wrapping material and in which the second continuous feed means further comprises a wrapping means to wrap the second web of wrapping material to form a second tubular element.

25. The tubular element manufacturing system according to claim 23 in which comprises a third feed means to feed a third component.

26. The tubular element manufacturing system according to claim 25 in which the third feed means feeds the third component onto the first web of wrapping material.

27. The tubular element manufacturing system according to claim 25 in which the third feed means feeds the third component onto the second web of wrapping material.

28. The tubular element manufacturing system according to claim 25 in which the third component is a porous medium.

29. The tubular element manufacturing system according to claim 24 in which a nozzle to dispense gel is adapted to dispense gel directly on the second web of wrapping material, or dispense on a further component on the second web of wrapping material.

30. The tubular element manufacturing system according to claim 21 in which the tubular manufacturing system further comprises a cutting means configured to cut the continuous length of tubular element into a plurality of discrete tubular elements.

31. A method of manufacturing a tubular element comprising gel, the method of manufacturing comprising the steps of: feeding a first web of wrapping material on a feed means; dispensing gel onto the first web of wrapping material; wherein the gel comprises water; dispensing a porous medium onto the first web of wrapping material such that the porous medium is loaded with gel, before wrapping the first wrapping material to form a continuous length of tubular elements. wrapping the first wrapping material to wrap the gel and form a continuous length of tubular element.

32. The method of manufacture a tubular element according to claim 31, wherein the method of manufacture further comprises the step of: dispensing gel onto the porous medium on the first web of wrapping material.

33. The method of manufacturing a tubular element according to claim 31, in which the method of manufacturing further comprises the step of: feeding a second web of wrapping material on a second feed means; and, wrapping the second web of wrapping material to form a second tubular element; and, feeding the second tubular element of wrapped second web of wrapping material onto the first web of wrapping material before wrapping the first wrapping material.

34. The method of manufacturing a tubular element according to claim 33 in which the method of manufacturing further comprises the step of: dispensing gel onto the second web of wrapping material before wrapping the second web of wrapping material to form a second tubular element and feeding the wrapped second web of wrapping material onto the first web of wrapping material.

35. The method of manufacturing a tubular element according to claim 33 in which the method of manufacturing further comprises the step of: dispensing porous medium onto the second web of wrapping material before wrapping the second web of wrapping material to form a second tubular element and feeding the wrapped second web of wrapping material onto the first web of wrapping material.

36. The method of manufacturing a tubular element according to claim 31 in which the method of manufacturing further comprises the step of: dispensing a preformed second tubular element, longitudinally, onto the first web of wrapping material before wrapping the first web of wrapping material.

37. A method of manufacturing a tubular element, the method of manufacturing comprising the steps of: feeding a first web of wrapping material on a feed means; dispensing porous medium onto the first web of wrapping material; feeding a second web of wrapping material on a second feed path; and, dispensing gel onto the second web of wrapping material, wherein the gel comprises water; and wrapping the gel with the second web of wrapping material, to form a tubular shape; and, feeding the second tubular element of wrapped gel and second web of wrapping material onto the first web of wrapping material before wrapping the first wrapping material wrapping the first wrapping material to wrap, the second tubular element of wrapped gel and second web of wrapping material, and form a continuous length of tubular element.

38. The method of manufacturing a tubular element according to claim 37, wherein the method of manufacturing further comprising the step of: dispensing porous medium onto the second web of wrapping material before wrapping the second web of wrapping material to form a tubular shape.

39. A method of manufacturing a tubular element, the method of manufacturing comprising the steps of: feeding a first web of wrapping material on a feed means; dispensing a porous medium onto the first web of wrapping material; dispensing a preformed second tubular element comprising gel, longitudinally, onto the first web of wrapping material before wrapping the first web of wrapping material, wherein the gel comprises water; feeding the preformed second tubular element comprising gel onto the first web of wrapping material before wrapping the first wrapping material wrapping the first wrapping material to wrap the porous medium and preformed second tubular element to form a continuous length of tubular element.

40. The method of manufacturing according to claim 31 in which further comprises the step of: cutting the continuous length of tubular element into lengths to form a plurality of tubular elements.

Description

[0392] Reference will now be made to the drawings, which depict one or more aspects described in this disclosure. However, it will be understood that other aspects not depicted in the drawings fall within the scope of this disclosure. Like numbers used in the figures refer to like components, steps and the like. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number. In addition, the use of different numbers to refer to components in different figures is not intended to indicate that the different numbered components cannot be the same or similar to other numbered components. The figures are presented for purposes of illustration and not limitation. Schematic drawings presented in the figures are not necessarily to scale.

[0393] FIG. 1 is a schematic sectional view of an aerosol generating device and a schematic side view of an aerosol generating article that may be inserted into the aerosol generating device.

[0394] FIG. 2 is a schematic sectional view of the aerosol generating device depicted in FIG. 1 and a schematic side view of the article depicted in FIG. 1 inserted into the aerosol generating device.

[0395] FIGS. 3-6 are schematic sectional views of various embodiments of aerosol generating articles.

[0396] FIG. 7 is a schematic side view of an aerosol generating article.

[0397] FIG. 8 is a schematic perspective view of an embodiment of the aerosol generating article depicted in FIG. 7 in which a section of the wrapper is removed for illustrative purposes.

[0398] FIG. 9 is a schematic side view of an aerosol generating article.

[0399] FIG. 10 is a schematic side view of an embodiment of the aerosol generating article depicted in FIG. 9 with a portion of wrapper removed.

[0400] FIG. 11 is a schematic view of a fluid guide of a sample aerosol generating article.

[0401] FIG. 12 is a schematic view of sample aerosol generating article in which the fluid guide depicted in FIG. 11 is inserted.

[0402] FIG. 13 shows a cross-sectional view, sectioned along the length of an aerosol generating article.

[0403] FIGS. 14, 15 and 16 show a perspective view and two cross-sectional views of a tubular element for an aerosol generating article.

[0404] FIG. 17 shows part of a manufacturing process for the tubular element for an aerosol generating article.

[0405] FIG. 18 shows part of a further manufacturing process for the tubular element for an aerosol generating article.

[0406] FIG. 19 shows part of an alternative manufacturing process for the tubular element for an aerosol generating article.

[0407] FIG. 20 shows an aerosol generating system comprising an electrically heated aerosol generating device and an aerosol generating article.

[0408] FIGS. 21, 22 and 23 show cross-sectional views of further tubular elements for an aerosol generating article.

[0409] FIG. 24 shows a cross-sectional view along the length of an aerosol generating article.

[0410] FIGS. 25-29 show schematic cross-sectional views of various tubular elements.

[0411] FIG. 30-34 show schematic cross-sectional views of various tubular elements.

[0412] FIG. 35 shows a schematic drawing of a manufacturing process according to the present invention.

[0413] FIG. 36 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 35.

[0414] FIG. 37 shows a schematic drawing of a manufacturing process according to the present invention.

[0415] FIG. 38 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 37.

[0416] FIG. 39 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 37.

[0417] FIG. 40 shows a schematic drawing of a manufacturing process according to the present invention.

[0418] FIG. 41 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 40.

[0419] FIG. 42 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 40.

[0420] FIG. 43 shows a schematic drawing of a manufacturing process according to the present invention.

[0421] FIG. 44 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 43.

[0422] FIG. 45 shows a schematic drawing of a manufacturing process according to the present invention.

[0423] FIG. 46 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 45.

[0424] FIG. 47 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 45.

[0425] FIG. 48 shows a schematic drawing of a manufacturing process according to the present invention.

[0426] FIG. 49 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 48.

[0427] FIG. 50 shows a schematic drawing of a manufacturing process according to the present invention.

[0428] FIG. 51 Figure shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 50.

[0429] FIG. 52 Figure shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 50.

[0430] FIG. 53 shows a schematic drawing of a manufacturing process according to the present invention.

[0431] FIG. 54 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 53.

[0432] FIG. 55 Figure shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 53.

[0433] FIG. 56 shows a schematic drawing of a manufacturing process according to the present invention.

[0434] FIG. 57 shows an enlarged schematic view of one section of the manufacturing process shown in FIG. 56.

[0435] FIGS. 1 to 6 show a longitudinal cross-sectional cut away view of an aerosol generating articles 100. In other words the FIGS. 1 to 6 show a view of an aerosol generating article 100 cut in half longitudinally. In the FIGS. 1 to 6 embodiments the aerosol generating article is tubular. If one viewed a whole end face of the aerosol generating article 100 of FIGS. 1 to 6, either the proximal end 101 or distal end 103 it would be circular. The tubular element 500, if used or shown in the embodiments of FIGS. 1 to 6 is also tubular. The tubular element 500 is a, possible, tubular component of the tubular aerosol generating article 100 of the FIGS. 1 to 6 embodiments. If one viewed a whole end face of the tubular element 500, used in or shown in the FIGS. 1 to 6 embodiment, whether the proximal end or distal end, the face of the tubular element would be circular. As FIGS. 1 to 6 are a two dimensional longitudinal cross-sectional cut away view, the side curvature of the aerosol generating article and of the tubular element 600, among other components, cannot be seen. The drawings are for illustrative purposes to explain the invention and may not be to scale. The tubular element 500 if shown in FIGS. 1 to 6 is to illustrate the tubular element 500 in an aerosol generating article 100 but the features of the aerosol generating article 100 are optional to the embodiment shown of the tubular element 500 and should not be seen as essential features of the tubular element 500.

[0436] FIGS. 1-2 illustrate an example of an aerosol generating article 100 and aerosol generating device 200. The aerosol generating article 100 has a proximal or mouth end 101 and a distal end 103. In FIG. 2, the distal end 103 of the aerosol generating article 100 is received in a receptacle 220 of the aerosol generating device 200. The aerosol generating device 200 includes a wrapper 110 defining the receptacle 220, which is configured to receive the aerosol generating article 100. The aerosol generating device 200 also includes a heating element 230 that forms a cavity 235 configured to receive the aerosol generating article 100, preferably by interference fit. The heating element 230 may comprise an electrically resistive heating component. In addition, the device 200 includes a power supply 240 and control electronics 250 that cooperate to control heating of heating element 230.

[0437] The heating element 230 may heat the distal end 103 of the aerosol generating article 100, which contains a tubular element 500 (not shown). In this example the tubular element 500 comprises a gel 124 comprising an active agent, and the active agent comprises nicotine. Heating of the aerosol generating article 100 causes the tubular element 500 comprising a gel 124 comprising an active agent to generate an aerosol containing the active agent, which can transfer out of the aerosol generating article 100 at the proximal end 101. The aerosol generating device 200 comprises a housing 210.

[0438] FIGS. 1-2 do not show the exact heating mechanism.

[0439] In some examples the heating mechanism could be by conduction heating where the heat is transferred from the heating element 230 of the aerosol generating device 200 to the aerosol generating article 100. This can take place easily when the aerosol generating article 100 is positioned in the receptacle 220 of the aerosol generating device 200 and the distal end 103 (which is preferably the end where the tubular element 500 comprising gel is located) and thus the aerosol generating article 100 is in contact with the heating element 230 of the aerosol generating device 200. In specific examples the heating element comprises a heating blade that protrudes from the aerosol generating device 200 and is suitable for penetrating into the aerosol generating article 100 to make direct contact with the gel 124 of the tubular element 500.

[0440] In this example the heating mechanism is by induction where the heating element emits radio-magnetic radiation which is absorbed by the tubular element when the aerosol generating article 100 is position in the receptacle 220 of the aerosol generating device 200.

[0441] FIGS. 3a and 3b depicts an embodiment of an aerosol generating article 100 including a wrapper 110 and a fluid guide 400. FIGS. 3a and 3b are a longitudinal cross-sectional cut away view of an aerosol generating article 100. In other words the FIG. 3a and FIG. 3b view is of an aerosol generating article 100 cut in half longitudinally. In the FIG. 3a and FIG. 3b embodiment the aerosol generating article is tubular. If one viewed a whole end face of the aerosol generating article 100 of FIG. 3a or 3b, either the proximal end 101 or distal end 103 it would be circular. The tubular element 500 in FIG. 3a or FIG. 3b is also tubular. The tubular element 500 is a tubular component of the tubular aerosol generating article 100 of the FIG. 3a and FIG. 3b embodiments. If one viewed a whole end face of the tubular element 500 of the FIG. 3a or FIG. 3b embodiment, whether the proximal end or distal end, the face of the tubular element would be circular. As FIG. 3a and FIG. 3b are a two dimensional longitudinal cross-sectional cut away view, the side curvature of aerosol generating article and of the tubular element 600, among other components, cannot be seen. In FIG. 3a the proximal end of the tubular element 500 is not shown with a straight edge. FIG. 3b shows the proximal end of the tubular element 500 as a straight line across the width of the aerosol generating article. The drawings are for illustrative purposes to explain the invention and may not be to scale. The tubular element 500 is shown in FIG. 3a and FIG. 3b to illustrate the tubular element in an aerosol generating article but the features of the aerosol generating article 100 as optional to the embodiment shown of the tubular element and should not be seen as essential features of the tubular element 500.

[0442] The fluid guide 400 has a proximal end 401, a distal end 403 and an inner longitudinal passageway 430 from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410 and a second portion 420. The first portion 410 defines a first portion of the passageway 430, which extends from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the passageway 430, which extends from the distal end 423 of the second portion 420 to the proximal end 421 of the second portion 420. The first portion 410 of the passageway 430 has a constricted cross-sectional area moving from the distal end 413 to the proximal end 411 of the first portion 410 to cause fluid, for example air, to accelerate through this first portion 410 of the inner longitudinal passageway 430 when negative pressure is applied at the proximal end 101 of the aerosol generating article 100. The cross-sectional area of the first portion 410 of the inner longitudinal passageway 430 narrows from the distal end 413 to the proximal end 411 of the first portion 410. The second portion 420 of the inner longitudinal passageway 430 has an expanding cross-sectional area from the distal end 423 to the proximal end 421 of the second portion 420 of the fluid guide 400. In the second portion 420 of the inner longitudinal passageway 430, fluid may decelerate.

[0443] The wrapper 110 defines an open, proximal end 101 of the aerosol generating article 100 and a distal end 103. A tubular element 500 comprising gel comprising an active agent (not shown), is disposed in the distal end 103 of the aerosol generating article 100. The aerosol generating article 100 comprises an end plug 600 at its extreme distal end 103. The end plug 600 is positioned to the distal side of the tubular element 500. The end plug 600 comprises material of a high resistance to draw hence biasing fluid to enter the aerosol generating article 100 though the apertures 150 when a negative pressure is applied to the proximal end 101 of the aerosol generating article 100. Aerosol generated or released from the tubular element 500 comprising an active agent, when heated may enter the cavity 140 in the aerosol generating article downstream from the tubular element 500, to be carried through the inner longitudinal passageway 430.

[0444] Apertures 150 extend through the wrapper 110. At least one aperture 150 is in communication with an outer longitudinal passageway 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the apertures 150 and the proximal end 101.

[0445] When a negative pressure is applied to the proximal end 101 of the aerosol generating article 100, fluid enters the apertures 150, flows through the outer longitudinal passageways 440 into the cavity 140 and to the tubular element 500 comprising a gel comprising an active agent, where the fluid may entrain aerosol when the tubular element 500 comprising a gel comprising an active agent, is heated. The fluid then flows through the inner longitudinal passageway 430, and through the proximal end 101 of the aerosol generating article 100. As fluid flows through the first portion 410 of the inner longitudinal passageway 430, the fluid accelerates. As fluid flows through the second portion of the inner longitudinal passageway 430, the fluid decelerates. In the depicted embodiment, the wrapper 110 defines a proximal cavity 130 between proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which could serve to decelerate the fluid prior to exiting the mouth end 101.

[0446] FIG. 4 depicts another embodiment of an aerosol generating article 100 including a wrapper 110 and a fluid guide 400.

[0447] The fluid guide 400 has a proximal end 401, a distal end 403 and an inner longitudinal passageway 430 from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410, a second portion 420, and a third portion 435. The first portion 410 is between the second 420 and third 435 portions. The first portion 410 defines a first portion of the inner longitudinal passageway 430, which extends from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the inner longitudinal passageway 430, which extends from the distal end 423 of the second portion 420 to the proximal end 421 of the second portion 420. The third portion 435 defines a third portion of the inner longitudinal passageway 430, which extends from the distal end 433 of the third portion to the proximal end 431 of the third portion. The third portion 435 has a substantially constant inner diameter from the proximal end 431 to the distal end 433. The first portion 410 of the inner longitudinal passageway 430 has a constricted cross-sectional area moving from the distal end 413 to the proximal end 411, of the first portion 410, to cause fluid to accelerate through this first portion 410 of the inner longitudinal passageway 430 when a negative pressure is applied at the proximal end 101 of the aerosol generating article 100. The cross-sectional area of the first portion 410 of the inner longitudinal passageway 430 narrows from the distal end 413 to the proximal end 411, of the first portion 410. The second portion 420 of the inner longitudinal passageway 430 has an expanding cross-sectional area from the distal end 423 to the proximal end 421 of the second portion 420 of the inner fluid passageway 430. In the second portion 420 of the inner longitudinal passageway 430, fluid may decelerate as it travels distal to proximal in direction.

[0448] Like the article 100 depicted in FIG. 3, the article depicted in FIG. 4 includes a wrapper 110 that defines an open, proximal end 101 and a distal end 103, with an end plug 600 of a high resistance to draw. A tubular element 500 comprising a gel comprising an active agent, is disposed in the distal end 103 of the aerosol generating article. Aerosol released from the gel comprising an active agent, when heated may enter the cavity 140 in the aerosol generating article 110, to be carried through the inner longitudinal passageway 430.

[0449] While not shown in FIG. 4, the aerosol generating article 100 includes at least one aperture (such as apertures 150 shown in FIG. 3) that extends through the wrapper 110 and is in communication with an outer longitudinal passageway 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the apertures and the proximal end 101. Although the seal need not be fluid impermeable, it is advantageous that the seal here does have a high resistance to draw or some degree of impermeability, to bias the fluid entering the apertures 150 along the outer longitudinal passageways in the distal direction towards the tubular element 500. The third portion 435 of the fluid guide 400 extends the length of the fluid guide 400 and outer longitudinal passageway 440 to provide additional distance between the apertures (not shown in FIG. 4, which may be located in proximity to a proximal end 401 of the inner longitudinal passageway) and the tubular element 500 comprising a gel comprising an active agent, so that leakage of the gel comprising an active agent, through the apertures 150 is not likely.

[0450] When a negative pressure is applied at the proximal end 101 of the aerosol generating article 100 depicted in FIG. 4, fluid enters the apertures 150, flows through the outer longitudinal passageway 440 into the cavity 140 and to the tubular element 500 comprising gel comprising an active agent, where the fluid may entrain material from the gel comprising an active agent is heated. The fluid may then flow through the inner longitudinal passageway 430, and through the proximal end 101 of the aerosol generating article. As fluid flows through the inner longitudinal passageway 430, the fluid flows through the third portion 435, the first portion 410, and then the second portion 420 of the aerosol generating article 100. As fluid flows through the first portion 410 of the inner longitudinal passageway 430, the fluid accelerates. As fluid flows through the second portion 420 of the inner longitudinal passageway 430, the fluid decelerates. In alternative specific embodiments the second portion 420 and third portion 435 of the inner longitudinal passageway 430 are optional. In the depicted embodiment, the wrapper defines a proximal cavity 130 between proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which could serve to decelerate the fluid prior to exiting the proximal end 101.

[0451] FIG. 5 and FIG. 6 depict additional embodiments of aerosol generating articles 100 that include a wrapper 110, an end plug 600, a tubular element 500 that comprises a gel comprising an active agent, a proximal cavity 130, a cavity 140, and a fluid guide 400. The fluid guide 400 has a proximal end 401, a distal end 403 and an inner longitudinal passageway 430 from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410 and a third portion 435. The first portion 410 defines a first portion 410 of the inner longitudinal passageway 430, which extends from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The third portion 435 defines a third portion of the inner longitudinal passageway 430, which extends from the proximal end 433 of the third portion 435 to the distal end 431 of the third portion 435. The third portion 435 has a substantially constant inner diameter from the proximal end 433 to the distal end 431.

[0452] In FIG. 5, the first portion 410 of the inner longitudinal passageway 430 has a substantially constant inner diameter from the distal end 413 to the proximal end 411 of the first portion 410. The inner diameter of the inner longitudinal passageway 430 at the first portion 410 is smaller than the inner diameter of the inner longitudinal passageway 430 at the third portion 435. The restricted inner diameter of the inner longitudinal passageway 430 at the first portion 410, relative to at the third portion 435, may cause fluid to accelerate as it flows from the third portion 435 to the first portion 410.

[0453] In FIG. 6, the first portion 410 of the fluid guide 400 includes multiple segments 410A, 410B, 410C, with stepped internal diameters. The most distal segment 410A has the largest inner diameter, and the most proximal segment 410C has the smallest inner diameter. As fluid flows through the inner longitudinal passageway 430 from the first segment 410A to the second segment 401B and from the second segment 410B to the third segment 410C, the fluid may accelerate as the inner longitudinal passageway 430 cross-sectional area constricts in a stepped manner.

[0454] The first portions 410 in FIG. 5 and FIG. 6 provide examples of a construction that may be beneficial when the material employed to form the first portion 410 is not readily moldable. For example, the first portion 410 or the segments 410A, 410B, 410C of the first portion 410 may be formed from cellulose acetate tow. In contrast, the first portions 410 of the fluid guide 400 depicted in FIG. 3 and FIG. 4 provide examples of construction that may be beneficial when the material employed to form the first portion 410 is moldable, such as when the first portion is formed from, for example, polyether ether ketone (PEEK).

[0455] Like the aerosol generating article 100 depicted in FIG. 3 and FIG. 4, the aerosol generating articles depicted in FIG. 5 and FIG. 6 include a wrapper 110 that defines an open, proximal end 101 and a distal end 103 with an end plug 600, the end plug 600 having a high resistance to draw. A tubular element 500, in these examples, comprising gel 124 comprising an active agent, is disposed in the distal end 103 of the aerosol generating article 100. Aerosol released from the tubular element 500 comprising gel 124 comprising an active agent when heated may enter the cavity 140 in the aerosol generating article 100 to be carried through the inner longitudinal passageway 430.

[0456] While not shown in FIG. 5 and FIG. 6, the aerosol generating article 100 includes at least one aperture (such as apertures 150 shown in FIG. 3) that extends through the wrapper 110 and is in communication with an outer longitudinal passageway 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the aperture or apertures 150 and the proximal end 101. This helps to bias the fluid entering through the apertures 150 along the outer longitudinal passageways 440 in the tubular element 500 or distal direction. The third portion 435 of the inner longitudinal passageway 430, among other things, serves to extend the length of the fluid guide 400 and outer longitudinal passageway 440 to provide additional distance between the apertures 150 (not shown in FIG. 5 and FIG. 6, which may be located in proximity to a proximal end of the outer longitudinal passageway 440) and the tubular element 500 comprising gel 124 comprising an active agent so that leakage of the gel 124 comprising an active agent through the apertures 150 is not likely.

[0457] When a negative pressure is applied at the proximal end 101 of the aerosol generating article 100 depicted in FIG. 5 and FIG. 6, fluid enters the apertures 150, flows through the outer longitudinal passageway 440 into the cavity 140 to the tubular element 500 comprising gel 124 comprising an active agent, where the fluid may entrain material from the gel when the tubular element 500 is heated. The fluid may then flow through the inner longitudinal passageway 430, and through the proximal end 101. As fluid flows through the inner longitudinal passageway 430, the fluid flows through the third portion 435 and then the first portion 410 of the aerosol generating article 100. As fluid flows into the first portion 410 of the inner longitudinal passageway 430, the inner longitudinal passageway 430 may accelerate because the inner diameter of the inner longitudinal passageway 430 at the first portion 410 is less than at the third portion 435. In the aerosol generating article 100 depicted in FIG. 6, the fluid may accelerate as it passes each segment 410A, 410B, 410C of the first portion 410.

[0458] In the embodiments depicted in FIG. 4 and FIG. 5, the wrapper defines a cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the aerosol generating article 100, which could serve to decelerate the fluid that exits the inner longitudinal passageway 430 at the proximal end 401 of the fluid guide 400 prior to exiting the proximal end 101.

[0459] FIGS. 7-8 illustrate an embodiment of an aerosol generating article 100. The aerosol generating article 100 includes a wrapper 110 and apertures 150 through the wrapper 110. The aerosol generating article includes an end plug 600 that forms the distal end 103 of the aerosol generating article 100. The end plug has a high resistance to draw. A tubular element 500 comprising gel comprising an active agent, is disposed on the proximal side of the end plug 600, in the aerosol generating article 100. When heated, the tubular element 500 may form an aerosol that enters a cavity 140 to the proximal side of the tubular element 500.

[0460] FIG. 7 shows a side view of a tubular aerosol generating article 100. If one were to view a face of either the proximal end 101 or the distal end 103, the end face would be circular. FIG. 7 is a two dimensional drawing and thus the curvature of the tubular aerosol generating article cannot be seen. FIG. 8 is a partially cut away perspective view of the same embodiment as shown and described by FIG. 7. It can be seen that the face of the distal end, although partly blocked is circular. It can be seen that the face of the proximal end 101, although partly cut away will also be circular. Also from FIG. 8 it can be seen that the tubular element 500 is tubular in shape. Also from FIG. 8 it can be seen that the end cap 600 is also tubular in shape, for this embodiment.

[0461] At least one of the apertures 150 is in communication with at least one outer longitudinal passageway 440 formed between the fluid guide 400 and the wrapper 110 and between sidewalls 450. The fluid guide 400 has a rim 460 that presses against an inner surface of the wrapper 110 to form a seal. The seal is formed between the proximal end 101 and the apertures 150.

[0462] When a negative pressure is applied at the proximal end 101, fluid, for example air, may enter the apertures 150, and flow through the outer longitudinal passageways 440 to the cavity 140, and then through the tubular element 500 where material from the gel 124 is released into the fluid. The fluid then travels through the inner longitudinal passageway 430 through the fluid guide 400, into cavity 130 defined by the wrapper 110, and through (and exit) the proximal end 101 of the aerosol generating article 100. The inner longitudinal passageway 430 of the fluid guide 400 may be configured in any suitable manner, such as examples shown in FIGS. 3-6.

[0463] FIGS. 9-10 illustrate an embodiment of an aerosol generating article 100 that includes a mouthpiece 170 that forms a portion of the wrapper 110 and the fluid guide 400 of the aerosol generating article 100. The aerosol generating article 100 include a tubular element 500 that forms the distal end 103 of the aerosol generating article 100 and also is formed by a portion of the wrapper 110. The tubular element 500 is configured to be received by a distal portion of the mouthpiece 170, such as by interference fit. The tubular element comprising gel 124 comprising an active agent (not shown) may be disposed in the distal end 103. The aerosol generating article 100 comprises an end plug 600 at the extreme distal end 103. The end plug 600 has a high resistance to draw.

[0464] FIG. 9 shows part of a cut away side view of a tubular aerosol generating article 100. If one were to view a whole face of either the proximal end 101 or the distal end 103, the end face would be circular. FIG. 9 is a two dimensional drawing and thus the curvature of the tubular aerosol generating article cannot be seen. FIG. 10 is a partially cut away perspective view of the same partly cut away, part of an aerosol generating article 100 as shown and described by FIG. 9. It can be seen that the face of the distal end, although partly blocked is circular. It can be seen that the face of the proximal end 101, although partly cut away will also be circular. Also from FIG. 10 it can be seen that the tubular element 500 is tubular in shape. Also from FIG. 10 it can be seen that the end cap 600 is also tubular in shape, for this embodiment.

[0465] The fluid guide 400 includes an inner longitudinal passageway 430 (not shown) that includes a portion that accelerates fluid, and, may include a portion that decelerates fluid. A seal is formed between the wrapper 110 and the fluid guide 400 because the wrapper 110 and the fluid guide 400 are formed from a single part. An aperture 150 is formed in the wrapper 110 and is in communication with an outer longitudinal passageway 640 that is formed at least in part by an inner surface of the wrapper 110. Part of the outer longitudinal passageway 640 is generally formed between the inner surface of the wrapper 110 and an exterior of the fluid guide 400. The outer longitudinal passageway 640 extends less than the full distance around the article 100. In this embodiment, the outer longitudinal passageway 640 extends around 50 percent of the distance around the circumference of the aerosol generating article 100. The outer longitudinal passageway 640 directs fluid, for example air, from the aperture 150 towards the tubular element 500 (not shown) in proximity of the distal end 103.

[0466] When a negative pressure is applied at the proximal end 101, fluid, for example ambient air, enters the aerosol generating article 100 through the aperture 150. The fluid flows through the outer longitudinal passageway 640 towards a tubular element 500, comprising gel 124 comprising an active agent, disposed at the distal end 103. The fluid then flows through an inner longitudinal passageway 430 of the fluid guide 400, where the fluid is accelerated and optionally decelerated. The fluid, for example air, may then exit the proximal end 101 of the aerosol generating article 100.

[0467] FIG. 11 is an illustration of a fluid guide 400 formed from polyetheretherketone (PEEK) material by computer numeric control (CNC) machining. The fluid guide 400 depicted in FIG. 11 has a length of 25 millimetres, an outer diameter at the proximal end of 6.64 millimetres, and an outer diameter at the distal end of 6.29 millimetres. The outer diameter at the distal end is the diameter of the distal end from the base of the sidewalls. The fluid guide 400 has 12 outer longitudinal passageways 640 formed around its exterior surface, each sidewall having a substantially semi-circular transverse cross-sectional area. The outer longitudinal passageways 640 have a radius of 0.75 millimetres and a length of 20 millimetres. The fluid guide 400 has an inner longitudinal passageway 430 (not shown) comprising three portions, a first portion (a fluid accelerating portion) a second portion (fluid decelerating portion) downstream or proximal to the first portion and a third portion upstream or distal to the first portion. The third portion of the inner longitudinal passageway 430 of the fluid guide 400 extends from the distal end 103 of the aerosol generating article 100 and has an inner diameter at the distal end of 5.09 millimetres, which tapers down to a diameter of 4.83 millimetres at a proximal end of the first portion of the inner longitudinal passageway 430. The length of the first portion of the inner longitudinal passageway is 15 millimetres. The first portion of the inner longitudinal passageway 430 extends from the proximal end of the third portion to a distal end of the second portion. The first portion of the inner longitudinal passageway 430 has an inner diameter of 2 millimetres at its distal end, which constricts to 1 millimetre at the proximal end. The length of the first portion of the inner longitudinal passageway is 5.5 millimetres. The second portion of the inner longitudinal passageway 430 extends from the proximal end of the first portion to a proximal end at the proximal end of the article. The second portion of the inner longitudinal passageway 430 has an inner diameter of 1 millimetre at its distal end, which is the same as the inner diameter at the proximal end of the first portion. The inner diameter of the second portion increases at a decreasing rate (in a curve) to the proximal end, which has an inner diameter of 5 millimetres. The length of the second portion is 4.5 millimetres. Accordingly, fluid drawn through the interior passageway of the fluid guide, from the distal end to the proximal end, encounters a chamber with a substantially constant inner diameter (the third portion), a constricted section configured to accelerate the fluid (the first portion), and an expanded section configured to decelerate the fluid (the second portion). It has been found that providing such an inner longitudinal passageway 430 for the aerosol released from the heated tubular element 500 (not shown) may enable aerosol volume and droplet size to be controlled such that a satisfactory aerosol is released. FIG. 11 is a side view of a tubular shaped fluid guide 400. The FIG. 11 is a two dimensional drawing and therefore the curvature of the tubular shape, of the fluid guide 400, in this embodiment, cannot be seen. If one were to view an end face of the fluid guide 400, of this embodiment, the face would be circular.

[0468] FIG. 12 is an illustration of an assembled aerosol generating article 100. The aerosol generating article 100 includes a wrapper 110 into which the fluid guide 400 of FIG. 11 is inserted. The wrapper depicted in FIG. 12 is generally a cylindrical paper tube having a length of 45 millimetres. One end of the wrapper 110 is distal to provide the distal end of the wrapper for holding the tubular element 500 (not shown). The proximal portion of the exterior of the fluid guide 400, above the outer longitudinal passageways, has a diameter of 6.64 millimetres. This diameter is substantially identical to the inner diameter of the wrapper, such that an interference fit seal may be formed between the proximal portion of the exterior of the fluid guide 400 and the interior of the wrapper 110. The distal portion of the exterior of the fluid guide 400, extending the length of the outer longitudinal passageways, may have a diameter that is slightly less than the diameter of the proximal portion of the exterior of the fluid guide 400, such that the fluid guide may be easily inserted into the wrapper 110 up to the proximal portion of the exterior, where the interference fit is made. FIG. 12 is a side view of an aerosol generating article 100. The FIG. 12 is a two dimensional drawing and therefore the curvature of the tubular shape, of the aerosol generating article 100, in this embodiment, cannot be seen. If one were to view an end face of the aerosol generating article 100, of this embodiment, the face would be circular.

[0469] FIG. 13 illustrates an aerosol generating article 100 manufactured with a tubular element 500 comprising gel 124 which is illustrated further in FIGS. 14, 15 and 16. FIG. 13 is a longitudinal cross-section, cut away, view of an aerosol generating article 100. The FIG. 13 is a two dimensional drawing and therefore the curvature of the tubular shape, of the fluid guide 100, and its components, for example, the tubular element 500, in this embodiment, cannot be seen. If one were to view a whole end face of the aerosol generating article 100, of this embodiment, the face would be circular. Likewise, if one were to view a whole end face of the tubular element 500, of this embodiment, the face would be circular.

[0470] The aerosol generating article 100, of FIG. 13, comprises four elements arranged in coaxial alignment: at the distal end 103 an end plug 600 of high Resistance to Draw (RTD), a tubular element 500 which comprises gel 124, a fluid guide 400 and a mouthpiece 170 at the proximal end 101. These four elements are arranged sequentially and are circumscribed by a wrapper 110 to form the aerosol generating article 100. (In a similar but alternative embodiment there is a cavity 140 between the fluid guide 400 and the tubular element 500.) The aerosol-generating article 100 has a proximal or mouth end 101, and a distal end 103 located at the opposite end of the aerosol-generating article 100 from the proximal end 101. Not all components of the tubular element 500 are necessarily shown or labelled in FIG. 13.

[0471] In use, fluid, for example air, is drawn through the aerosol generating article 100, via the apertures 150 (not shown but similar to those described for the examples of FIGS. 1 to 10) when a negative pressure is applied at proximal end 101.

[0472] The end plug 600 is located at the extreme distal 103 end of the aerosol generating article 100.

[0473] In this example the tubular element 500 is located immediately downstream of the end plug 600 and abuts the end plug 600.

In FIG. 9, a distal end portion of the outer wrapper 110 of the aerosol generating article 100 is circumscribed by a band of tipping paper (not shown).
As is illustrated further in FIGS. 14, 15 and 16, the tubular element 500 is a cellulose acetate tube 122 containing gel 124 in the core, for example the core is filled with gel 124. In this example gel 124 comprises an active, the active agent is nicotine and an aerosol former. Other examples similar to this example comprise different active agents, or none. Not all components of the tubular element 500 of FIGS. 14, 15 and 16 are necessarily shown or labelled.

[0474] FIG. 14 shows a perspective view of the tubular element 500, FIG. 15 shows a cross-sectional view coplanar with the central axis of the tubular element 500, and FIG. 16 shows a cross-sectional view perpendicular to the central axis. FIG. 16 shows an end face of a tubular element 500.

[0475] The tubular element 500 is located in the aerosol generating article 100 (FIG. 13) at the distal end 103 of the aerosol generating article 100 so that tubular element 500 can be penetrated by a heating element of an aerosol generating device 200, the heating element in this example penetrates through the end plug 600 (at the extreme distal end 103 of the aerosol generating article 100) to contact the tubular element 500, which comprises gel 124. Thus, the heating element contacts the gel 124 or is in close proximity to the gel 124.

[0476] The gel 124 comprises an active agent that is released into the fluid, for example air, flowing from apertures 150 along outer longitudinal passageways (not shown) in the fluid guide 400 to the tubular element 500 near the distal end 103, then to the proximal end 101 via the inner longitudinal passageway 430 (not shown). In this illustrated example the active agent is nicotine. Optionally the gel 124 further comprises a flavour, for example, menthol.

[0477] The tubular element 500 may additionally comprise a plasticizer.

[0478] The fluid guide 400 is located immediately downstream of the tubular element 500 and abuts the tubular element 500. (In a similar but alternative specific example, for example FIG. 24, there is cavity between the fluid guide 400 and the tubular element 500, thus the fluid guide does not contact the tubular element). In use, material released from the tubular element 500 comprising gel 124, passes along the fluid guide 400 towards the proximal end 101 of the aerosol generating article 100.

[0479] In the example of FIG. 13 the mouthpiece 170 is located immediately downstream of the fluid guide 400 and abuts the fluid guide 400. In the example of FIG. 13, the mouthpiece 170 comprises a conventional cellulose acetate tow filter of low filtration efficiency.

[0480] To assemble the aerosol-generating article 100, the four elements described above are aligned and wrapped within the outer wrapper 110. In FIG. 13, the outer wrapper is a conventional cigarette paper.

[0481] The tubular element 500 may be formed by an extrusion process, for example as illustrated in FIG. 17. The cellulose acetate 122 longitudinal sides of the tubular element 500 may be formed by extruding a cellulose acetate material along a die 184 and around a mandrel 180 that projects rearwardly with respect to the direction of travel T of the extruded cellulose acetate material. The rearward projection of the mandrel 180 is shaped like a pin and is a cylindrical member having an external diameter of 3 to 7 millimetres, with a length of 55 to 100 millimetres. (To assist explanation, it is not illustrated to scale in the figures).

[0482] The cellulose acetate material 122, in this example, is thermoset, by exposure to steam S, which is at a pressure of greater than 1 bar.

[0483] The mandrel 180 is provided with a conduit 182, along which the gel 124 is extruded into the core of the set cellulose acetate material 122 that forms the longitudinal sides of the tubular element 500 in this example. In other examples the cellulose acetate material 122 is thermoset prior to extruding the gel 124 into the core of the of cellulose acetate material 122.

[0484] The composite cylindrical rod is cut into lengths, to form the individual tubular elements 500.

[0485] The composite cylindrical rod is formed by a hot extrusion process in this example. The composite cylindrical rod is allowed to cool, or subject to a cooling process, prior to processing into lengths. Alternatively, in other examples the composite cylindrical rod may be formed by a cold extrusion process.

[0486] In the illustrated tubular elements 500 of this example, the cellulose acetate 122 is shown as the longitudinal sides of the tubular element 500 with a core, the core to be filled with gel 124. However, alternatively in other examples, the cellulose acetate 122 longitudinal sides may have any shape, with a core (or more than one core) for receiving the gel 124 that extends generally along the tubular rod. In alternative specific examples the core is filled with porous medium loaded with gel 125.

[0487] In the present example the celluloses acetate 122 longitudinal sides, of the tubular element have a minimum thickness of 0.6 millimetres.

[0488] In the manufacturing process illustrated in FIG. 17, the gel 124 is extruded continuously.

[0489] In the alternative example as illustrated in FIG. 18, the gel 124 may be extruded in bursts, separated by gaps 128, as shown in FIG. 18. In alternative specific examples the porous medium loaded with gel 125 is extruded in bursts, to have separating gaps in the core of the tubular rod.

[0490] The gel 124 may be heated above room temperature before injection into the mandrel 180. The mandrel 180 may be thermally conductive (for example, a metal mandrel), and some externally applied heat (for example, from the steam S) applied to thermoset the cellulose acetate. This may transfer heat energy to the gel, heating the gel may reduce its viscosity and facilitate its extrusion.

[0491] In an alternative specific example as illustrated in FIG. 19, the mandrel 180 is configured to reduce heating of the gel 124 prior to extrusion. In some of these specific examples the mandrel 180 is formed from a substantially thermally insulating material. Alternatively, or additionally, the mandrel 180 is cooled, for example by having a liquid-cooled jacket 186 (for example a water-cooled jacket), having a circulating layer of cooled liquid forming a thermal barrier between externally applied heat (for example steam S) and the gel 124. Maintaining the gel 124 at a cool temperature may facilitate shaping the gel 124 within the cellulose acetate 122 longitudinal sides of the tubular element 500.

[0492] In this example the tubular elements 500 are formed by cutting through the gaps 128, of the composite rod, which aids prevention of contamination of the cutting machinery with the gel 124, thus improving cutting performance. The composite rod, in this example, is cooled prior to cutting, by a period of resting until it reaches a suitable temperature for cutting. After cutting, the cut lengths have hollow ends if cut in the gaps 128, which in some examples are trimmed off to form the tubular element, and before assembly into an aerosol generating article 100. The bursts of gel 124, in this example is 60 millimetres long, and separated by 10 millimetres gaps. In other examples the hollow ends are not trimmed at both ends in order to create a cavity 140 between the gel 124 and the fluid guide 400.

[0493] Alternatively, to the illustrated examples here, in specific examples, the gel 124 may be extruded at room temperature. Also, in alternatively specific examples the cellulose acetate is replaced with other materials, for example, polylactic acid.

[0494] In the FIG. 19 embodiment the mandrel has a cylindrical shape to aid in the manufacturing of a tubular shaped, tubular element.

[0495] FIG. 20 illustrates a portion of an aerosol-generating device 200 with partially inserted aerosol generating article 100, as described above and illustrated in FIG. 13.

[0496] The aerosol generating device 200 comprises a heating element 230. As shown in FIG. 20, the heating element 230 is mounted within an aerosol generating article 100 receiving chamber of the aerosol generating device 200. In use, the aerosol generating article 100 is inserted into the aerosol generating article receiving chamber of the aerosol generating device 200 such that the heating element 230 is inserted, via the end plug 600 into the tubular element 500 of the aerosol generating article 100 as shown in FIG. 20. In FIG. 20, the heating element 230 of the aerosol-generating device 200 is a heater blade.

[0497] The aerosol-generating device 200 comprises a power supply and electronics that allow the heating element 230 to be actuated. Such actuation may be manually operated or may occur automatically in response to negative pressure being applied at the proximal end of the aerosol generating article 100 inserted into the aerosol generating article receiving chamber of the aerosol-generating device 200. A plurality of openings is provided in the aerosol-generating device to allow air to flow to the aerosol-generating article 100; the direction of fluid, for example air, flow in the aerosol generating device 200 is illustrated by arrows in FIG. 20. The fluid can then enter the aerosol generating article 100 via the apertures 150 (not shown).

[0498] Once the internal heating element 230 is inserted into the tubular element 500 of the aerosol-generating article 100, and actuated, the tubular element 500 comprising gel 124 comprising an active agent is heated to a temperature of 375 degrees Celsius by the heating element 230 of the aerosol-generating device 200. At this temperature, material from the tubular element 500 of the aerosol generating article 100 leaves the gel. When negative pressure is applied to the proximal end 101 of the aerosol generating article 100, this material from the tubular element 500 is drawn downstream through the aerosol-generating article 100, in particular drawn through the fluid guide 400 towards the proximal end and out of the proximal end 101 of the aerosol generating article 100.

[0499] As the aerosol passes downstream thorough the aerosol generating article 100, the temperature of the aerosol is reduced due to transfer of thermal energy from the aerosol to the fluid guide 400. In this example, when the aerosol enters the fluid guide 400, the temperature of the aerosol is about 150 degrees Celsius. Due to cooling within the fluid guide 400, the temperature of the aerosol as it exits the fluid guide 400 is 40 degrees Celsius. This leads to the formation of aerosol droplets.

[0500] In the illustrated example of FIG. 20 the tubular element 500 comprises cellulose acetate forming the longitudinal sides 122 of the cylindrical rod, with gel 124 in the core or central portion of the tubular element 500. Alternatively in other specific examples, the longitudinal sides of the tubular element 500 may be cardboard; crimped paper, such as crimped heat resistant paper or crimped parchment paper; or a polymeric material, for example low density polyethylene (LDPE).

[0501] In FIGS. 14, 15, 16, the tubular element 500 has a single core provided with a single gel 124, with the gel 124 filling the core, surrounded by cellulose acetate along the longitudinal sides of the tubular element 500. However, in alternative specific examples, the tubular element 500 comprises more than one core. In specific embodiments the tubular element comprises more than one gel 124. Not all components of the tubular element 500 of FIGS. 14, 15 and 16 are necessarily shown or labelled.

[0502] As illustrated in the example of FIG. 21 the tubular element 500 comprises a plurality of gels 524A, 524B extending along the axial length of the core of tubular element 500, as shown in cross-section in FIG. 21. The tubular element 500, in this FIG. 21 embodiment, comprises cellulose acetate longitudinal sides 522, 622, 722. Not all components of the tubular element 500 are necessarily shown or labelled in the FIG. 21 embodiment.

[0503] The plurality of gels 524A, 524B may be extruded into the cellulose acetate 522 through separate conduits in the mandrel (not shown) forming the core of the tubular element 500. The use of gels 124 with different volatilities may facilitate optimisation of delivery of the active agent.

[0504] In the example illustrated in FIG. 22 the tubular element 500 comprises cellulose acetate longitudinal sides 622, the tubular element 500 additionally comprises a plurality of cores 624A, 624B, 624C, as shown in cross-section in FIG. 22.

[0505] Not all components of the tubular element 500 are necessarily shown or labelled in this FIG. 22 embodiment.

[0506] In this specific example, the plurality of cores is provided with different gels 624A, 624B, 624C, the gels having different active agents, for example different nicotine and flavouring, as shown in FIG. 22. The use of gels with different volatilities may facilitate optimisation of delivery of the active ingredient, in particular delivery over time of a heating cycle of an aerosol generating device.

[0507] In other specific examples (not shown) each of the plurality of cores 624A, 624B, 624C is provided with the same gel 124 (not shown). The use of a plurality of cores facilitates optimising air flow performance through the tubular element 500.

[0508] The plurality of cores may be formed by use of a mandrel (not shown) with a corresponding plurality of projections extending rearwardly with respect to the direction of travel T of the extruded cellulose acetate material. The gel may be extruded through respective conduits in the plurality of rearwardly extending mandrel projections.

[0509] In FIGS. 14, 15, 16, the tubular element 500 comprises cellulose acetate 122 longitudinal sides filled with gel 124 in the core. However, alternatively, in specific examples in combination with other features, the core of the tubular element 500 is only partially filled with gel 124 across the cross-section perpendicular to the axial length. Advantageously this facilitates axial air flow through the length of the tubular element 500. For example, as shown in FIG. 23, the gel 724 may be provided as a coating on the internal face of the longitudinal sides of the tubular element 500. Not all components of the tubular element 500 are necessarily shown or labelled in the FIG. 23 embodiment.

[0510] In this illustrated example, FIG. 23 embodiment, the tubular element 500 has a hollow conduit 726 extending axially along its length, by use of a mandrel (not shown) with a central rod extending further downstream from where the gel 724 is extruded into the tube during manufacturing, to form the hollow conduit within the extruded gel 724.

[0511] Although FIG. 20 illustrates an aerosol generating article 100 that is used with a blade-like heating element 230 of the aerosol generating device 200, the tubular element 500 may, alternatively, be used in other aerosol generating articles 100 that are heated differently.

[0512] For example, FIG. 24 illustrates, a cut away view, of an example of an aerosol generating article 100 that is suitable for induction heating as well as for heating with a blade like heating element. FIG. 24 illustrates an example of an aerosol generating article 100 of the present invention suitable for use with a tubular element of the present invention. FIG. 24 is a cross-sectional, cut away, view of a tubular aerosol generating article and its components, for example a tubular element 500, and thus does not show the curvature of the tubular shapes. Not all components of the tubular element 500 are necessarily shown or labelled in this FIG. 24.

[0513] In the FIG. 24 example the aerosol generating article 100 comprises a mouthpiece 170 at the proximal end 101, a fluid guide 400, a cavity 700, a tubular element 500 and an end plug 600 in the order proximal to distal. In this example the tubular element 500 comprises a gel 824 comprising an active agent and further comprises a susceptor (both not shown). The susceptor in this example is a single aluminium strip centrally located along the longitudinal axis of the tubular element 500. On insertion of the distal end 103 of the aerosol generating article 100 into an aerosol generating device 200 (not shown), the portion of the aerosol generating article 100 comprising the tubular element 500 is positioned to be in proximity to the induction heating elements 230 (not shown) of the aerosol generating device 200 (not shown). Electromagnetic radiation produced by the induction heating elements 230 is absorbed by the susceptor and aids heating of the gel 824 in the tubular element 500, in turn aiding the release of material from the gel 824, for example the active agent entrained into the passing aerosol when a negative pressure is applied at the proximal end 101 of the aerosol generating article 100. Fluid, for example air, enters the outer longitudinal passageways 834 via apertures 150 (not shown) to transfer to the cavity 700 and then to the tubular element 500 where the fluid mixes with the gel 824 and is entrained with active agents before returning to the cavity and then via the inner longitudinal passageway (not shown) of the fluid guide 400 before exiting at the proximal end 101. In this example the longitudinal sides 822 of the tubular element 500 comprise paper. The aerosol generating article comprises an outer wrapper 850. This aerosol generating article 100 illustrated in FIG. 24 and as described can be used with the aerosol generating device 200 as illustrated in FIGS. 1-2 and as described. Preferably the aerosol generating article 100 of FIG. 16 is heated by induction from the aerosol generating device 200.

[0514] The tubular element 500 may have numerous different combinations of, among other things; gel 124, porous medium loaded with gel 125, active agent, inner longitudinal elements, void space, filling material (preferably porous) and wrapper. A desired aerosol may be created by the particular combination and arrangement of its ingredients.

[0515] For example:

[0516] FIG. 25 illustrates an example wherein the tubular element 500 comprises: a wrapper 110; a second tubular element 115, the second tubular element 115 comprising gel 124, the second tubular element 115 comprises a paper wrapper, the second tubular element is located centrally along the longitudinal axis of the tubular element 500; porous filler material 132 located between the second tubular element 115 and the wrapper 110. The porous filler material 132 helps to hold the second tubular element centrally within the tubular element 500. The gel 124 in this example is located within the central portion of the second tubular element 115.

[0517] FIG. 26 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising gel 124, the second tubular element comprises a paper wrapper, the second tubular element is located centrally along the longitudinal axis of tubular element 500; gel 124 located between the second tubular element 115 and the wrapper 110. The gel located between the second tubular element 115 and the wrapper 110 helps to hold the second tubular element 115 centrally within the tubular element 500. The gel 124 in this example is located within the central portion of the second tubular element 115 as well as between the second tubular element 115 and the wrapper 110.

[0518] FIG. 27 illustrates an example where the tubular element 500 comprises: a wrapper 110; an inner longitudinal element comprising porous medium loaded with gel 125, the inner longitudinal element comprising porous medium loaded with gel 125, is centrally located along the longitudinal axis of the tubular element 500; gel 124 located between the inner longitudinal element comprising porous medium loaded with gel 125 and the wrapper 110. The gel 124 may assist in holding the inner longitudinal element comprising porous medium loaded with gel 125 centrally within the tubular element 500. In this example the inner longitudinal element is a cross shape, in its longitudinal cross-section, and parts of the inner longitudinal element contact the inner surface of the wrapper 110. Other examples may use inner longitudinal elements of other shapes and sizes, and thus may not necessarily contact the inner surface off the wrapper 110. Other specific examples may also use inner longitudinal elements of different materials.

[0519] FIG. 28 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising gel 124, the second tubular element 115 comprises a paper wrapper, the second tubular element is located centrally along the longitudinal axis of the tubular element 500; porous medium loaded with gel 125 located between the second tubular element 115 and the wrapper 110. In this example the porous medium loaded with gel 125 helps to hold the second tubular element 115 centrally within the tubular element 500.

[0520] FIG. 29 illustrates an example where the tubular element 500 comprises: a wrapper 110; porous medium loaded with gel 125; and gel 124; wherein the porous medium loaded with gel 125 is located adjacent the inner surface of the wrapper 110, and, surrounding the gel 124. In this example there is both gel 124 and porous medium loaded with gel 125. The porous medium loaded with gel 125 coating the inside surface of the wrapper, although the shape of the porous medium loaded with gel 125 may have been formed first and then wrapped by the wrapper 110. In this example the porous medium loaded with gel 125 is surrounding the gel 124, that is held centrally along the longitudinal axis of the tubular element 500. The porous medium loaded with gel 125 may assist in holding the gel 124 along the central position.

[0521] FIG. 30 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous medium loaded with gel 125, the second tubular element 115 comprises a paper wrapper; the second tubular element 115 is located centrally along the longitudinal axis of the tubular element 500; porous filler material 132 located between the second tubular element 115 and the wrapper 110. The porous filler material 132 helps to hold the second tubular element centrally within the tubular element 500. The porous medium loaded with gel 125 in this example is located within the central portion of the second tubular element 115. In this example the paper wrapper of the second tubular element 115 surrounds the porous medium loaded with gel 125.

[0522] FIG. 31 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous medium loaded with gel 125, the second tubular element 115, is centrally located along the longitudinal axis of the tubular element 500, the second tubular element further comprises a paper wrapper; porous medium loaded with gel 125, located between the second tubular element 115 and the wrapper 110. In this example the porous medium loaded with gel 125 is in two locations, within the second tubular element 115 and between the second tubular element and the wrapper 110. These may have the same or different, porous medium, gel, or active agent.

[0523] FIG. 32 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous filler material 132, the second tubular element 115 is centrally located along the longitudinal axis of the tubular element 500, the second tubular element 115 further comprises a paper wrapper; porous medium loaded with gel 125 located between the second tubular element 115 and the wrapper 110. The porous medium loaded with gel may assist in holding the second tubular element 115 centrally along the longitudinal axis of the tubular element 500. In this example the porous medium loaded with gel 125 is adjacent the inner surface of the wrapper 110. The porous medium loaded with gel 125 coats the inner surface of the wrapper 110.

[0524] FIG. 33 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous medium loaded with gel 125, the second tubular element 115 is centrally located along the longitudinal axis of the tubular element 500, the second tubular element 115 further comprises a paper wrapper; gel 124, located between the second tubular element 115 and the wrapper 110. In this example the gel 124 may assist in holding the second tubular element 115 centrally along the longitudinal axis of the tubular element 500. In this example the gel 124 is adjacent the inner surface of the wrapper 110. In this example the porous medium loaded with gel 125 is centrally located within the second tubular element 115, surrounded by the paper wrapper of the second tubular elements 115.

[0525] FIG. 34 illustrates an example where the tubular element 500 comprises: a wrapper 110; an inner longitudinal element comprising porous medium loaded with gel 125, the inner longitudinal element comprising porous medium loaded with gel 125, is cylindrical and centrally located along the longitudinal axis of the tubular element 500; gel 124 located between the inner longitudinal element comprising porous medium loaded with gel 125 and the wrapper 110. The gel 124 may assist in holding the inner longitudinal element comprising porous medium loaded with gel 124 centrally within the tubular element 500. In this example the inner longitudinal element is a cylindrical in shape, in its longitudinal cross-section, and is held apart from the inner surface of the wrapper 110 by gel 124. Other examples may use inner longitudinal elements of other shapes and sizes, and materials.

[0526] FIG. 35 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a first web of wrapping material 110. Dry porous medium 127 is dispensed on the first web of wrapping material 110 transported over a garniture 305. Preferably simultaneously a second feed means feeds a second web of wrapping material 115 onto a garniture 303. Nozzle 301 is a cylindrical nozzle, in this example. Nozzle 301 dispenses gel 124 onto the second web of wrapping material 115. The second web of wrapping material 115, with gel 124, is wrapped, to form a second tubular element. The second tubular element is transported by the second garniture 303 to be positioned on the dry porous medium 127 on the web of wrapping material. The first web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths, giving a plurality of discrete tubular elements 500. The manufacturing process of this example produces a tubular element comprising a second tubular element comprising gel, and where there is dry porous medium between the second tubular element and the wrapper of the tubular element, as shown in cross-section view in FIG. 25.

[0527] FIG. 36 shows one step of the process as illustrated in FIG. 35. The nozzle 301 for dispensing gel 124 is cylindrical to assist in dispensing gel 124 on the second web of wrapping material 115 which will form the second tubular element, which is preferably cylindrical in shape. The wrapped second web of wrapping material 115 is positioned on the dry porous medium 127 which is positioned on the first web of wrapping material 110.

[0528] FIG. 37 illustrates a manufacturing process of a tubular element according to the present invention. A first feed means feeds a first web of wrapping material 110. Nozzle 307 dispenses gel 124 onto the first web of wrapping 110 material transported over a garniture 305. Nozzle 307 is a ribbon nozzle that dispenses many rows of gel 124 on the surface, in this example, of the web of wrapping material 110. An advantage of the ribbon nozzle 307 is that it enables a large area or spread of gel 124 to be evenly dispensed. This is also illustrated in FIG. 39. Preferably simultaneously a second feed means feeds a second web of wrapping material 115 onto a garniture 303. Nozzle 301 is a cylindrical nozzle. Nozzle 301 dispenses gel 124 onto the second web of wrapping material 115. The second web of wrapping material 115, with gel 124, is wrapped, to form a second tubular element. The second tubular element is transported by the second garniture 303 to be positioned on the gel 124 on the web of wrapping material 110. The web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths.

[0529] FIG. 38 shows one step of the process as illustrated in FIG. 37. The nozzle 301 for dispensing gel 124 is cylindrical to assist in dispensing gel 124 on the second web of wrapping material 115 which will form the second tubular element, which is preferably cylindrical in shape. The wrapped second web of wrapping material 115 is positioned on gel 124 which is positioned on the web of wrapping material 110. The example tubular element 500 being manufactured and illustrated in FIGS. 37, 38 and 39 produces a tubular element 500 comprising a second tubular element 304 which comprises gel, and the tubular element 500 further comprises gel 124 positioned between the second tubular element and the wrapper 110 of the tubular element 500, as also illustrated in cross-sectional view in FIG. 26.

[0530] FIG. 40 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a web of wrapping material 110. Dry porous medium 127 is positioned on the web of wrapping material 110. Nozzle 307 dispenses gel 124 onto dry porous medium 127 positioned on the web of wrapping material 110 which is transported over a garniture 305. The dry porous medium 127 is loaded with gel 124 to become a porous medium loaded with gel 125. Nozzle 307 is a ribbon nozzle that dispenses many rows of gel 124 on the surface, in this example, on the dry porous medium 127 on the web of wrapping material 110. An advantage of the ribbon nozzle 307 is that it enables a large area or spread of gel 124 to be evenly dispensed. This is also illustrated in FIG. 42. Preferably simultaneously a second feed means feeds a second web of wrapping material 115 onto a garniture 303. Nozzle 301 is a cylindrical nozzle. Nozzle 301 dispenses gel 124 onto the second web of wrapping material 115. The second web of wrapping material 115, with gel 124, is wrapped, to form a second tubular element. The second tubular element is transported by the second garniture 303 to be positioned on the porous medium loaded with gel 125 on the web of wrapping material 110. The first web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths, to give a plurality of tubular elements 500.

[0531] FIG. 41 shows one step of the process as illustrated in FIG. 40. The nozzle 301 for dispensing gel 124 is cylindrical to assist in dispensing gel 124 on the second web of wrapping material 115 which will form the second tubular element, which is preferably cylindrical in shape. The wrapped second web of wrapping material 115 is positioned on porous medium loaded with gel 125 which is positioned on the web of wrapping material 110.

[0532] The example tubular element 500 being manufactured and illustrated in FIGS. 40, 41 and 42 produces a tubular element 500 comprising a second tubular element 304 which comprises gel 124, and the tubular element 500 further comprises porous medium loaded with gel 125 positioned between the second tubular element 304 and the wrapper 110 of the tubular element 500. As also illustrated in cross-sectional view in FIG. 28.

[0533] FIG. 43 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a first web of wrapping material 110. Dry porous medium 127 is dispensed onto the first web of wrapping material 110 that is transported over a garniture 303. A ribbon nozzle 307 dispenses gel 124 over the surface of the dry porous medium 127 and this gel 124 is loaded into the dry porous medium 127 to become a porous medium loaded with gel 125. Nozzle 301 is a cylindrical nozzle. Nozzle 301 dispenses gel onto the porous medium loaded with gel 125, which is positioned on the web of wrapping material (as also illustrated in FIG. 44). The web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths. This example produces tubular elements 500 that have gel 124 in the centre core of the tubular element 500 with porous medium loaded with gel 125 in the circumference portion under the wrapper 110. This example does not have a second tubular element 304. The cross-sectional view of the tubular element 500 manufactured as illustrated in FIGS. 43 and 44 is illustrated in FIG. 29.

[0534] FIG. 45 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a first web of wrapping material 110. Dry porous medium 127 is positioned onto the first web of wrapping material 110. The dry porous material 127 positioned onto the first web of wrapping material 110 is transported over a garniture 305. Preferably simultaneously a second feed means feeds a second web of wrapping material 115 onto a garniture 303. Dry porous medium 127 is positioned on the second web of wrapping material 115. Nozzle 307 is a ribbon nozzle. Nozzle 307 dispenses gel 124 onto the dry porous medium 127 positioned on the second web of wrapping material 115. The dry porous medium 127 is loaded with gel 124 to become a porous medium loaded with gel 125. This is also illustrated in FIG. 46. The second web of wrapping material 115 is wrapped around the porous medium loaded with gel 125, to form a second tubular element 304. The second tubular element 304 is transported by the second garniture 303 to be positioned on the dry porous medium 127 on the web of wrapping material 110. This is also illustrated in FIG. 47. The first web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths, giving a plurality of tubular elements 500.

[0535] The example tubular element 500 being manufactured and illustrated in FIGS. 45, 46 and 47 produces a tubular element 500 comprising a second tubular element 304 which comprises porous medium loaded with gel 125, and the tubular element 500 further comprises dry porous medium 127 positioned between the second tubular element 304 and the wrapper 110 of the tubular element 500. As also illustrated in cross-sectional view in FIG. 30.

[0536] FIG. 48 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a first web of wrapping material 110. Dry porous medium 127 is positioned onto the first web of wrapping material 110. Ribbon nozzle 307 dispenses gel 124 onto the dry porous medium 127. The dry porous medium 127 is loaded with gel 124 to become a porous medium loaded with gel 125. The porous medium loaded with gel 125 positioned onto the first web of wrapping material 110 is transported on a garniture 305. Preferably simultaneously a second feed means feeds a second web of wrapping material 115 onto a garniture 303. Dry porous medium 127 is positioned on the second web of wrapping material 115. Another ribbon nozzle 307 dispenses gel 124 onto the dry porous medium 127 positioned on the second web of wrapping material 115. The dry porous medium 127 is loaded with gel 124 to become porous medium loaded with gel 125. The second web of wrapping material 115, with porous medium loaded with gel 125, is wrapped, to form a second tubular element 304. The second tubular element is transported by the second garniture 303 to be positioned on the porous medium loaded with gel 125 on the web of wrapping material 110. This is also illustrated in FIG. 49. The web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths.

[0537] The example tubular element 500 being manufactured and illustrated in FIGS. 48 and 49 produces a tubular element 500 comprising a second tubular element 304 which comprises porous medium loaded with gel 125, and the tubular element 500 further comprises porous medium loaded with gel 125 positioned between the second tubular element 304 and the wrapper 110 of the tubular element 500. As also illustrated in cross-sectional view in FIG. 31.

[0538] FIG. 50 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a first web of wrapping material 110. Dry porous medium 127 is positioned onto the web of wrapping material 110. Ribbon nozzle 307 dispenses gel 124 onto the dry porous medium 127. The dry porous medium 127 is loaded with gel 124 to become porous medium loaded with gel 125. As also illustrated in FIG. 52. The porous medium loaded with gel 125 positioned onto the first web of wrapping material 110 is transported over a garniture 305. Preferably simultaneously a second feed means feeds a second web of wrapping material 115 onto a garniture 303. Nothing is added or dispensed onto this second web of wrapping material 115 in this example. The second web of wrapping material 115 is wrapped, to form a continuous length of second tubular element 304. The continuous length of second tubular element 304 is transported by the second garniture 303 to be positioned on the porous medium loaded with gel 125 on the first web of wrapping material 110. This is also illustrated in FIG. 51. The first web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths.

[0539] The example tubular element 500 being manufactured and illustrated in FIGS. 50, 51 and 52 produces a tubular element 500 comprising a second tubular element 304 which is hollow, and the tubular element 500 further comprises porous medium loaded with gel 125 positioned between the second tubular element 304 and the wrapper 110 of the tubular element 500.

[0540] FIG. 53 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a first web of wrapping material 110. Ribbon nozzle 307 dispenses gel 124 onto the first web of wrapping material 110. This is also illustrated in FIG. 55. The gel 124 positioned onto the first web of wrapping material 110 is transported over a garniture 305. Preferably simultaneously a second feed means feeds a second web of wrapping material 115 onto a garniture 303. Dry porous medium 127 is positioned on the second web of wrapping material 115. Another ribbon nozzle 307 dispenses gel 124 onto the dry porous medium 127 positioned on the second web of wrapping material 115. The dry porous medium 127 is loaded with gel 124 to become a medium loaded with gel 125. The second web of wrapping material 115, with porous medium loaded with gel 125, is wrapped, to form a second tubular element 304. The second tubular element is transported by the second garniture 303 to be positioned on the gel 124 on the web of wrapping material 110. This is also illustrated in FIG. 54. The first web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths.

[0541] The example tubular element 500 being manufactured and illustrated in FIGS. 53, 54 and 55 produces a tubular element 500 comprising a second tubular element 304 which comprises porous medium loaded with gel 125, and the tubular element 500 further comprises gel 124 positioned between the second tubular element 304 and the wrapper 110 of the tubular element 500. As also illustrated in cross-sectional view in FIG. 33.

[0542] FIG. 56 illustrates a manufacturing process of a tubular element 500 according to the present invention. A first feed means feeds a first web of wrapping material 110. Nozzle 307 dispenses gel 124 onto the web of wrapping material 110. Nozzle 307 is a ribbon nozzle. The gel 124 positioned onto the first wrapping material 110 is transported over a garniture 303. Not simultaneously in this example, a second feed means (not shown) feeds a second dry porous medium 127 and another ribbon nozzle 307 (not shown) dispenses gel 124 onto the dry porous medium 127. The dry porous medium 127 is loaded with gel 124 to become a porous medium loaded with gel 125. The porous medium loaded with gel 125 can be stored until required for the manufacture of the tubular element. When the porous medium loaded with gel 125 is required for the manufacture of the tubular element 500 the porous medium loaded with gel 125 is positioned onto the gel 124 on the first web of wrapping material 110. This is illustrated in FIG. 57. The first web of wrapping material 110 is then wrapped forming a continuous length of tubular element which can be cut to desired lengths.

[0543] The example tubular element 500 being manufactured and illustrated in FIGS. 56 and 57 produces a tubular element 500 comprising a central portion in cross-sectional view of porous medium loaded with gel 125, and an outer portion in cross-sectional view of the tubular element 500 which comprises gel 124. As also illustrated in cross-sectional view in FIG. 34.

[0544] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein.

[0545] As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.

[0546] As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

[0547] As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open-ended sense, and generally mean “including, but not limited to”. It will be understood that “consisting essentially of”, “consisting of”, and the like are subsumed in “comprising,” and the like.

[0548] The words “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and, is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

[0549] Any direction referred to herein, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions or orientations are described herein for clarity and brevity are not intended to be limiting of an actual device or system. Devices and systems described herein may be used in a number of directions and orientations.

[0550] The embodiments exemplified above are not limiting. Other embodiments consistent with the embodiments described above will be apparent to those skilled in the art.