AEROSOL-GENERATING ARTICLE WITH TUBULAR ELEMENT

Abstract

An aerosol-generating article including a plurality of elements assembled in the form of a rod is provided, the elements including: a first element including an aerosol-generating substrate; and a tubular element positioned upstream or downstream of the first element, the tubular element including: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body, and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity and an exterior of the tubular element, the cavity in the tubular element being an empty cavity.

Claims

1.-45. (canceled)

46. An aerosol-generating article comprising a plurality of elements assembled in the form of a rod, the elements comprising: a first element comprising an aerosol-generating substrate; and a tubular element positioned upstream or downstream of the first element, the tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body, and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity and an exterior of the tubular element, wherein the cavity in the tubular element is an empty cavity.

47. The aerosol-generating article according to claim 46, wherein the first end wall of the tubular element is adjacent to the first element.

48. The aerosol-generating article according to claim 46, wherein the aerosol-generating substrate is a rod of aerosol-generating substrate, and wherein the first element further comprises a susceptor element arranged within the rod of aerosol-generating substrate.

49. The aerosol-generating article according to claim 46, wherein the tubular element is a first tubular element, and is positioned downstream of the aerosol forming substrate with the first end wall of the first tubular element being adjacent to a downstream end of the aerosol-generating substrate.

50. The aerosol-generating article according to claim 49, further comprising a second tubular element, the second tubular element comprising: a tubular body defining a cavity extending from the first end of the tubular body to the second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity and an exterior of the second tubular element, wherein the second tubular element is positioned upstream of the aerosol-generating substrate with the first end wall of the second tubular element being adjacent to the upstream end of the aerosol-generating substrate.

51. The aerosol-generating article according to claim 50, wherein the second tubular element further comprises another folded end portion forming a second end wall at the second end of the tubular body, the second end wall delimiting an opening for airflow between the cavity and the exterior of the second tubular element.

52. The aerosol-generating article according to claim 51, wherein the opening delimited by the second end wall of the second tubular element is smaller than the opening delimited by the first end wall of the second tubular element.

53. An aerosol-generating article comprising a plurality of elements assembled in the form of a rod, the elements comprising: a first element comprising an aerosol-generating substrate; and a tubular element positioned upstream or downstream of the first element, the tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body, and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity and an exterior of the tubular element, wherein the aerosol-generating article further comprises an outer wrapper circumscribing at least the tubular element.

54. The aerosol-generating article according to claim 53, wherein the first end wall of the tubular element is adjacent to the first element.

55. The aerosol-generating article according to claim 53, wherein the aerosol-generating substrate is a rod of aerosol-generating substrate, and wherein the first element further comprises a susceptor element arranged within the rod of aerosol-generating substrate.

56. The aerosol-generating article according to claim 53, wherein the tubular element is a first tubular element, and is positioned downstream of the aerosol forming substrate with the first end wall of the first tubular element being adjacent to a downstream end of the aerosol-generating substrate.

57. The aerosol-generating article according to claim 56, further comprising a second tubular element, the second tubular element comprising: a tubular body defining a cavity extending from the first end of the tubular body to the second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity and an exterior of the second tubular element, wherein the second tubular element is positioned upstream of the aerosol-generating substrate with the first end wall of the second tubular element being adjacent to the upstream end of the aerosol-generating substrate.

58. The aerosol-generating article according to claim 57, wherein the second tubular element further comprises another folded end portion forming a second end wall at the second end of the tubular body, the second end wall delimiting an opening for airflow between the cavity and the exterior of the second tubular element.

59. The aerosol-generating article according to claim 58, wherein the opening delimited by the second end wall of the second tubular element is smaller than the opening delimited by the first end wall of the second tubular element.

60. An aerosol-generating article comprising a plurality of elements assembled in the form of a rod, the elements comprising: a first element comprising an aerosol-generating substrate; and a tubular element positioned fully upstream or fully downstream of the first element, the tubular element comprising: a tubular body defining a cavity extending from a first end of the tubular body to a second end of the tubular body, and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity and an exterior of the tubular element.

61. The aerosol-generating article according to claim 60, wherein the first end wall of the tubular element is adjacent to the first element.

62. The aerosol-generating article according to claim 60, wherein the aerosol-generating substrate is a rod of aerosol-generating substrate, and wherein the first element further comprises a susceptor element arranged within the rod of aerosol-generating substrate.

63. The aerosol-generating article according to claim 60, wherein the tubular element is a first tubular element, and is positioned downstream of the aerosol forming substrate with the first end wall of the first tubular element being adjacent to a downstream end of the aerosol-generating substrate.

64. The aerosol-generating article according to claim 63, further comprising a second tubular element, the second tubular element comprising: a tubular body defining a cavity extending from the first end of the tubular body to the second end of the tubular body; and a folded end portion forming a first end wall at the first end of the tubular body, the first end wall delimiting an opening for airflow between the cavity and an exterior of the second tubular element, wherein the second tubular element is positioned upstream of the aerosol-generating substrate with the first end wall of the second tubular element being adjacent to the upstream end of the aerosol-generating substrate.

65. The aerosol-generating article according to claim 64, wherein the second tubular element further comprises a folded end portion forming a second end wall at the second end of the tubular body, the second end wall delimiting an opening for airflow between the cavity and the exterior of the second tubular element.

Description

[0284] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0285] FIG. 1 shows a schematic side sectional view of an aerosol-generating article in accordance with a first embodiment of the invention;

[0286] FIG. 2 shows a schematic side sectional view of an aerosol-generating article in accordance with a second embodiment of the invention;

[0287] FIG. 2 shows a schematic side sectional view of an aerosol-generating article in accordance with a third embodiment of the invention;

[0288] FIG. 4 shows a perspective view of a tubular element of the aerosol-generating article of the first embodiment of the invention; and

[0289] FIGS. 5A to 5D show schematic side sectional views depicting the stages of formation of the tubular element of the aerosol-generating article of FIG. 1;

[0290] FIG. 6 shows a schematic side sectional view of an aerosol-generating article in accordance with a fourth embodiment of the invention;

[0291] FIG. 7 shows a schematic side sectional view of an aerosol-generating article in accordance with a fifth embodiment of the invention; and

[0292] FIG. 8 shows a schematic side sectional view of an aerosol-generating article in accordance with a sixth embodiment of the invention.

[0293] FIG. 1 shows an aerosol-generating article 1 article in accordance with a first embodiment of the invention. The aerosol-generating article 1 comprises a first element 11 comprising an aerosol-generating substrate 12 and a downstream section 14 at a location downstream of the first element 11. Further, the aerosol-generating article 1 comprises an upstream section 16 at a location upstream of the first element 11. Thus, the aerosol-generating article 1 extends from an upstream or distal end 18 to a downstream or mouth end 20.

[0294] The aerosol-generating article has an overall length of about 45 millimetres.

[0295] The downstream section 14 comprises a tubular element 100 located immediately downstream of the first element 11, the tubular element 100 being in longitudinal alignment with the first element 11. In the embodiment of FIG. 1, the upstream end of the tubular element 100 abuts the downstream end of the first element 11 and in particular the downstream end of the aerosol-generating substrate 12.

[0296] In addition, the downstream section 14 comprises a mouthpiece element 42 at a location downstream of the tubular element 100. In more detail, the mouthpiece element 42 is positioned immediately downstream of the tubular element 100. As shown in FIG. 1, an upstream end of the mouthpiece element 42 abuts the downstream end 40 of the tubular element 100. The mouthpiece element 42 is provided in the form of a cylindrical plug of low-density cellulose acetate. The mouthpiece element 42 has a length of about 12 millimetres and an external diameter of about 7.25 millimetres. The RTD of the mouthpiece element 42 is about 12 millimetres H.sub.2O.

[0297] The aerosol-generating article 1 comprises a ventilation zone 60 provided at a location along the tubular element 100. In more detail, the ventilation zone is provided at about 4 millimetres from the downstream end of the tubular element 100. A ventilation level of the aerosol-generating article 10 is about 40 percent.

[0298] The first element 11 is in the form of a rod comprising the aerosol-generating substrate 12 of one of the types described above. The aerosol-generating substrate 12 may substantially define the structure and dimensions of the rod 11. The rod 11 may further comprise a wrapper (not shown) circumscribing the aerosol-generating substrate 12. The rod 11 comprising the aerosol-generating substrate has an external diameter of about 7.25 millimetres and a length of about 12 millimetres.

[0299] The first element 11 also comprises an elongate susceptor element 44 within the aerosol-generating substrate 12. In more detail, the susceptor element 44 is arranged substantially longitudinally within the aerosol-generating substrate 12, such as to be approximately parallel to the longitudinal direction of the rod 11. As shown in the drawing of FIG. 1, the susceptor element 44 is positioned in a radially central position within the rod and extends effectively along the longitudinal axis of the rod 11.

[0300] The susceptor element 44 extends all the way from an upstream end to a downstream end of the aerosol-generating substrate 12. In effect, the susceptor element 44 has substantially the same length as the first element 11 comprising the aerosol-generating substrate 12.

[0301] In the embodiment of FIG. 1, the susceptor element 44 is provided in the form of a strip and has a length of about 12 millimetres, a thickness of about 60 micrometres, and a width of about 4 millimetres.

[0302] The upstream section 16 comprises an upstream element 46 located immediately upstream of the first element 11, the upstream element 46 being in longitudinal alignment with the first element 11. In the embodiment of FIG. 1, the downstream end of the upstream element 46 abuts the upstream end of the first element 11 and in particular the upstream end of the aerosol-generating substrate 12. This advantageously prevents the susceptor element 44 from being dislodged. Further, this ensures that the consumer cannot accidentally contact the heated susceptor element 44 after use.

[0303] The upstream element 46 is provided in the form of a cylindrical plug of cellulose acetate circumscribed by a stiff wrapper. The upstream element 46 has a length of about 5 millimetres. The RTD of the upstream element 46 is about 30 millimetres H.sub.2O.

[0304] The aerosol-generating article 1 further includes an outer wrapper 109 circumscribing at least the tubular element. As shown in FIG. 1, the outer wrapper also circumscribes the first element 11, the mouthpiece element 42 and the upstream element 46. The outer wrapper 109 extends from an upstream or distal end 18 to a downstream or mouth end 20.

[0305] The tubular element 100 comprises a tubular body 103 defining a cavity 106 extending from a first end 101 of the tubular body 103 to a second end 102 of the tubular body 103. The tubular element 100 also comprises a folded end portion forming a first end wall 104 at the first end 101 of the tubular body 103. The first end wall 104 delimits and opening 105, which permits airflow between the cavity 106 and the exterior of the tubular element 100. In particular, the embodiment of FIG. 1 is configured so that aerosol may flow from the first element 11 through the opening 105 into the cavity 106.

[0306] The cavity 106 of the tubular body 103 is substantially empty, and so substantially unrestricted airflow is enabled along the cavity 106. Consequently, the RTD of the tubular element 100 can be localised at a specific longitudinal position of the tubular element 100namely, at the first end wall 104and can be controlled through the chosen configuration of the first end wall 104 and its corresponding opening 105. In the embodiment of FIG. 1, the RTD of the tubular element 100 (which is essentially the RTD of the first end wall 104) is substantially 10 millimetres H.sub.2O. In the embodiment of FIG. 1, the tubular element 100 has a length of about 16 millimetres, an external diameter of about 7.25 millimetres, and an internal diameter (D.sub.FTS) of about 6.5 millimetres. Thus, a thickness of a peripheral wall of the tubular body 103 is about 0.75 millimetres.

[0307] As shown in FIG. 1, and also in more detail in the perspective view of FIG. 4, the first end wall 104 extends substantially transverse to the longitudinal direction of the aerosol generating article 1 and the longitudinal direction of the tubular element 100. The opening 105 is the only opening in the first end wall 104 and the opening 105 is positioned in a generally radially central position of the tubular element 100. Consequently, the first end wall 104 is generally annular shaped.

[0308] The combination of the first end wall 104 and its corresponding opening 105 provide an effective barrier arrangement which may restrict movement of the aerosol-generating substrate, whilst also enabling one or both of air and aerosol to flow from the first element 11 and through the opening 105 into the cavity 106. The opening 105 is generally aligned with the radially central position of the susceptor element 44 of the first element 11. This may be advantageous as it helps to keep a distance between the first end wall 105 and the susceptor, and thus mitigate undesirable heating of the first end wall 105. This may also be advantageous as it can provide direct unimpeded downstream flow of aerosol produced by the portion of the aerosol-generating substrate in close proximity to the susceptor element 44.

[0309] As will be described in more detail below with respect to FIGS. 5A-5D, the first end wall 104 is formed by folding an end portion of the tubular element 100 about a fold point. The fold point generally corresponds to the first end of the tubular body 103 of the tubular element 100.

[0310] FIG. 2 shows an aerosol-generating article 2 in accordance with a second embodiment of the invention. The aerosol-generating article 2 of the second embodiment is generally the same as the aerosol-generating article 1 of the first embodiment, with the exception that the aerosol-generating article 2 of the second embodiment does not comprise an upstream element 46 is provided in the form of a cylindrical plug of cellulose acetate circumscribed by a stiff wrapper. Instead, the aerosol-generating article 2 of the second embodiment comprises a second tubular element 200 located immediately upstream of the first element 11. Consequently, in this second embodiment, the tubular element 100 located immediately downstream of the first element 11 is referred to as a first tubular element 100.

[0311] The second tubular element 200 comprises a tubular body 203 defining a cavity 206 extending from a first end of the tubular body 203 to a second end of the tubular body 203. The tubular element 200 also comprises a folded end portion forming a first end wall 204a at the first end of the tubular body 103. The first end wall 204a delimits and opening 205a, which permits airflow between the cavity 206 and the exterior of the second tubular element 200. In particular, the embodiment of FIG. 2 is configured so that air may flow from the cavity 206 through the opening 205a and into the first element 11.

[0312] The second tubular element 200 is therefore similar to the first tubular element 100 in that an end portion of the tubular element 200 is folded to form an end wall 205a, which extends substantially transverse to the longitudinal direction of the aerosol-generating article, and which is disposed adjacent to an end of the aerosol-generating substrate 12. In this case, the second tubular element 200 is disposed upstream, rather than downstream, of the first element 11 comprising the aerosol-generating substrate 12, meaning that the end wall 204a is disposed adjacent to the upstream end of the aerosol-generating substrate 12.

[0313] However, unlike the first tubular element, the second tubular element 200 also comprises a second end wall 204b at the second end of its tubular body 203. This second end wall 204b is formed by folding an end portion of the second tubular element 200 at the second end of the tubular body of the second tubular element 200. The second end wall 204b delimits and opening 205b, which also permits airflow between the cavity 206 and the exterior of the second tubular element 200. In the case of the second end wall 204b, the opening 205b is configured to so that air may flow from the exterior of the aerosol-generating article 2 through the opening 205b and into the cavity 206. The opening 205b therefore provides the conduit through which air can be drawn into the aerosol-generating article 2 and through the aerosol-generating substrate 12. In the embodiment of FIG. 2, the first end wall 204a of the second tubular element 200 may be referred to as the downstream end wall of the second tubular element 200. Similarly, the second end wall 204b of the second tubular element 200 may be referred to as the upstream end wall of the second tubular element 200.

[0314] FIG. 3 shows an aerosol-generating article 3 in accordance with a third embodiment of the invention. The aerosol-generating article 3 of the third embodiment is generally the same as the aerosol-generating article 1 of the first embodiment, with the exception that the aerosol-generating article 3 of the third embodiment does not comprise any form of upstream element 46 upstream of the first element 11. Consequently, the upstream or distal end 18 of the aerosol-generating article 3 is defined by the first element 11. Furthermore, in the third embodiment of the invention the first element 11 does not comprise a susceptor element 44 located within the aerosol-generating substrate 12. Such an aerosol-generating article 3 may therefore be one which is configured to receive a heater blade of an aerosol-generating device. The heater blade may be inserted into the aerosol-generating substrate 12 through the upstream end 18 of the aerosol-generating article 3.

[0315] The tubular element 300 of the aerosol-generating article 3 of the third embodiment is substantially the same as the tubular element 100 of the aerosol-generating article 1 of the first embodiment, with the exception that the tubular element 300 is longer than the tubular element 100.

[0316] FIGS. 5A to 5D show a tubular element for an aerosol generating article in according with the invention, through different stages of its formation. These Figures therefore illustrate a method of forming the tubular element, such as the tubular element 100 of FIG. 1.

[0317] As illustrated by FIG. 5A, the method commences by providing a tubular element 500 comprising a first end portion 504 and a tubular body 103 adjacent to and integral with the first end portion 504. To form the first end wall 104, a folding force is applied to the tubular element 500 to bend the first end portion 504 about a fold point 501 corresponding to the first end of the tubular body 103.

[0318] The folding force deflects the first end portion 504 inwards relative to the tubular body 103 (as indicated by the dashed curved arrows in FIGS. 5A, 5B and 5C) and towards the cavity 106 of the tubular body 103. The folding force continues to be applied until the first end portion 504 has been folded by an angle of greater than 90 degrees, as measured relative to the walls of the tubular body 103. Such a position is depicted in FIG. 5C. As can be seen from FIG. 5C, in such a position, at least part of the first end portion 504 of the tubular element 500 extends into the cavity 106 of the tubular body 103. Put another way, at least part of the first end portion 504 of the tubular element 500 has a longitudinal position which resides between that of the first end of the tubular body 103 and that of the second end of the tubular body 103.

[0319] Once the first end portion 504 reaches the position of FIG. 5C, the folding force ceases to be applied. At this point, the inherent resilient properties of the paper material (such as paper, paperboard or cardboard) of the tubular element 500 will cause the first end portion 504 to partially revert back along its folding path, such that the first end portion 504 reaches a positon in which it extends substantially transverse to the longitudinal direction of the tubular body 103. This position is illustrated by FIG. 5D, which depicts the fully formed tubular element 100. In particular, the folded first end portion 504 forms a first end wall 104 at the first end of the tubular body 103, the first end wall 104 delimiting an opening 105 for airflow between the cavity 106 and the exterior of the tubular element 100.

[0320] In the arrangement of FIGS. 5A to 5D the second end of the tubular element 500 is not folded; however, it will be appreciated that similar method steps may be applied to this second end of the tubular element 500 in order to arrive at a tubular element having two folded end portions, each forming respective first and second end walls for the tubular element.

[0321] FIG. 6 shows an aerosol-generating article 6 in accordance with a fourth embodiment of the invention. The aerosol-generating article 6 of the fourth embodiment is generally the same as the aerosol-generating article 3 of the third embodiment and like-for-like reference numerals are used where appropriate. However, the aerosol-generating article 6 of the fourth embodiment does not comprise a mouthpiece element 42 at a location downstream of the tubular element 600. Instead, the tubular element 600 of FIG. 6 extends all the way from the downstream end of the aerosol-forming substrate 12 to the mouth end 20 of the aerosol-generating article 6. The downstream section 14 of the aerosol-generating article 6 in FIG. 6 is therefore entirely formed by the tubular element 600.

[0322] Furthermore, in the embodiment of FIG. 6, the first end wall 604 of the tubular element 600 is not disposed adjacent to the downstream end of the aerosol-forming substrate 12. Instead, the first end wall 604 of the tubular element 600 is disposed at the mouth end 20 of the aerosol-generating article 6. The first end wall 604 delimits and opening 605, which permits airflow between the cavity 606 and the exterior of the tubular element 600. The opening 605 is configured so that one or both of air and aerosol may flow from the cavity 606 through the opening 605b to the exterior of the aerosol-generating article 6.

[0323] FIG. 7 shows an aerosol-generating article 7 in accordance with a fifth embodiment of the invention. The aerosol-generating article 7 of the fifth embodiment is generally the same as the aerosol-generating article 6 of the fourth embodiment and like-for-like reference numerals are used where appropriate. However, the aerosol-generating article 7 of the fifth embodiment now comprises a mouthpiece element in the form of a hollow tube 742 at a location downstream of the tubular element 700. The tubular element 700 of FIG. 7 therefore extends all the way to the upstream end of this hollow tube 742. The downstream section 14 of the aerosol-generating article 6 in FIG. 6 is therefore defined by the tubular element 700 and the hollow tube 742.

[0324] FIG. 8 shows an aerosol-generating article 8 in accordance with a sixth embodiment of the invention. The aerosol-generating article 8 of the sixth embodiment is generally the same as the aerosol-generating article 1 of the first embodiment and like-for-like reference numerals are used where appropriate.

[0325] However, in the embodiment of FIG. 8, the tubular element 800 is not in contact with the first element 11 comprising the aerosol-generating substrate 12. Instead, an empty space 850 exists between the downstream end of the first element 11 and the first end wall 804 at the upstream end 801 of the tubular element 800. Consequently, in the embodiment of FIG. 8, the first end wall 804 of the tubular element 800 does not provide a barrier which is in contact with the aerosol-generating substrate 12 for restricting movement of the aerosol-generating substrate 12. However, the empty space 850 does provide a region in which any loose particles or pieces from the aerosol-generating substrate 12 may congregate during use of the aerosol-generating article 8. The first end wall 804 may, with the assistance of gravity, prevent such loose particles or pieces from moving further downstream within the aerosol-generating article 8.