AEROSOL-GENERATING ARTICLE WITH LOW DENSITY SUBSTRATE

Abstract

An aerosol-generating article is provided, including: an aerosol-generating substrate; and a downstream section extending from a downstream end of the aerosol-generating substrate to a downstream end of the aerosol-generating article, the aerosol-generating substrate having a density of no more than 0.5 grams per cubic centimetre, and the aerosol-generating substrate having a length-to-diameter ratio of no more than 6.0. An aerosol-generating system including the aerosol-generating article and an aerosol-generating device is also provided.

Claims

1.-15. (canceled)

16. An aerosol-generating article, comprising: an aerosol-generating substrate; and a downstream section extending from a downstream end of the aerosol-generating substrate to a downstream end of the aerosol-generating article, wherein the aerosol-generating substrate has a density of no more than 0.5 grams per cubic centimetre, and wherein the aerosol-generating substrate has a length-to-diameter ratio of no more than 6.0.

17. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate has a length-to-diameter ratio of at least 0.5.

18. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate has a diameter of at least 5 millimetres.

19. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate has a diameter of no more than 8 millimetres.

20. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate has a length of no more than 40 millimetres.

21. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate has a length of at least 10 millimetres.

22. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate has a density of at least 0.24 grams per cubic centimetre.

23. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate comprises tobacco cut filler.

24. The aerosol-generating article according to claim 16, wherein the aerosol-generating substrate comprises an aerosol former, the aerosol-generating substrate having an aerosol former content of at least 10 percent by weight.

25. The aerosol-generating article according to claim 16, wherein the downstream section comprises a hollow tubular element.

26. The aerosol-generating article according to claim 16, further comprising a first ventilation zone at a location along the downstream section.

27. The aerosol-generating article according to claim 16, wherein the downstream section has a resistance-to-draw of less than 30 millimetres H.sub.2O.

28. The aerosol-generating article according to claim 16, further comprising an upstream section upstream of the aerosol-generating substrate, the upstream section having an resistance-to-draw from 10 millimetres H.sub.2O to 70 millimetres H.sub.2O.

29. An aerosol-generating system, comprising: an aerosol-generating article according to claim 16; and an aerosol-generating device having a distal end and a mouth end, the aerosol-generating device comprising: a body extending from the distal end to the mouth end, the body defining a device cavity configured to removably receive the aerosol-generating article at the mouth end of the aerosol-generating device, and a heater configured to heat the aerosol-generating substrate when the aerosol-generating article is received within the device cavity.

30. The aerosol-generating system according to claim 29, wherein the heater of the aerosol-generating device is further configured to circumscribe the aerosol-generating article when the aerosol-generating article is received within the device cavity.

Description

[0418] In the following, the invention will be further described with reference to the drawings of the accompanying Figures, wherein:

[0419] FIG. 1 shows a schematic side sectional view of an aerosol-generating article in accordance with an embodiment of the invention;

[0420] FIG. 2 shows a schematic side sectional view of another aerosol-generating article in accordance with another embodiment of the invention;

[0421] FIG. 3 shows a schematic side sectional view of a variant of the aerosol-generating article of FIG. 1;

[0422] FIG. 4 shows a schematic side sectional view of a variant of the aerosol-generating article of FIG. 1;

[0423] FIG. 5 shows a schematic side sectional view of a further aerosol-generating article in accordance with an embodiment of the invention;

[0424] FIG. 6 shows a schematic side sectional view of a variant of the aerosol-generating article of FIG. 5; and

[0425] FIG. 7 shows a schematic side sectional view of a mouth end portion of an exemplary aerosol-generating device and system, where the aerosol-generating article shown in FIG. 1 is received within the aerosol-generating device.

[0426] The aerosol-generating article 10 shown in FIG. 1 comprises an aerosol-generating substrate 12 and a downstream section 14 at a location downstream of the aerosol-generating substrate 12. Thus, the aerosol-generating article 10 extends from an upstream or distal end 16which substantially coincides with an upstream end of the aerosol-generating substrate 12to a downstream or mouth end 18, which coincides with a downstream end of the downstream section 14.

[0427] The aerosol-generating article 10 has an overall length of about 45 millimetres.

[0428] The aerosol-generating substrate 12 comprises tobacco cut filler impregnated with about 12 percent by weight of an aerosol former, such as glycerin. The tobacco cut filler comprises 90 percent by weight of tobacco leaf lamina. The cut width of the tobacco cut filler is about 0.7 millimetres. The aerosol-generating substrate 12 comprises about 130 milligrams of tobacco cut filler.

[0429] The aerosol-generating substrate 12 has a density of about 0.28 grams per cubic centimetre

[0430] The aerosol-generating substrate 12 has a diameter of about 7.2 millimetres. The aerosol-generating substrate 12 has a length of about 11.5 millimetres. Consequently, the aerosol-generating substrate 12 has a length to diameter ratio of about 1.6.

[0431] The ratio of the length of the aerosol-generating substrate to the length of the aerosol-generating article is about 0.26.

[0432] The downstream section 14 comprises a hollow tubular element 20 located immediately downstream of the aerosol-generating substrate 12, the hollow tubular element 20 being in longitudinal alignment with the aerosol-generating substrate 12. In the embodiment of FIG. 1, the upstream end of the hollow tubular element 20 abuts the downstream end of the aerosol-generating substrate 12.

[0433] The hollow tubular element 20 defines a hollow section of the aerosol-generating article 10. The hollow tubular element does not substantially contribute to the overall RTD of the aerosol-generating article. In more detail, an RTD of the downstream section is about 0 millimetres H.sub.2O.

[0434] The hollow tubular element 20 is provided in the form of a hollow cylindrical tube made of cellulose acetate or of stiff paper, such as paper having a grammage (basis weight) of at least about 90 grams per square metre. The hollow tubular element 20 defines an internal cavity 22 that extends all the way from an upstream end 24 of the hollow tubular segment to a downstream end 26 of the hollow tubular element 20. The internal cavity 22 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 22. The hollow tubular element 20 does not substantially contribute to the overall RTD of the aerosol-generating article 10.

[0435] The hollow tubular element 20 has a length of about 33 millimetres, an external diameter (D.sub.E) of about 7.3 millimetres, and an internal diameter (D.sub.I) of about 7.1 millimetres. Thus, a thickness of a peripheral wall of the hollow tubular element 20 is about 0.1 millimetres.

[0436] The aerosol-generating article 10 comprises a ventilation zone 30 provided at a location along the hollow tubular element 20. In more detail, the ventilation zone 30 is provided at about 18 millimetres from the downstream end 26 of the hollow tubular element 20. As such, in the embodiment of FIG. 1 the ventilation zone 30 is effectively provided at 18 millimetres from the mouth end 18 of the aerosol-generating article 10. A ventilation level of the aerosol-generating article 10 is about 40 percent.

[0437] In the embodiment of FIG. 1, the aerosol-generating article does not comprise any additional component upstream of the aerosol-generating substrate 12 or downstream of the hollow tubular segment 20.

[0438] The aerosol-generating article 100 shown in FIG. 2 differs from the aerosol-generating article 10 described above only by the provision of an upstream section at a location upstream of the aerosol-generating element. Accordingly, the aerosol-generating article 100 will only be described insofar as it differs from the aerosol-generating article 10.

[0439] On top of an aerosol-generating substrate 12 and a downstream section 14 at a location downstream of the aerosol-generating substrate 12, the aerosol-generating article 100 comprises an upstream section 40 at a location upstream of the aerosol-generating substrate 12. As such, the aerosol-generating article 10 extends from a distal end 16 substantially coinciding with an upstream end of the upstream section 40 to a mouth end or downstream end 18 substantially coinciding with a downstream end of the downstream section 14.

[0440] The upstream section 40 comprises an upstream element 42 located immediately upstream of the aerosol-generating substrate 12, the upstream element 42 being in longitudinal alignment with the aerosol-generating substrate 12. In the embodiment of FIG. 2, the downstream end of the upstream element 42 abuts the upstream end of the aerosol-generating substrate 12. The upstream element 42 is provided in the form of a cylindrical plug of cellulose acetate circumscribed by a stiff wrapper. The upstream element 42 has a length of about 5 millimetres. The RTD of the upstream element 42 is about 30 millimetres H.sub.2O.

[0441] FIG. 3 shows an aerosol-generating article 200 which is a variant of the aerosol-generating article 10 described above. The aerosol-generating article 200 is generally the same as the aerosol-generating article 10 of the embodiment of FIG. 1, with the exception that the aerosol-generating article 200 of the variant of the first embodiment does not comprise a cylindrical hollow tubular element 22 as described above. Instead, the aerosol-generating article 200 of the variant of the first embodiment comprises a modified tubular element 220 located immediately downstream of the aerosol-generating element 12.

[0442] The modified tubular element 220 comprises a tubular body 222 defining a cavity 224 extending from a first end of the tubular body 222 to a second end of the tubular body 222. The modified tubular element 220 also comprises a folded end portion forming a first end wall 226 at the first end of the tubular body 222. The first end wall 226 delimits an opening 228, which permits airflow between the cavity 224 and the exterior of the modified tubular element 220. In particular, the embodiment of FIG. 3 is configured so that aerosol may flow from the aerosol-generating element 12 through the opening 228 into the cavity 224.

[0443] Much like the cavity 22 of the first embodiment shown in FIG. 1, the cavity 224 of the tubular body 222 is substantially empty, and so substantially unrestricted airflow is enabled along the cavity 222. Consequently, the RTD of the modified tubular element 220 can be localised at a specific longitudinal position of the modified tubular element 220namely, at the first end wall 226and can be controlled through the chosen configuration of the first end wall 226 and its corresponding opening 228.

[0444] In the embodiment of FIG. 3, the modified tubular element 220 has a length of about 33 millimetres, an external diameter (D.sub.E) of about 7.3 millimetres, and an internal diameter (DFTS) of about 7.1 millimetres. Thus, a thickness of a peripheral wall of the tubular body 222 is about 0.1 millimetres.

[0445] FIG. 4 shows an aerosol-generating article 300 which is a variant of the aerosol-generating article 100 described above. The aerosol-generating article 300 is generally the same as the aerosol-generating article 100 of the embodiment of FIG. 2, with the exception that the aerosol-generating article 300 of the variant of the second embodiment does not comprise an upstream element 42 provided in the form of a cylindrical plug of cellulose acetate circumscribed by a stiff wrapper. Instead, the aerosol-generating article 300 of the variant of the second embodiment comprises a second tubular element 44 located immediately upstream of the aerosol-generating element 12. Consequently, in this variant of the second embodiment, the hollow tubular element 20 located immediately downstream of the aerosol-generating element 12 can be referred to as a first tubular element 20.

[0446] The second tubular element 44 comprises a tubular body 46 defining a cavity 48 extending from a first end of the tubular body 46 to a second end of the tubular body 46. The second tubular element 44 also comprises a folded end portion forming a first end wall 50 at the first end of the tubular body 46. The first end wall 50 delimits an opening 52, which permits airflow between the cavity 48 and the exterior of the second tubular element 44. In particular, the embodiment of FIG. 4 is configured so that air may flow from the cavity 48 through the opening 52 and into the aerosol-generating element 12.

[0447] Further, the second tubular element 44 comprises a second end wall 54 at the second end of its tubular body 46. This second end wall 54 is formed by folding an end portion of the second tubular element 44 at the second end of the tubular body 46. The second end wall 54 delimits an opening 56, which also permits airflow between the cavity 48 and the exterior of the second tubular element 44. In the case of the second end wall 54, the opening 56 is configured to so that air may flow from the exterior of the aerosol-generating article 300 through the opening 56 and into the cavity 48. The opening 56 therefore provides a conduit through which air can be drawn into the aerosol-generating article 300 and through the aerosol-generating element 12.

[0448] In the variant of FIG. 4, a downstream end of the second tubular element 44 abuts the upstream end of the aerosol-generating substrate 12. The second tubular element 44 has a length of about 5 millimetres. The RTD of the second tubular element 44 is about 30 millimetres H.sub.2O.

[0449] The aerosol-generating article 400 shown in FIG. 5 differs from the aerosol-generating article 10 described above by the provision of a downstream plug of material 501. The plug of material 501 comprises cellulose acetate tow filtration material having a denier per filament of 8.4 and a total denier of 21,000. The plug of filter material 501 has a length of about 10 millimetres.

[0450] The aerosol-generating article 400 further comprises a hollow tubular element 502 downstream of the plug of material 501. The hollow tubular element 502 comprises a tube of filamentary tow. The hollow tubular element 502 has a length of about 8 millimetres. The hollow tubular element 502 has a wall thickness of about 1 millimetre.

[0451] The aerosol-generating article 400 has a diameter of about 6.7 millimetres. The aerosol-generating substrate 12 has a length of about 35 millimetres.

[0452] The aerosol-generating article 500 shown in FIG. 6 differs from the aerosol-generating article 400 described above only by the provision of a capsule 601 embedded within the filtration material of the plug of material 501. The capsule 601 is a breakable capsule comprising a solid, frangible shell surrounding a liquid payload. The liquid payload comprises a flavourant or aerosol modifying agent. The capsule 601 has a diameter of about 3 millimetres and has a mass of about 20 milligrams.

[0453] FIG. 7 illustrates an aerosol-generating system 1000 comprising an aerosol-generating device 1 and the aerosol-generating article 10, shown in FIG. 1. FIG. 7 shows the downstream, mouth end portion of the aerosol-generating device 1 where the device cavity is defined and the aerosol-generating article 10 can be received. The aerosol-generating device 1 comprises a housing (or body) 4, extending between a mouth end 2 and a distal end (not shown). The housing 4 comprises a peripheral wall 6. The peripheral wall 6 defines a device cavity for receiving an aerosol-generating article 10. The device cavity is defined by a closed, distal end and an open, mouth end. The mouth end of the device cavity is located at the mouth end of the aerosol-generating device 1. The aerosol-generating article 10 is configured to be received through the mouth end of the device cavity and is configured to abut a closed end of the device cavity.

[0454] A device air flow channel 5 is defined within the peripheral wall 6. The air-flow channel 5 extends between an inlet 7 located at the mouth end of the aerosol-generating device 1 and the closed end of the device cavity. Air may enter the aerosol-generating substrate 12 via an aperture provided at the closed end of the device cavity, ensuring fluid communication between the air flow channel 5 and the aerosol-generating substrate 12.

[0455] The aerosol-generating device 1 further comprises a heater (not shown) and a power source (not shown) for supplying power to the heater. A controller (not shown) is also provided to control such supply of power to the heater. The heater is configured to heat the aerosol-generating article 10 during use, when the aerosol-generating article 1 is received within the device 1. The heater is arranged to externally heat the aerosol-generating substrate 12 for optimal aerosol generation. The ventilation zone 30 is arranged to be exposed when the aerosol-generating article 10 is received within the aerosol-generating device 1.

[0456] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term about. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.