AEROSOL GENERATING ARTICLE WITH THICK PAPER

Abstract

An aerosol generating article (10) includes an aerosol generating substrate (20), a filter element (22), and a first paper wrapper (30) and a second paper wrapper (40) circumscribing the aerosol forming substrate. The first paper wrapper having a thickness in a range from 40 about 90 micrometers to about 160 micrometers. The second paper wrapper joining the aerosol forming substrate to a filter element.

Claims

1. An aerosol generating article comprising: an aerosol generating substrate; a filter element; and a first paper wrapper and a second paper wrapper circumscribing the aerosol forming substrate, the first paper wrapper having a thickness in a range from about 90 micrometers to about 160 micrometers; and the second paper wrapper joining the aerosol forming substrate to a filter element.

2. The aerosol generating article according to claim 1, wherein the first paper wrapper separates the second paper wrapper from the aerosol generating substrate.

3. The aerosol generating article according to claim 1, wherein the first paper wrapper extends an entire length of the aerosol generating substrate.

4. The aerosol generating article according to claim 1, wherein the first paper wrapper has a paper thickness in a range from about 100 micrometers to about 140 micrometers.

5. The aerosol generating article according to claim 1, wherein the second paper wrapper has a paper thickness in a range from about 10 micrometers to about 50 micrometers.

6. The aerosol generating article according to claim 1, wherein the first paper wrapper does not extend beyond the aerosol generating substrate.

7. The aerosol generating article according to claim 1, wherein the aerosol generating substrate defines a substantially cylindrical shape having a diameter in a range from about 6.8 mm to about 7.1 mm.

8. The aerosol generating article according to claim 1, wherein the first paper wrapper has a ratio of paper thickness to tobacco substrate diameter in a range from about 1:120 to about 1:40.

9. The aerosol generating article according to claim 1, wherein the aerosol generating substrate comprises homogenized tobacco material.

10. The aerosol generating article according to claim 9, wherein the homogenized tobacco material comprises tobacco material, from about 1 percent to about 5 percent of a binder, and from about 5 percent to about 30 percent of an aerosol-former, in dry weight basis.

11. The aerosol generating article according to claim 1, wherein the aerosol generating substrate comprises a metallic induction heating element.

12. The aerosol generating article according to claim 1, wherein the aerosol generating substrate comprises a plurality of metallic induction heating elements.

13. An aerosol generating system comprising, the aerosol generating article according to claim 1 and an aerosol generating device comprising a heating element configured to heat the aerosol generating substrate.

14. The aerosol generating system according to claim 13, wherein the heating element is a resistive heating blade element configured to be inserted into the aerosol generating substrate.

15. The aerosol generating system according to claim 13, wherein the heating element is an inductive heating element configured to inductively heat metallic induction heating elements embedded within the aerosol generating substrate.

16. The aerosol generating article according to claim 5, wherein the first paper wrapper has a paper thickness in a range from 125 micrometers to about 140 micrometers.

17. The aerosol generating article according to claim 1, wherein the first paper wrapper has a paper thickness in a range from 100 micrometers to about 140 micrometers, and the second paper wrapper has a paper thickness in a range from about 10 micrometers to about 35 micrometers.

18. The aerosol generating article according to claim 17, wherein the first paper wrapper has a ratio of paper thickness to tobacco substrate diameter in a range from about 1:100 to about 1:50.

19. The aerosol generating article according to claim 16, wherein the aerosol generating substrate comprises a plurality of metallic induction heating elements.

20. The aerosol generating article according to claim 17, wherein the aerosol generating substrate comprises a plurality of metallic induction heating elements.

Description

[0077] The words “preferred” and “preferably” refer to examples of the invention that may afford certain benefits under certain circumstances. However, other examples may also be preferred under the same or other circumstances. Furthermore, the recitation of one or more preferred examples does not imply that other examples are not useful and is not intended to exclude other examples from the scope of the disclosure, including the claims.

[0078] FIG. 1A is a schematic cross-sectional diagram of an aerosol generating article.

[0079] FIG. 1B is a schematic cross-sectional diagram of another aerosol generating article.

[0080] FIG. 2 is a schematic cross-sectional diagram of the aerosol generating substrate element along line 2-2 in FIG. 1A.

[0081] FIG. 3 is a schematic cross-sectional diagram of the aerosol generating substrate element along line 3-3 in FIG. 2.

[0082] FIG. 4 is a schematic cross-sectional diagram of an aerosol generating system.

[0083] FIG. 5 is a schematic cross-sectional diagram a heating blade inserted into the aerosol generating substrate element.

[0084] The aerosol generating articles depicted in FIGS. 1-5 illustrate one or more examples of aerosol generating articles, components of aerosol generating articles, or aerosol generating systems described above. The schematic drawings are not necessarily to scale and are presented for purposes of illustration and not limitation. The drawings 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 and spirit of this disclosure.

[0085] The aerosol generating article includes an aerosol generating substrate 20, a filter element 22, and a first paper wrapper 30 and a second paper wrapper 40 circumscribing the aerosol forming substrate 20. The first paper wrapper 30 has a thickness in a range from about 60 micrometers to about 160 micrometers. The first paper wrapper 30 or the second paper wrapper 40 joins the aerosol forming substrate 20 to a filter element 22.

[0086] Preferably, the aerosol generating article includes an aerosol generating substrate 20, a filter element 22, and a first paper wrapper 30 and a second paper wrapper 40 circumscribing the aerosol forming substrate 20. The first paper wrapper 30 has a thickness in a range from about 90 micrometers to about 160 micrometers. The second paper wrapper 40 joins the aerosol forming substrate 20 to a filter element 22.

[0087] The aerosol generating article 10, of FIG. 1A and FIG. 1B, illustrate aerosol generating articles 10. FIG. 1A illustrates the first paper wrapper 30 circumscribing the aerosol generating substrate 20 and the second paper wrapper 40 circumscribing the first paper wrapper 30 and the filter element 22. The first paper wrapper 30 extends along the entire length of the aerosol generating substrate 20. The second paper wrapper 40 joins the aerosol generating substrate 20 to the filter element 22. The second paper wrapper 40 extends onto only a downstream portion of the first paper wrapper 30.

[0088] FIG. 1B illustrates the second paper wrapper 40 circumscribing the aerosol generating substrate 20 and the first paper wrapper 30 circumscribing the second paper wrapper 40 and the filter element 22. The first paper wrapper 30 joins the aerosol generating substrate 20 to the filter element 22. The first paper wrapper 30 is coextensive with the second paper wrapper 40 along the entire length of the aerosol generating substrate 20 from the distal end 13 to a proximal end 11.

[0089] An intermediate section 24 separates a filter element 22 from the aerosol generating substrate element 12. The aerosol generating substrate 12, intermediate section 24, and a filter element 22 are aligned from a distal end 13 to a proximal end 11 in serial order and form a cylinder. The second paper wrapper 40 or the first paper wrapper 30 circumscribes the aerosol generating article 10 to join the aerosol generating substrate element 12 to the intermediate section 24, and a filter element 22.

[0090] The intermediate section 24 may comprise on or more of, a hollow cellulose acetate tube or a polylactic acid filter segment. The filter element 22 may define a mouthpiece segment and be formed of cellulose acetate material. The aerosol generating substrate element 12, the intermediate section 24, and a filter element 22 may be individually wrapped with a paper layer and then joined to each other with the second paper wrapper 40 or the first paper wrapper 30. In particular, the aerosol-generating substrate element 12 is wrapped with the second paper wrapper 40 or the first paper wrapper 30, as described herein.

[0091] The aerosol generating article 10 has a mouth end or proximal end 11 and an upstream, distal end 13 located at the opposite end of the article to the mouth end 11. The aerosol generating article 10 shown in FIG. 1A and FIG. 1B are particularly suitable for use with an electrically operated aerosol generating device comprising a heater for heating the aerosol generating substrate element 12.

[0092] FIG. 2 is a schematic cross-sectional diagram of the aerosol generating substrate element 12 along line 2-2 in FIG. 1A. FIG. 3 is a schematic cross-sectional diagram of the aerosol generating substrate element 12 along line 3-3 in FIG. 2.

[0093] The first paper wrapper 30 circumscribes the aerosol generating substrate 20 to define the aerosol generating substrate element 12 with a substantially cylindrical shape. The second paper wrapper circumscribes the first paper wrapper 30 to define a substantially cylindrical shape

[0094] The aerosol generating substrate 20 defines a substantially cylindrical shape having a diameter 23 in a range from about 6.8 mm to about 7.1 mm. The aerosol generating substrate element 12 defines a substantially cylindrical shape having a diameter 33 in a range from about 7.1 mm to about 7.3 mm or from about 7.15 mm to about 7.25 mm.

[0095] The first paper wrapper 30 has a thickness T in a range from about 60 micrometers to about 160 micrometers. The first paper wrapper 30 may preferably have a thickness in a range from about 78 micrometers to about 160 micrometers, or about 78 micrometers to about 140 micrometers, or from about 100 micrometers to about 140 micrometers, or from about 125 micrometers to about 140 micrometers.

[0096] The first paper wrapper 30 has a ratio of paper thickness T to tobacco substrate diameter 23 in a range from about 1:120 to about 1:40, or about 1:100 to about 1:50, or from about 1:70 to about 1:50, or about 1:60 to about 1:50.

[0097] The first paper wrapper 30 circumscribes the entire circumference of the aerosol generating substrate 20 with very little first overlap 100 of the first paper wrapper 30 onto itself. The first overlap 100 region forms more than one paper layer. In FIG. 2, the first overlap 100 forms two layers of paper. The first overlap 100 may be about 20% or less of the circumference of the aerosol generating substrate 20. The first overlap 100 may be about 10% or less of the circumference of the aerosol generating substrate 20. The first overlap 100 may be about 5% or less of the circumference of the aerosol generating substrate 20. The first paper wrapper 30 may not extend beyond the ends 25, 26 of the aerosol generating substrate 20. The first paper wrapper 30 circumscribes an entire length of the aerosol generating substrate 20 between the ends 25, 26 of the aerosol generating substrate 20.

[0098] The second paper wrapper 40 circumscribes the entire circumference of the first paper wrapper 30 with very little second overlap 101 of the second paper wrapper 40 onto itself. The second overlap 101 region forms more than one paper layer. In FIG. 2, the second overlap 101 forms two layers of paper. The second overlap 101 may be about 20% or less of the circumference of the aerosol generating substrate 20. The second overlap 101 may be about 10% or less of the circumference of the aerosol generating substrate 20. The second overlap 101 may be about 5% or less of the circumference of the aerosol generating substrate 20. The second paper wrapper 40 may extend beyond the downstream end 26 of the aerosol generating substrate 20. The second paper wrapper 40 circumscribes only a downstream about 25% of the entire length of the aerosol generating substrate 20 between the ends 25, 26 of the aerosol generating substrate 20.

[0099] The first overlap 100 region is offset from the second overlap 101 region by at least about 45 degrees about the circumference of the aerosol generating substrate 20.

[0100] FIG. 2 illustrates that where the second paper wrapper 40 overlays the first paper wrapper 30, each paper wrapper forms substantially single turn or single layer around the circumference of the aerosol generating substrate 20. At least about 80%, or at least about 90%, or at least about 95% of the aerosol generating substrate 20 circumference is circumscribed by less than three paper layers or wrappers 30, 40. At least about 80%, or at least about 90%, or at least about 95% of the aerosol generating substrate 20 circumference is circumscribed by less than two paper layers or wrappers that do not extend beyond a length or the ends 25, 26 of the aerosol generating substrate 20. At least about 80%, or at least about 90%, or at least about 95% of the aerosol generating substrate 20 circumference is circumscribed by less than two paper layers or wrappers which circumscribe the aerosol generating substrate 20 along substantially a length or the entire length of the aerosol generating substrate 20.

[0101] FIG. 4 is a schematic cross-sectional diagram of an aerosol generating system 201. FIG. 5 is a schematic cross-sectional diagram a heating blade 230 inserted into the aerosol generating substrate element 12. The aerosol generating article 10 may be used with the aerosol generating device 200 as illustrated in FIG. 4 and FIG. 5.

[0102] The aerosol generating device 200 includes a housing 210 defining the receptacle 220, which is configured to receive the aerosol generating article 10. The aerosol generating device 200 also includes a heating blade element 230 configured to pierce the aerosol generating substrate element 12 of the aerosol generating article 10. The heating blade 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 blade element 230.

[0103] The aerosol generating article 10 illustrates an aerosol-generating substrate element 12, an intermediate section 24, and a filter element 22 aligned from a distal end 13 to a proximal end 11 in serial order and form a cylinder. The distal end 13 of the aerosol generating article 10. The aerosol generating substrate 12 has a length of about 12 millimetres. The aerosol generating substrate 12 is cylindrical in shape and has a substantially circular cross-section. The aerosol generating substrate 12 may comprise a gathered sheet of homogenised tobacco material. The sheet of homogenised tobacco material may comprise about 10 percent by weight on a dry basis of glycerine. The intermediate section 24 may be a hollow cellulose acetate tube having a length of about 8 millimetres and a thickness of 1 millimetre. The mouthpiece segment or filter element 22 may comprises a plug of cellulose acetate tow of 8 denier per filament and has a length of about 7 millimetres.

[0104] FIG. 5 illustrates the heating blade element 230 disposed within the aerosol generating substrate 12, 20. The heating blade element 230 may heat the aerosol generating substrate 12 of the aerosol generating article 10. Heating of the aerosol generating substrate 12 causes the aerosol generating substrate 12 to generate an aerosol containing the nicotine which can transfer out of the aerosol generating article 10 at the proximal end 11.

[0105] The heating blade element 230 may have a width 233 of about 5 mm. The aerosol generating substrate 20 defines a substantially cylindrical shape having a diameter 23 in a range from about 6.8 mm to about 7.1 mm, or about 6.9 mm to about 7.0 mm. The aerosol generating substrate element 12 defines a substantially cylindrical shape having a diameter 33 in a range from about 7.1 mm to about 7.3 mm, or about 7.15 mm to about 7.25 mm. The heating blade element 230 may lie within about 1 mm from the first paper wrapper 30.

[0106] In some examples the heating mechanism may be by induction where the heating element emits radio-magnetic radiation which is absorbed by one or more metallic induction heating elements when the aerosol generating article 10 is positioned in the receptacle 220 of the aerosol generating device 200.

[0107] Once the aerosol generating article 10 is releasably received in the aerosol generating device 200 and on the heating blade element 230, the aerosol generating device 200 is actuated to heat the aerosol generating substrate 12 to a temperature of approximately 375 degrees Celsius. As a user draws on the mouth end 11 of the aerosol generating article 10, the volatile compounds evolved from the aerosol generating substrate 12 are drawn downstream through the aerosol generating article 10 and condense to form an aerosol that is drawn through the mouthpiece 11 of the aerosol generating article 10 into the user's mouth.

[0108] The examples described above are not limiting. Other examples consistent with the these described above will be apparent to those skilled in the art.