AEROSOL-GENERATING ARTICLE COMPRISING A DUAL-LAYER WRAPPING STRUCTURE

Abstract

An aerosol-generating article (10) comprising an aerosol-forming substrate (11) and a dual-layer wrapping structure (30). The dual-layer wrapping structure comprises an inner wrapper (31) that circumscribes the aerosol-forming substrate, the inner wrapper comprising an inner wrapper internal surface and an inner wrapper external surface opposite the inner wrapper internal surface. The dual-layer wrapping structure comprises an outer wrapper (32) that circumscribes the inner wrapper, the outer wrapper comprising an outer wrapper internal surface and an outer wrapper external surface opposite the outer wrapper internal surface. The outer wrapper internal surface and the inner wrapper external surface are attached to one another by means of a first adhesive (51). The dual-layer wrapping structure defines an overlapping region (41) in which the dual-layer wrapping structure overlaps itself, the overlapping region comprising a first section (42) and a second section (43) externally disposed on the first section, the first section and the second section being attached to one another by means of a second adhesive (52). The outer wrapper has a basis weight between about 10 grams per square metre and 28 grams per square metre.

Claims

1. An aerosol-generating article comprising: an aerosol-forming substrate: a dual-layer wrapping structure, comprising: an inner wrapper that circumscribes the aerosol-forming substrate, the inner wrapper comprising an inner wrapper internal surface and an inner wrapper external surface opposite the inner wrapper internal surface; an outer wrapper that circumscribes the inner wrapper, the outer wrapper comprising an outer wrapper internal surface and an outer wrapper external surface opposite the outer wrapper internal surface, wherein the outer wrapper internal surface and the inner wrapper external surface are attached to one another by means of a first adhesive: wherein the dual-layer wrapping structure defines an overlapping region in which the dual-layer wrapping structure overlaps itself, the overlapping region comprising a first section and a second section externally disposed on the first section; wherein the first section and the second section are attached to one another by means of a second adhesive; wherein the outer wrapper has a basis weight between about 10 grams per square metre and 28 grams per square metre; and wherein the inner wrapper has a thickness between about 20 micrometres and about 100 micrometres.

2. The aerosol-generating article of claim 1, wherein the inner wrapper has a basis weight between about 10 grams per square metre and 28 grams per square metre: more preferably the inner wrapper, the outer wrapper or both the inner wrapper and the outer wrapper have a basis weight between about 10 grams per square metre and 16 grams per square metre.

3. The aerosol-generating article of claim 1, further comprising a heating element embedded within the aerosol-forming substrate.

4. The aerosol-generating article of claim 3, wherein the heating element is a susceptor.

5. The aerosol-generating article of claim 1, wherein the outer wrapper has a thickness between about 20 micrometres and about 100 micrometres; preferably the inner wrapper, the outer wrapper or both the inner wrapper and the outer wrapper have a thickness between about 25 micrometres and about 75 micrometres: more preferably the inner wrapper, the outer wrapper or both the inner wrapper and the outer wrapper have a thickness between about 30 micrometres and about 50 micrometres.

6. The aerosol-generating article of claim 1, wherein the inner wrapper, the outer wrapper or both the inner wrapper and the outer wrapper comprise an embossed pattern.

7. The aerosol-generating article of claim 1, wherein the outer wrapper has a porosity between about 30 and about 80 Coresta units, preferably between about 30 and about 50 Coresta units, most preferably between 30 and 40 Coresta units.

8. The aerosol-generating article of claim 1, wherein the inner wrapper external surface, the inner wrapper internal surface or both the inner wrapper external surface and the inner wrapper internal surface have a roughness between about 50 Bekk seconds and about 1000 Bekk seconds, more preferably between about 100 Bekk seconds and about 200 Bekk seconds.

9. The aerosol-generating article of claim 1, wherein a diameter of the aerosol-generating article is between about 3 mm and about 8 mm.

10. The aerosol-generating article of claim 1, further comprising a filter disposed downstream of the aerosol-forming substrate.

11. The aerosol-generating article of claim 1, wherein a length of the aerosol-generating article is between about 30 mm and about 100 mm.

12. An aerosol-generating system comprising: the aerosol-generating article of claim 1; and an aerosol-generating device.

13. The aerosol-generating system of claim 12, wherein the aerosol-generating device comprises a resistive heating element.

14. The aerosol-generating system of claim 13, wherein the aerosol-generating device comprises an inductive heating arrangement.

15. A method of manufacturing the aerosol-generating article of claim 1, the method comprising the steps of: providing an aerosol-forming substrate; transferring an inner wrapper from a first bobbin to a gluing machine; transferring an outer wrapper from a second bobbin to the gluing machine, wherein the outer wrapper has a basis weight between about 10 grams per square metre and 28 grams per square metre, and wherein the inner wrapper has a thickness between about 20 micrometres and about 100 micrometres; attaching an outer wrapper internal surface and an inner wrapper external surface by means of a first adhesive, such that the inner wrapper and the outer wrapper form a dual-layer wrapping structure; disposing the dual-layer wrapping structure such that the inner wrapper circumscribes the aerosol-forming substrate and the outer wrapper circumscribes the inner wrapper; defining an overlapping region in which the dual-layer wrapping structure overlaps itself, the overlapping region thus comprising a first section and a second section externally disposed on the first section, wherein the first section and the second section are attached to one another by means of a second adhesive.

Description

[0285] These and other features and advantages of the invention will become more evident in the light of the following detailed description of preferred embodiments, given only by way of illustrative and non-limiting example, in reference to the attached figures:

[0286] FIG. 1 depicts a longitudinal section of an aerosol-generating article comprising an embedded susceptor and a dual-layer wrapping structure.

[0287] FIG. 2a illustrates a cross section of the aerosol-generating article of FIG. 1.

[0288] FIG. 2b shows a cross section of an overlapping region defined by the dual-layer wrapping structure of the aerosol-generating article circled in FIG. 2a.

[0289] FIG. 3 shows a longitudinal section of an aerosol-generating article comprising a tubular element and a filter.

[0290] FIG. 4 illustrates a longitudinal section of an aerosol-generating article comprising an upstream element and an aerosol-cooling element.

[0291] FIG. 5 depicts several examples of wrappers comprising an embossed pattern.

[0292] FIG. 6 shows a schematic representation of a method of manufacturing an aerosol-generating article.

[0293] FIG. 7 represents a longitudinal section of an aerosol-generating system comprising an aerosol-generating device and any of the aerosol-generating articles of FIGS. 1 to 4.

[0294] FIG. 8 depicts an external view of the aerosol-generating system of FIG. 7.

[0295] FIG. 1 depicts a longitudinal section of an aerosol-generating article 10 having an upstream end 13 and a downstream end 14, the aerosol-generating article 10 defining a longitudinal direction between the upstream end 13 and the downstream end 14. The article 10 comprises an aerosol-forming substrate 11 and a dual-layer wrapping structure 30 circumscribing the aerosol-forming substrate 11.

[0296] The dual-layer wrapping structure 30 comprises an inner wrapper 31 and an outer wrapper 32. An outer wrapper internal surface and an inner wrapper external surface are attached to one another by means of a first adhesive 51.

[0297] In the embodiment of FIG. 1, a heating element 40 is embedded within the aerosol-forming substrate 11. The heating element 40 is a susceptor 40. The susceptor 40 extends along the entire length of the aerosol-forming substrate 11.

[0298] FIG. 2a illustrates a cross-section of the aerosol-generating article 10 of FIG. 1. This figure shows that the dual-layer wrapping structure 30 defines an overlapping region 41 in which the dual-layer wrapping structure 30 overlaps itself. The overlapping region 41 comprises a first section 42 and a second section 43 externally disposed on the first section 42. A second adhesive 52 is disposed between the first section 42 and the second section 43.

[0299] The overlapping region of FIG. 2a is represented in greater detail in FIG. 2b, for the sake of clarity.

[0300] FIG. 3 shows an aerosol-generating article which, similarly to that of FIGS. 1 and 2, comprises an aerosol-forming substrate 11 and a dual-layer wrapping structure 30. The aerosol-generating article 10 additionally comprises a support element 12 disposed immediately downstream of the aerosol-forming substrate 11. The support element 12 defines an opening extending in the longitudinal direction and adapted for substrate aerosol to flow towards the downstream end 14. Put another way, the support element 12 comprises a hollow tubular segment. In the embodiment of FIG. 3, a filter 17 is disposed immediately downstream of the support element 12 in the longitudinal direction. The wrapper 30 is identical to that of the aerosol-generating article 10 of FIGS. 1 and 2. A susceptor 40 extends along the entire length of the aerosol-forming substrate 11.

[0301] FIG. 4 shows an aerosol-generating article 10 comprising the dual-layer wrapping structure 30 of FIGS. 1, 2 and 3. The aerosol-generating article 10 of FIG. 4 will be described below insofar as it differs from the aerosol-generating articles 10 of FIGS. 1, 2 and 3.

[0302] The aerosol-generating article 10 of FIG. 4 comprises a support element 12 located immediately downstream of an aerosol-forming substrate 11. In the embodiment of FIG. 4, the upstream end of the support element 12 abuts the downstream end of the aerosol-forming substrate 11. In addition, the aerosol-generating article 10 comprises an aerosol-cooling element 15 located immediately downstream of the support element 22. In the embodiment of FIG. 4, the upstream end of the aerosol-cooling element 15 abuts the downstream end of the support element 12.

[0303] The support element 12 comprises a first hollow tubular segment. The aerosol-cooling element 15 comprises a second hollow tubular segment. The hollow tubular segments are provided in the form of a hollow cylindrical tube made of cellulose acetate. Other configurations in which the support element, the aerosol-cooling element or both do not comprise a hollow tubular segment are also compatible with the embodiment of FIG. 4.

[0304] In FIG. 4, the support element 12 and the aerosol-cooling element 15 together define an intermediate hollow section of the aerosol-generating article 10. As a whole, the intermediate hollow section is adapted for substrate aerosol to flow towards the downstream end 14 and does not substantially contribute to the overall resistance-to-draw of the aerosol-generating article 10.

[0305] In the embodiment of FIG. 4, a filter 17 is disposed immediately downstream of the aerosol-cooling element 15 in the longitudinal direction. As shown in FIG. 4, an upstream end of the filter 17 abuts the downstream end of the aerosol-cooling element 15.

[0306] The filter 17 is provided in the form of a cylindrical plug of low-density cellulose acetate.

[0307] In FIG. 4, the aerosol-generating article 10 comprises an upstream element 16. The upstream element 16 abuts the upstream end of the aerosol-forming substrate 11. This advantageously prevents the susceptor 40 from being dislodged. Further, this ensures that the consumer cannot accidentally contact the heated susceptor 40 after use.

[0308] The upstream element 16 is provided in the form of a cylindrical plug of cellulose acetate.

[0309] In some non-represented examples of the embodiments of FIGS. 3 and 4, the aerosol-generating article 10 comprises a mouthpiece disposed immediately downstream of the filter 17.

[0310] FIG. 5 depicts examples of embossed patterns which may be comprised in the inner wrapper 31 and the outer wrapper 32 of any of the above embodiments.

[0311] The embossed pattern of FIG. 5a comprises diagonal lines.

[0312] FIG. 5b shows a crisscross embossed pattern in which intersecting lines are equally separated from each other.

[0313] FIG. 5c shows a crisscross embossed pattern comprises vertical horizontal bands. The intersecting lines are equally separated from each other within the same band, but the separation between lines in the adjacent band is different. Therefore, the bands form a check pattern.

[0314] The embossed pattern of FIG. 5d comprises dots.

[0315] The embossed pattern of FIG. 5e comprises horizontal lines.

[0316] FIG. 5b shows a ridged pattern.

[0317] FIG. 6 illustrates the manufacturing of an aerosol-generating article 10 comprising a dual-layer wrapping structure 30.

[0318] An inner wrapper 31 is transferred from a first bobbin 61 to a gluing machine 31. An outer wrapper 32 is transferred from a second bobbin 62 to the gluing machine 31.

[0319] In the gluing machine 31, an outer wrapper internal surface and an inner wrapper external surface are attached by means of a first adhesive 51, such that the inner wrapper and the outer wrapper form the dual-layer wrapping structure 30.

[0320] Once the dual-layer wrapping structure 30 is formed, it is disposed around an aerosol-forming substrate 11 using a funnel 80. Thus, the inner wrapper 31 circumscribes the aerosol-forming substrate 11 and the outer wrapper 32 circumscribes the inner wrapper 31.

[0321] Upon extending the dual-layer wrapping structure around the aerosol-forming substrate 11, an overlapping region 41 is defined as shown in FIGS. 2a and 2b.

[0322] FIG. 7 shows a schematic longitudinal section of an aerosol-generating system comprising an aerosol-generating device 200 and an aerosol-generating article 10. The aerosol-generating article 10 may be any of the articles of FIGS. 1 to 4.

[0323] The aerosol-generating device 200 comprises a substantially cylindrical device housing 207, with a shape and size similar to a conventional cigar.

[0324] The aerosol-generating device 200 further comprises a power supply 201, in the form of a rechargeable nickel-cadmium battery, a controller 202 in the form of a printed circuit board including a microprocessor, an electrical connector 203 and a heating element 204. The heating element 204 is configured to heat the aerosol-forming substrate 11.

[0325] In the embodiment of FIG. 7, the heating element 204 is an inductive heating arrangement 204 comprising at least one inductor coil 206 intended to cooperate with the susceptor 40 of the aerosol-generating article 10. However, other forms of heating elements, such as resistive heating elements, may be used. Likewise, the inductive heating arrangement 204 may comprise a susceptor. The latter arrangement is preferable for use together with aerosol-generating articles which do not include a susceptor.

[0326] The power supply 201, the controller 202 and the inductor coil 206 are all housed within the device housing 207. The inductor coil 206 of the aerosol-generating device 200 is arranged at the proximal end of the device 200. The electrical connector 203 is arranged at a distal end of the device housing 207.

[0327] As used herein, the term proximal refers to a user end, or mouth end of the aerosol-generating device or aerosol-generating article. The proximal end of a component of an aerosol-generating device or an aerosol-generating article is the end of the component closest to the user end, or mouth end of the aerosol-generating device or the aerosol-generating article. As used herein, the term distal refers to the end opposite the proximal end.

[0328] The controller 202 is configured to control the supply of power from the power supply 201 to the inductor coil 206. The controller 202 further comprises a DC/AC inverter, including a Class-D power amplifier. The controller 202 is also configured to control recharging of the power supply 201 from the electrical connector 203. The controller 202 further comprises a puff sensor (not shown) configured to sense when a user is drawing on an aerosol-generating article received in a device cavity 208.

[0329] The inductor coil 206 is connected to the controller 202 and the power supply 201, and the controller 202 is configured to supply a varying electric current to the substrate inductor coil 206. When the varying electric current is supplied to the inductor coil 206, it generates a varying magnetic field, which heats the susceptor 40 by induction.

[0330] As represented in FIG. 8, the device housing 207 also defines a device air inlet 213 in close proximity to the distal end of the cavity 208 for receiving the aerosol-generating article 10. The device air inlet 213 is configured to enable ambient air to be drawn into the device housing 207 towards the aerosol-forming substrate 11.