AEROSOL-GENERATING ARTICLE HAVING DOWNSTREAM ELEMENT COMPRISING NOVEL FILTRATION MATERIAL

Abstract

An aerosol-generating article (10)(100)(1000) comprises: an aerosol-generating substrate (12)(112)(1004); a downstream element (42)(150)(1008) provided downstream of the aerosol-generating substrate (12)(112)(1004) and in axial alignment with the aerosol-generating substrate, the downstream element comprising a cellulosic filtration material. The fibrous material comprises a plurality of regenerated cellulose fibres selected from one or more of viscose fibres, modal fibres, Lyocell fibres and viscose rayon fibres; or a plurality of natural fibres selected from one or more of flax fibres, hemp fibres, jute fibres, kenaf fibres, ramie fibres, abaca fibres, phormium fibres, sisal fibres, coir fibres, cotton fibres, and kapok fibres. The cellulosic fibrous material further comprises an additive coating applied to the plurality of regenerated cellulose or natural fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis.

Claims

1. An aerosol-generating article comprising: an aerosol-generating substrate; a downstream element provided downstream of the aerosol-generating substrate and in axial alignment with the aerosol-generating substrate, the downstream element comprising a cellulosic filtration material comprising: a fibrous material comprising a plurality of regenerated cellulose fibres, wherein the regenerated cellulose fibres are one or more of viscose fibres, modal fibres, Lyocell fibres and viscose rayon fibres; and an additive coating applied to the plurality of regenerated cellulose fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis.

2. An aerosol-generating article comprising: an aerosol-generating substrate; a downstream element provided downstream of the aerosol-generating substrate and in axial alignment with the aerosol-generating substrate, the downstream element comprising a cellulosic filtration material comprising: a fibrous material comprising a plurality of natural fibres, wherein the natural fibres are one or more of are one or more of flax fibres, hemp fibres, jute fibres, kenaf fibres, ramie fibres, abaca fibres, phormium fibres, sisal fibres, coir fibres, cotton fibres, and kapok fibres; and an additive coating applied to the plurality of natural fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis.

3. An aerosol-generating article according to claim 1 or 2, wherein the additive coating further comprises at least one polysaccharide.

4. An aerosol-generating article according to claim 3, wherein the at least one polysaccharide is selected from hemicellulose, corn starch, potato starch, acetylated starch, and combinations thereof.

5. An aerosol-generating article according to claim 3 or 4, wherein the additive coating comprises at least 20 percent by weight of the at least one polysaccharide.

6. An aerosol-generating article according to any of claims 3 to 5, wherein the weight ratio of exogenous lignin to polysaccharide in the additive coating on a dry weight basis is between 0.25 and 4.

7. An aerosol-generating article according to any of claims 3 to 6, wherein the weight ratio of the at least one polysaccharide to exogenous lignin in the additive coating on a dry weight basis is at least 2.

8. An aerosol-generating article according to any of claims 3 to 7, wherein the additive coating further comprises at least one cross-linking agent.

9. An aerosol-generating article according to claim 8, wherein the at least one cross-linking agent is selected from acetic anhydride, succinic anhydride, pyridine, triacetin and combinations thereof.

10. An aerosol-generating article according to claim 8 or 9, wherein the additive coating comprises at least 0.1 percent by weight of the at least one cross-linking agent, on a dry weight basis.

11. An aerosol-generating article according to any preceding claim, wherein the cellulosic filtration material comprises at least 1 percent by weight of the additive coating.

12. An aerosol-generating article according to claim 11, wherein the cellulosic filtration material comprises between 1 percent by weight and 15 percent by weight of the additive coating.

13. An aerosol-generating article according to any preceding claim, wherein the downstream element is substantially free from cellulose acetate.

14. An aerosol-generating article according to any preceding claim, wherein the downstream element is a mouthpiece filter segment comprising a segment of the cellulosic filtration material circumscribed by a filter wrapper.

15. A method of producing a cellulosic filtration material for use in the downstream element of the aerosol-generating article according to claim 1, the method comprising the steps of: providing a plurality of regenerated cellulose fibres, wherein the regenerated cellulose fibres are one or more of viscose fibres, modal fibres, Lyocell fibres and viscose rayon fibres; forming an additive coating solution comprising at least 5 percent by weight of exogenous lignin, on a dry weight basis and optionally one or more polysaccharides in water; applying the additive coating solution to the plurality of regenerated cellulose fibres; and drying and optionally curing the coated fibres.

16. A method according to claim 15, wherein the step of providing the plurality of regenerated cellulose fibres comprises forming the plurality of regenerated cellulose fibres in the presence of an additive enhancer.

17. A Method of producing a cellulosic filtration material for use in the downstream element of the aerosol-generating article according to claim 2, the method comprising the steps of: providing a plurality of natural fibres, wherein the natural fibres are one or more of flax fibres, hemp fibres, jute fibres, kenaf fibres, ramie fibres, abaca fibres, phormium fibres, sisal fibres, coir fibres, cotton fibres and kapok fibres; forming an additive coating solution comprising at least 5 percent by weight of exogenous lignin, on a dry weight basis and optionally one or more polysaccharides in water; applying the additive coating solution to the plurality of natural fibres; and drying and optionally curing the coated fibres.

18. A method according to claim 17, wherein the plurality of natural fibres are mercerised prior to the step of applying the additive coating solution.

Description

[0255] Examples will now be further described with reference to the drawings of the accompanying Figures in which:

[0256] FIG. 1 shows a schematic side sectional view of an aerosol-generating article in accordance with an embodiment of the invention;

[0257] FIG. 2 shows a schematic side sectional view of another aerosol-generating article in accordance with another embodiment of the invention; and

[0258] FIG. 3 shows a schematic side sectional view of another aerosol-generating article in accordance with a further embodiment of the invention.

[0259] The aerosol-generating article 1000 shown in FIG. 1 comprises an aerosol-generating element 1002 in the form of a substantially cylindrical rod 1004 of shredded tobacco circumscribed by a wrapper 1006. Further, the aerosol-generating article 1000 comprises a substantially cylindrical mouthpiece 1008 comprising a segment 1010 of a cellulosic filtration material circumscribed by a plug wrap 1012.

[0260] The mouthpiece 1008 is attached to the aerosol-generating element 1002 by a band 1014 of tipping paper. Perforations 1016 formed through the tipping paper and the plug wrap are provided to enable admission of ventilation air into the segment 1010 when the consumer draws upon the mouthpiece 1008 during use. The aerosol-generating article 1000 has a length of 70 millimetres and an external diameter of 7.6 millimetres.

[0261] The segment 1010 is in the form of a plug element comprising a cellulosic filtration material. One example of a suitable cellulosic filtration material comprises viscose fibres and an additive coating applied to the viscose fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis. A further example of a suitable cellulosic filtration material comprises cotton fibres and an additive coating applied to the cotton fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis.

[0262] The aerosol-generating article 10 shown in FIG. 2 comprises a rod 12 of aerosol-generating substrate 12 and a downstream section 14 at a location downstream of the rod 12 of aerosol-generating substrate. Further, the aerosol-generating article 10 comprises an upstream section 16 at a location upstream of the rod 12 of aerosol-generating substrate. Thus, the aerosol-generating article 10 extends from an upstream or distal end 18 to a downstream or mouth end 20, and has an overall length of about 45 millimetres.

[0263] The downstream section 14 comprises a support element 22 located immediately downstream of the rod 12 of aerosol-generating substrate, the support element 22 being in longitudinal alignment with the rod 12. In the embodiment of FIG. 2, the upstream end of the support element 18 abuts the downstream end of the rod 12 of aerosol-generating substrate. In addition, the downstream section 14 comprises an aerosol-cooling element 24 located immediately downstream of the support element 22, the aerosol-cooling element 24 being in longitudinal alignment with the rod 12 and the support element 22. In the embodiment of FIG. 1, the upstream end of the aerosol-cooling element 24 abuts the downstream end of the support element 22. In the embodiment of FIG. 2, the support element 22 and the aerosol-cooling element 24 together define an intermediate hollow section 50 of the aerosol-generating article 10.

[0264] The support element 22 comprises a first hollow tubular segment 26. The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made of filtration material. The first hollow tubular segment 26 defines an internal cavity 28 that extends all the way from an upstream end 30 of the first hollow tubular segment to an downstream end 32 of the first hollow tubular segment 20. The internal cavity 28 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 28.

[0265] The first hollow tubular segment 26 has a length of about 8 millimetres, an external diameter of about 7.25 millimetres, and an internal diameter of about 1.9 millimetres. Thus, a thickness of a peripheral wall of the first hollow tubular segment 26 is about 2.67 millimetres.

[0266] The aerosol-cooling element 24 comprises a second hollow tubular segment 34. The second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made of filtration material. The second hollow tubular segment 34 defines an internal cavity 36 that extends all the way from an upstream end 38 of the second hollow tubular segment to a downstream end 40 of the second hollow tubular segment 34. The internal cavity 36 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity 36.

[0267] The second hollow tubular segment 34 has a length of about 8 millimetres, an external diameter of about 7.25 millimetres, and an internal diameter of about 3.25 millimetres. Thus, a thickness of a peripheral wall of the second hollow tubular segment 34 is about 2 millimetres. Thus, a ratio between the internal diameter of the first hollow tubular segment 26 and the internal diameter of the second hollow tubular segment 34 is about 0.75.

[0268] The aerosol-generating article 10 comprises a ventilation zone 60 provided at a location along the second hollow tubular segment 34. In more detail, the ventilation zone is provided at about 2 millimetres from the upstream end of the second hollow tubular segment 34. A ventilation level of the aerosol-generating article 10 is about 25 percent.

[0269] In the embodiment of FIG. 2, the downstream section 14 further comprises a mouthpiece element 42 at a location downstream of the intermediate hollow section 50. In more detail, the mouthpiece element 42 is positioned immediately downstream of the aerosol-cooling element 24. As shown in the drawing of FIG. 2, an upstream end of the mouthpiece element 42 abuts the downstream end 40 of the aerosol-cooling element 18.

[0270] The mouthpiece element 42 is provided in the form of a cylindrical plug element 44 comprising a cellulosic filtration material. One example of a suitable cellulosic filtration material comprises viscose fibres and an additive coating applied to the viscose fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis. A further example of a suitable cellulosic filtration material comprises cotton fibres and an additive coating applied to the cotton fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis.

[0271] The mouthpiece element 42 has a length of about 12 millimetres and an external diameter of about 7.25 millimetres.

[0272] The rod 12 comprises an aerosol-generating substrate of one of the types described above.

[0273] The rod 12 of aerosol-generating substrate has an external diameter of about 7.25 millimetres and a length of about 12 millimetres.

[0274] The aerosol-generating article 10 further comprises an elongate susceptor 46 within the rod 12 of aerosol-generating substrate. In more detail, the susceptor 46 is arranged substantially longitudinally within the aerosol-generating substrate, such as to be approximately parallel to the longitudinal direction of the rod 12. As shown in the drawing of FIG. 2, the susceptor 46 is positioned in a radially central position within the rod and extends effectively along the longitudinal axis of the rod 12. In more detail, the susceptor 46 is in thermal contact with the aerosol-generating substrate. The susceptor 46 extends all the way from an upstream end to a downstream end of the rod 12. In effect, the susceptor 46 has substantially the same length as the rod 12 of aerosol-generating substrate.

[0275] In more detail, in the embodiment of FIG. 2, the susceptor 46 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.

[0276] The upstream section 16 comprises an upstream element 48 located immediately upstream of the rod 12 of aerosol-generating substrate, the upstream element 48 being in longitudinal alignment with the rod 12. In the embodiment of FIG. 2, the downstream end of the upstream element 48 abuts the upstream end of the rod 12 of aerosol-generating substrate. This advantageously prevents the susceptor 46 from being dislodged. Further, this ensures that the consumer cannot accidentally contact the heated susceptor 46 after use.

[0277] The upstream element 48 comprises a segment of material 50 in the form of a cylindrical plug of filtration material and a first wrapper 52 circumscribing the segment of material 50. The segment of material 50 has a length of about 5 millimetres. The RTD of the segment of material 50 is about 30 millimetres H.sub.2O.

[0278] The aerosol-generating article 10 further comprises a combining wrapper 54 which attaches the upstream element 48 to the remaining components of the aerosol-generating article. In the embodiment of FIG. 2 a single combining wrapper 54 is depicted, which circumscribes and holds together the upstream element 48, the rod 12, and the downstream section 14 to form the aerosol-generating article.

[0279] However, it will be clear that alternative configurations are possible, wherein two or more combining wrappers are employed to assemble the different components of the aerosol-generating article. For example, a first combining wrapper could be used to attach the support element 22 to the aerosol-cooling element 24, and the resulting assembly could then be attached by means of a second combining wrapper to the upstream section 16 and the rod 12. The resulting combination of components could then be attached to the mouthpiece element 42 By means of a tipping wrapper. As shown in the drawing of FIG. 1, the aerosol-generating article 10 further comprises a wrapper 70 circumscribing the rod 12 of aerosol-generating substrate. The wrapper 70 is separate and distinct from the first wrapper 52 circumscribing the segment of material 50. Neither one of the first wrapper 52 and the wrapper 70 comprises a metallic foil.

[0280] In the aerosol-generating article 10 of FIG. 2, one or more of the first hollow tubular segment 26 of the support element 22, the second hollow tubular segment 34 of the aerosol-cooling element 24, and the segment of material 50 of the upstream element 48 may be made of the same material according to the present invention used in the mouthpiece element 42.

[0281] The aerosol-generating article 100 shown in FIG. 3 comprises a rod of aerosol-generating substrate 112 and a downstream section 114 at a location downstream of the rod 112 of aerosol-generating substrate. Additionally, the aerosol-generating article 100 comprises an upstream section 116. Thus, the aerosol-generating article 100 extends from an upstream or distal end 118which substantially coincides with an upstream end of the upstream section 116to a downstream or mouth end 120, which coincides with a downstream end of the downstream section 114. The downstream section 114 comprises a hollow tubular element 122 and a mouthpiece element 150. The upstream section 116 comprises an upstream plug element 124.

[0282] The aerosol-generating article 100 has an overall length of about 45 millimetres and an outer diameter of about 7.2 mm.

[0283] The rod of aerosol-generating substrate 112 comprises a shredded tobacco material. The rod of aerosol-generating substrate 112 comprises 150 milligrams of a shredded tobacco material comprising from 13 percent by weight to 16 percent by weight of glycerine. The density of the aerosol-generating substrate is about 300 mg per cubic centimetre. The RTD of the rod of aerosol-generating substrate 112 is between about 6 to 8 mm H.sub.2O. The rod of aerosol-generating substrate 112 is individually wrapped by a plug wrap (not shown).

[0284] The hollow tubular element 122 is located immediately downstream of the rod 112 of aerosol-generating substrate, the hollow tubular element 122 being in longitudinal alignment with the rod 112. The upstream end of the hollow tubular element 122 abuts the downstream end of the rod 112 of aerosol-generating substrate.

[0285] The hollow tubular element 122 defines a hollow section of the aerosol-generating article 110. The hollow tubular element 122 does not substantially contribute to the overall RTD of the aerosol-generating article. In more detail, an RTD of the hollow tubular element 122 is about 0 mm H.sub.2O.

[0286] As shown in FIG. 3, the hollow tubular element 122 is provided in the form of a hollow cylindrical tube made of cardboard. The hollow tubular element 122 defines an internal cavity that extends all the way from an upstream end of the hollow tubular element 122 to a downstream end of the hollow tubular element 122. The internal cavity is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity.

[0287] The hollow tubular element 122 has a length of about 21 millimetres, an external diameter of about 7.2 millimetres, and an internal diameter of about 6.7 millimetres. Thus, a thickness of a peripheral wall of the hollow tubular element 122 is about 0.25 millimetres.

[0288] The aerosol-generating article 100 comprises a ventilation zone 160 provided at a location along the hollow tubular element 122. The ventilation zone 160 comprises a circumferential row of openings or perforations circumscribing the hollow tubular element 122. The perforations of the ventilation zone 160 extend through the wall of the hollow tubular element 122, in order to allow fluid ingress into the internal cavity from the exterior of the article 100. A ventilation level of the aerosol-generating article 10 is about 16 percent.

[0289] On top of a rod 112 of aerosol-generating substrate and a downstream section 14 at a location downstream of the rod 12, the aerosol-generating article 100 comprises an upstream section 140 at a location upstream of the rod 112. As such, the aerosol-generating article 10 extends from a distal end 116 substantially coinciding with an upstream end of the upstream section 140 to a mouth end or downstream end 118 substantially coinciding with a downstream end of the downstream section 114.

[0290] As described briefly above, the upstream section 116 comprises an upstream plug element 124 located immediately upstream of the rod 112 of aerosol-generating substrate, the upstream plug element 124 being in longitudinal alignment with the rod 112. The downstream end of the upstream plug element 124 abuts the upstream end of the rod 112 of aerosol-generating substrate. The upstream plug element 124 is provided in the form of a hollow cylindrical plug of filtration material having a wall thickness of about 1 mm and defining an upstream internal cavity. The upstream element 124 has a length of about 5 millimetres. An external diameter of the upstream plug element 124 is about 7.1 mm. An internal diameter of the upstream plug element 42 is about 5.1 mm.

[0291] The mouthpiece element 150 extends from the downstream end of the hollow tubular element 122 to the downstream or mouth end of the aerosol-generating article 100. The mouthpiece element 150 has a length of about 7 mm. An external diameter of the mouthpiece element 150 is about 7.2 mm.

[0292] The mouthpiece element 150 is provided in the form of a cylindrical plug element comprising a cellulosic filtration material. One example of a suitable cellulosic filtration material comprises viscose fibres and an additive coating applied to the viscose fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis. A further example of a suitable cellulosic filtration material comprises cotton fibres and an additive coating applied to the cotton fibres, the additive coating comprising at least 5 percent by weight of exogenous lignin on a dry weight basis.

[0293] In the aerosol-generating article 100 of FIG. 3, the plug element 124 of the upstream section 116 may be made of the same material according to the present invention used in the mouthpiece element 150.

[0294] 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 A5% 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.