AN AEROSOL-GENERATING ARTICLE COMPRISING A MOUTHPIECE ASSEMBLY

Abstract

An aerosol-generating article is provided for producing an inhalable aerosol upon heating, the article including: a mouthpiece assembly including first, second, and third tubes; and an aerosol-forming substrate, in which the first tube abuts a downstream end face of the second tube, and the third tube abuts an upstream end face of the second tube, an internal diameter of the second tube is smaller than an internal diameter of the first tube and of the third tube, the internal diameter of the first tube is between 3 mm and 8 mm, a ratio of the internal diameter of the first tube to the internal diameter of the second tube is between 1.2 and 5, a ratio of the internal diameter of the first tube to the internal diameter of the third tube is between 0.5 and 2, and the second tube is a cellulose acetate tube.

Claims

1.-12. (canceled)

13. An aerosol-generating article for producing an inhalable aerosol upon heating, the aerosol-generating article comprising: a mouthpiece assembly comprising a first tube, a second tube, and a third tube; and an aerosol-forming substrate, wherein the first tube abuts a downstream end face of the second tube, and the third tube abuts an upstream end face of the second tube, wherein an internal diameter of the second tube is smaller than an internal diameter of the first tube, wherein the internal diameter of the second tube is smaller than an internal diameter of the third tube, wherein the internal diameter of the first tube is between 3 mm and 8 mm, wherein a ratio of the internal diameter of the first tube to the internal diameter of the second tube is between 1.2 and 5, wherein a ratio of the internal diameter of the first tube to the internal diameter of the third tube is between 0.5 and 2, and wherein the second tube is a cellulose acetate tube.

14. The aerosol-generating article according to claim 13, wherein the internal diameter of the first tube is larger than the internal diameter of the third tube.

15. The aerosol-generating article according to claim 13, wherein the first tube is a cellulose acetate tube.

16. The aerosol-generating article according to claim 13, wherein the third tube is a cellulose acetate tube.

17. The aerosol-generating article according to claim 13, wherein a ratio of the internal diameter of the third tube to the internal diameter of the second tube is between 1.5 and 5.

18. The aerosol-generating article according to claim 13, wherein the first tube has an internal diameter of 4 mm.

19. The aerosol-generating article according to claim 13, wherein the second tube has an internal diameter of between 1 mm and 3 mm.

20. The aerosol-generating article according to claim 13, wherein the third tube has an internal diameter of between 3 mm and 8 mm.

21. The aerosol-generating article according to claim 13, further comprising a ventilation zone.

22. The aerosol-generating article according to claim 21, wherein the ventilation zone comprises one or more rows of ventilation perforations.

23. The aerosol-generating article according to claim 22, wherein the one or more rows of ventilation perforations are formed through a wall of at least one of the first tube, the second tube, and the third tube.

Description

[0250] Specific embodiments will now be described, by way of example only, with reference to the following examples and the accompanying drawings, in which:

[0251] FIG. 1 shows schematically an exploded sectional side view of a mouthpiece assembly for an aerosol-generating article according to the invention;

[0252] FIG. 2 shows schematically a sectional side view of the mouthpiece assembly of FIG. 1;

[0253] FIG. 3 shows schematically a sectional side view of a mouthpiece assembly for an aerosol-generating article according to the invention;

[0254] FIG. 4 shows schematically a sectional side view of a mouthpiece assembly for an aerosol-generating article according to the invention;

[0255] FIG. 5 shows schematically a sectional side view of an aerosol-generating article according to the invention; and

[0256] FIG. 6 shows schematically a sectional side view of an aerosol-generating article according to the invention.

[0257] Some aerosol-generating articles heat rather than combust an aerosol-generating substrate, such as a tobacco-containing substrate. An aerosol may be generated in such aerosol-generating articles through the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, heat is transferred from the heat source to the aerosol-generating substrate, which may release volatile compounds. These volatile compounds are entrained in air drawn through the aerosol-generating article by a user. As the released volatile compounds cool, they condense to form an aerosol. The aerosol may be inhaled by a user through a mouthpiece.

[0258] It would be desirable to provide an aerosol-generating article that can cause more of the released volatile compounds to condense, which may provide for increased flow of aerosol through the mouthpiece. This may provide a better user experience.

[0259] FIGS. 1 and 2 show schematically an example of a mouthpiece assembly 110 for an aerosol-generating article 112 for producing an inhalable aerosol upon heating.

[0260] The mouthpiece assembly 110 has a downstream end 114 and an upstream end 116. The downstream end 114 of the mouthpiece assembly 110 is the end region of the mouthpiece assembly 110 towards which the aerosol flows after it has been produced. The upstream end 116 of the mouthpiece assembly 110 is the end region of the mouthpiece assembly 110 that is opposite to and/or distal from the downstream end 114. In some examples, the upstream end 116 of the mouthpiece assembly 110 is the end region of the mouthpiece assembly through which the produced aerosol flows before it flows through the downstream end 114.

[0261] In other words, in use, aerosol that has been generated flows from the upstream end 116 of the mouthpiece assembly 110 and towards the downstream end 114 of the mouthpiece assembly 10.

[0262] In the example shown in FIGS. 1 and 2, the mouthpiece assembly 110 includes a first tube 118, a second tube 120 and a third tube 122. As is shown in FIGS. 1 and 2, in this example, the second tube 120 is positioned in between the first tube 118 and the third tube 122.

[0263] In this example, the first tube 118, the second tube 120 and the third tube 122 are each formed from cellulose acetate. In other words, in the example of FIGS. 1 and 2, the first tube 118, the second tube 120 and the third tube 122 are each a cellulose acetate tube.

[0264] In FIG. 1, the first tube 118, the second tube 120 and the third tube 122 are separated from one another. In FIG. 2, the first tube 118, the second tube 120 and the third tube 122 are provided in a configuration in which the first tube 118 and the third tube 122 abut the second tube 120, as will be explained.

[0265] Each of the first tube 118, the second tube 120 and the third tube 122 has a downstream end face and an upstream end face. The downstream end face of a tube 118, 120, 122 is the end face that is located towards the downstream end 114 of the mouthpiece assembly 10. The upstream end face of a tube 118, 120, 122 is the end face that is located towards the upstream end 116 of the mouthpiece assembly 10.

[0266] The first tube 118 has a downstream end face 124 and an upstream end face 126. The second tube 120 has a downstream end face 128 and an upstream end face 130. The third tube 122 has a downstream end face 132 and an upstream end face 134.

[0267] In the example shown in FIGS. 1 and 2, the first tube 118 and the second tube 120 are arranged such that the upstream end face 124 of the first tube 118 abuts the downstream end face 126 of the second tube 120.

[0268] In the example shown in FIGS. 1 and 2, the second tube 120 and the third tube 122 are arranged such that the downstream end face 134 of the third tube 122 abuts the upstream end face 128 of the second tube 120.

[0269] In this example, the first tube 118 abuts the second tube 120, and the third tube 122 abuts the second tube 120. In other examples, the first, second and third tubes 118, 120, 122 may be connected or attached to one another. The first, second and third tubes 118, 120, 122 may be attached to one another by, for example, one or more fixing elements, or an adhesive.

[0270] The first tube 118 may be considered as a “mouthpiece” tube because, in use, the first tube 118 is the component of the mouthpiece assembly 110 that may come into contact with a user's mouth.

[0271] The second tube 120 may be considered as a “venturi” tube because, in use, the second tube 120 may provide a constriction in the flow path of the produced aerosol, as will be explained.

[0272] The third tube 122 may be considered as a “diffuser” tube because, in use, the third tube 122 may provide space for generated aerosol to combine with air.

[0273] The first tube 118 has a first tube internal diameter 136. The second tube has a second tube internal diameter 138. The third tube 122 has a third tube internal diameter 140. In the example shown in FIGS. 1 and 2, each of the first tube 118, the second tube 120 and the third tube 122 has a uniform internal diameter that is the same along the whole length of each tube.

[0274] It is to be understood that an internal diameter of the first tube 118, the second tube 120 or the third tube 122 is the diameter or distance between the internal walls of the tube.

[0275] The internal diameter of the second tube 120 is smaller than the internal diameter of the first tube 118. In other words, the second tube internal diameter 138 is smaller than the first tube internal diameter 136.

[0276] The internal diameter of the second tube 120 is smaller than the internal diameter of the third tube 122. In other words, the second tube internal diameter 138 is smaller than the third tube internal diameter 140.

[0277] In some examples, such as in the example shown in FIGS. 1 and 2, the internal diameter of the first tube 118 is larger than the internal diameter of the third tube 122. In other words, in some examples, the first tube internal diameter 136 is larger than the third tube internal diameter 140.

[0278] In the example of the mouthpiece assembly 110 shown in FIGS. 1 and 2, the first tube internal diameter 136 is 4 mm, the second tube internal diameter 138 is 2.5 mm, and the third tube internal diameter is 3.5 mm.

[0279] In the example of the mouthpiece assembly 110 shown in FIGS. 1 and 2, the first tube 118 has a length of 5 mm, the second tube 120 has a length of 5 mm, and the third tube 122 has a length of 5 mm.

[0280] FIG. 3 shows schematically another example of a mouthpiece assembly 210 for an aerosol-generating article 112 for producing an inhalable aerosol upon heating.

[0281] The example of FIG. 3 has the same components as the example shown in FIGS. 1 and 2, and the components are numbered correspondingly.

[0282] However, the mouthpiece assembly 210 shown in FIG. 3 has two differences over the mouthpiece assembly 110 shown in FIGS. 1 and 2.

[0283] Firstly, in the mouthpiece assembly 210 of FIG. 3, the internal diameter of the first tube 118 is not uniform along its whole length. Instead, the first tube internal diameter 136 changes along the length of the first tube 118. The internal diameter of the first tube 118 increases from the upstream end face 124 of the first tube 118 to the downstream end face 126 of the first tube 118. In other words, in the example shown in FIG. 3, the first tube internal diameter 136 is larger at the downstream end face 126 of the first tube 118 than it is at the upstream end face 124 of the first tube 118.

[0284] Secondly, in the mouthpiece assembly 210 of FIG. 3, the internal diameter of the third tube 122 is not uniform along its whole length. Instead, the third tube internal diameter 140 changes along the length of the third tube 122. The internal diameter of the third tube 122 decreases from the upstream end face 132 of the third tube 122 to the downstream end face 134 of the third tube 122. In other words, in the example shown in FIG. 3, the third tube internal diameter 140 is smaller at the downstream end face 134 of the third tube 122 than it is at the upstream end face 132 of the third tube 122.

[0285] In the example of FIG. 3, the internal diameter of the first tube 118 is the mean diameter or distance between the internal walls of the first tube 118. The internal diameter of the third tube 122 is the mean diameter or distance between the internal walls of the third tube 122. The internal diameter of the second tube 120 is the diameter or distance between the internal walls of the second tube 120.

[0286] FIG. 4 shows schematically another example of a mouthpiece assembly 310 for an aerosol-generating article 112 for producing an inhalable aerosol upon heating.

[0287] The example of FIG. 4 has the same components as the example shown in FIGS. 1 and 2, and the components are numbered correspondingly.

[0288] However, the mouthpiece assembly 310 shown in FIG. 4 has a difference over the mouthpiece assembly 110 shown in FIGS. 1 and 2.

[0289] In the mouthpiece assembly 310 of FIG. 4, the internal diameter of the first tube 118 is not uniform along its whole length. Instead, the first tube internal diameter 136 changes along the length of the first tube 118. The internal diameter of the first tube 118 increases from the upstream end face 124 of the first tube 118 to the downstream end face 126 of the first tube 118. In other words, in the example shown in FIG. 4, the first tube internal diameter 136 is larger at the downstream end face 126 of the first tube 118 than it is at the upstream end face 124 of the first tube 118.

[0290] In the example of FIG. 4, the internal diameter of the first tube 118 is the mean diameter or distance between the internal walls of the first tube 118. The internal diameter of the second tube 120 is the diameter or distance between the internal walls of the second tube 120. The internal diameter of the third tube 122 is the diameter or distance between the internal walls of the second tube 120.

[0291] FIG. 5 shows schematically an example of an aerosol-generating article 112. In the example of FIG. 5, the aerosol-generating article 112 includes the mouthpiece assembly 110 that is shown schematically in FIGS. 1 and 2.

[0292] The aerosol-generating article 112 also includes an aerosol-forming substrate 142. The aerosol-forming substrate includes components that are vaporisable to form an aerosol. In the example of FIG. 5, the aerosol-forming substrate 142 is a liquid nicotine formulation. In another example, the aerosol-forming substrate 142 may be a different formulation. In some examples, the aerosol-forming substrate 142 may be a gel formulation.

[0293] In the example shown in FIG. 5, the aerosol-generating article 112 includes a fourth tube 144. The example of Figure also includes a fifth tube 146. The fourth tube 144 is arranged concentrically with the first tube 118, the second tube 120 and the third tube 122. The fifth tube 146 is arranged concentrically with the first tube 118, the second tube 120 and the third tube 122.

[0294] In this example, the fourth tube 144 is provided in a central opening of the third tube 122 and the fifth tube 146. In another example, the fourth tube 144 may be provided only in a central opening of the third tube 122. The fourth tube 144 abuts the third tube 122 and the fifth tube 146. In another example, the fourth tube 144 is affixed to the third tube 122 and the fifth tube 146 by a one or more fixing elements, or an adhesive.

[0295] In some examples, the fourth tube 144 may be formed from a material that is substantially impermeable to air. For example, the fourth tube 144 may be formed from cardboard.

[0296] In the example shown in FIG. 5, the fifth tube 146 abuts the third tube 122. In another example, the third tube 122 and the fifth tube 146 may be connected or attached to one another. The third tube 122 and the fifth tube 146 may be attached to one another by, for example, one or more fixing elements, or an adhesive. The third tube 122 and the fifth tube 146 can be arranged such that an upstream end face of the fifth tube 146 abuts the downstream end face 132 of the third tube 122. In the example of FIG. 5, the fifth tube 146 has the same internal diameter as the third tube 122. Therefore, the fifth tube 146 has an internal diameter of 3.5 mm. In another example, the fifth tube 146 may have an internal diameter that is different than the internal diameter of the third tube 122.

[0297] In the example of FIG. 5, a space 148 is defined in the aerosol-generating article 112. The space 148 is located between the fifth tube 146 and the aerosol-forming substrate 142. In an example that doesn't include a fifth tube 146, the space 148 may be defined between the third tube 122 and the aerosol-forming substrate 142. In some examples, the space 148 may provide an area that allows vaporised volatile compounds of the aerosol-forming substrate 142 to cool and nucleate into an aerosol.

[0298] The aerosol-generating article 112 shown in FIG. 5 also includes an upstream element 150. The upstream element 150 is positioned upstream of the aerosol-forming substrate 142. In this example, the upstream element 150 abuts the aerosol-forming substrate 142. In the example of FIG. 5, the upstream element 150 is an annular plug of fibrous filtration material. The upstream element 150 of FIG. 5 has a length of 5 mm. The RTD of the upstream element 150 of FIG. 5 is about 130 millimetres H2O.

[0299] In the example of FIG. 5, the aerosol-generating article 112 also includes a wrapper 152. The wrapper 152 is provided on the external surface area of the components of the aerosol-generating article 112. The wrapper 152 partially encloses at least some of the components of the aerosol-generating article 112. In this example, the wrapper 152 partially encloses all of the components of the aerosol-generating article 112. As is shown in FIG. 5, in some examples, the wrapper 152 fully encloses all of the components of the aerosol-generating article 112 except for the downstream end face of the first tube 118 and an upstream end face of the upstream element 150.

[0300] The example of the aerosol-generating article 112 shown in FIG. 5 also includes a ventilation zone. The ventilation zone is provided at a location along the aerosol-generating article 112. In this example, the ventilation zone is provided in the region of the third tube 122. In this example, the ventilation zone is a row of circumferential perforations 154 formed through the wrapper 152 and the third tube 122. The perforations 154 allow for air to flow from outside of the aerosol-generating article 112, through the perforations 154, and into the opening defined by the third tube 122.

[0301] FIG. 6 shows schematically an alternative example of an aerosol-generating article 212. In the example of FIG. 6, the aerosol-generating article 212 includes the mouthpiece assembly 110 that is shown schematically in FIGS. 1 and 2.

[0302] In the example of the aerosol-generating article 212 shown in FIG. 6, the structure of the upstream end 116 is different to the structure of upstream end 116 of the example of the aerosol-generating article 112 shown in FIG. 5, as will be explained.

[0303] In the example of FIG. 6, the upstream element 150 is disposed immediately upstream of the aerosol-forming substrate 142 and abuts the aerosol-forming substrate 142. The upstream element 150 comprises an annular plug comprising fibrous filtration material. In this example, the upstream element 150 comprises an annular plug of cellulose acetate circumscribed by a stiff wrapper. In the example of FIG. 6, the upstream element 150 has a length of 5 mm and the RTD of the upstream element 150 is 30 millimetres H2O.

[0304] In the example of FIG. 6, the aerosol generating article 212 also includes a recess 156. The recess 156 extends from the upstream end 116 of the aerosol-generating article 212, through the upstream element 150 and through at least a portion of the aerosol-forming substrate 142.

[0305] The recess 156 is located along the central axis of the aerosol-generating article 212. In the example of FIG. 6, the recess 156 has a circular cross sectional shape. In the example shown, the recess 156 extends the full length of both the upstream element 150 and the aerosol-forming substrate 142 by passing through both the annular plug comprising fibrous filtration material of the upstream element 150, and the annular plug of porous medium of the aerosol-forming substrate 142. In this example, the recess 156 has a length of 15 mm, corresponding to the combined length of the upstream element 150 and the aerosol-forming substrate 142. In the example of FIG. 6, the recess has a diameter of 4 mm.

[0306] The aerosol generating article 212 of FIG. 6 has a wrapper 152. The wrapper 152 is provided on the longitudinal inner surface of the recess. The wrapper 152 extends the full length of the recess 156 and is provided on the entire longitudinal inner surface of the recess 156.

[0307] In the example shown in FIG. 6, the downstream end of the recess 156 is defined by the wrapper 152. This is achieved by mechanically folding the wrapper 152 at the downstream end of the recess 156.

[0308] The wrapper 152 extends out of the upstream end of the recess 156 and over the upstream end of the aerosol-generating article 212. The wrapper 152 also extends over the entire outer surface of the aerosol generating article 212. In this way, the wrapper 212 acts to connect the various components of the aerosol-generating article 212.

[0309] The wrapper 152 may include a cellulose based paper layer co-laminated with a layer of aluminium foil. In this example, the wrapper 152 is arranged so that the paper layer is on the outer surface of the aerosol-generating article 212.

[0310] Use of the aerosol-generating article 112 shown in FIG. 5 will now be described.

[0311] In use, the aerosol-generating article 112 is inserted into an aerosol-generating device. When the aerosol-generating article 112 is in its inserted position in the aerosol-generating device, a heating element of the aerosol-generating device is adjacent the aerosol-forming substrate 142. When the aerosol-generating device is activated, the heating element heats up. The increased temperature of the heating element heats the aerosol-forming substrate 142. Volatile compounds in the aerosol-forming substrate 142 then vaporise to form a vapour, which cools and nucleates into an aerosol in the space 148 between the fifth tube 146 and the aerosol-forming substrate 142.

[0312] As the user draws on (i.e. inhales from) the downstream end 114 of the aerosol-generating device 112, air is sucked into the fourth tube 144 through the perforations 154 due to the resulting pressure change inside the aerosol-generating device 112. The air that is drawn into the aerosol-generating article 112 though the perforations 154 entrains aerosol from the space 148. The fourth tube 144 prevents any entrained aerosol from being lost into the structure of the third tube 122 or the fifth tube 146.

[0313] The air with entrained aerosol then passes through the third tube 122 and into the second tube 120 due to the pressure regime inside the aerosol-generating article 112. The narrower internal diameter of the second tube 120 provides a Venturi effect, which causes the air with entrained aerosol to be compressed whilst the air is in the second tube 120.

[0314] Due to the user inhaling from the downstream end 114 of the aerosol-generating device 112, the air with entrained aerosol then flows out of the second tube 120 and into the first tube 118. When the air with entrained aerosol is drawn out of the second tube 120 and into the first tube 118, the wider diameter of the first tube 118 allows the air to expand and cool down, which causes more droplets to form in the aerosol. The aerosol can then subsequently be inhaled by the user through the downstream end of the first tube 118.

[0315] In normal use of the aerosol-generating article 112, the user inhales aerosol by engaging their mouth with the first tube 118 at the downstream end 114 of the aerosol-generating article 112. Since, in the example of FIG. 5, the first tube 118 is tube that is formed from cellulose acetate, the first tube 118 is firm and resilient, which provides an improved user experience.

[0316] The first tube 118 being formed from a stiff material such as cellulose acetate also ensures that the user can properly handle the aerosol-generating article 112.

[0317] The first tube 118 being formed from a material that is substantially impermeable to water, such as cellulose acetate, is also less sensitive to humidity from a user's mouth.

[0318] 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% 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.