Abstract
An aerosol-generating article is provided, including: a fluid guide having proximal and distal ends, and an inner longitudinal region including an inner longitudinal passageway between the distal end and the proximal end thereof, such that fluid can travel from the distal end to the proximal end, the fluid guide including a barrier between the inner and outer longitudinal passageways; a tubular element including a gel or a porous medium or a thread loaded or any combination, the gel or the medium or the thread or the combination includes an active agent, the tubular element having proximal and distal ends and disposed to a distal side of the fluid guide; an aperture to allow fluid to pass to the tubular element and exit the article at the proximal end; a combustible heat source at the distal end of the article; and a cavity between the fluid guide and the tubular element.
Claims
1.-16. (canceled)
17. An aerosol-generating article for generating an aerosol, the aerosol-generating article comprising: a fluid guide configured to allow movement of fluid, the fluid guide having a proximal end, a distal end, and an inner longitudinal region, where the inner longitudinal region comprises an inner longitudinal passageway between the distal end and the proximal end thereof, such that fluid can travel from the distal end of the fluid guide to the proximal end of the fluid guide, wherein the fluid guide comprises a barrier between the inner longitudinal passageway and an outer longitudinal passageway; a tubular element comprising a gel or a porous medium loaded with the gel or a thread loaded with the gel or any combination thereof, the gel or the porous medium loaded with the gel or the thread loaded with the gel or any combination thereof comprises an active agent, the tubular element having a proximal end and a distal end, the tubular element being disposed to a distal side of the fluid guide in the aerosol-generating article; at least one aperture configured to allow fluid to pass to the tubular element and exit the aerosol-generating article at the proximal end; a combustible heat source disposed at the distal end of the aerosol-generating article; and a cavity disposed between the fluid guide and the tubular element, configured to allow fluid to mix and contact the tubular element.
18. The aerosol-generating article according to claim 17, further comprising a cavity between the combustible heat source and the tubular element.
19. The aerosol-generating article according to claim 17, further comprising a susceptor.
20. The aerosol-generating article according to claim 17, wherein the at least one aperture is disposed in an outer passageway of the fluid guide.
21. The aerosol-generating article according to claim 17, wherein the at least one aperture is disposed in the cavity between the fluid guide and the tubular element.
22. The aerosol-generating article according to claim 17, wherein the at least one aperture is disposed in a side wall of the tubular element.
23. The aerosol-generating article according to claim 17, wherein the tubular element further comprises a wrapper.
24. The aerosol-generating article as claimed in claim 19, wherein the susceptor is disposed between the combustible heat source and the tubular element.
25. The aerosol-generating article as claimed in claim 24, wherein the susceptor has peripheral portions extending along a longitudinal axis of the aerosol-generating article, in proximity to a longitudinal circumference of the aerosol-generating article, in a proximal direction.
26. The aerosol-generating article as claimed in claim 24, wherein the susceptor has peripheral portions extending along a longitudinal axis of the aerosol-generating article, in proximity to a longitudinal circumference of the aerosol-generating article, in a distal direction.
27. The aerosol-generating article as claimed in claim 17, wherein the active agent is nicotine.
28. The aerosol-generating article according to claim 19, wherein the susceptor is disposed longitudinally within the tubular element.
29. A method of manufacturing an aerosol-generating article as claimed in claim 17, the method comprising the steps of: linearly positioning, in order, a fluid guide, a tubular element, and a combustible heat source, on a web of wrapping material, such that there is a gap between a proximal end of tubular element and a distal end of fluid guide, to create a cavity in the aerosol-generating article; and wrapping the web of wrapping material around the fluid guide, the tubular element, and the combustible heat source to form the aerosol-generating article.
30. The method according to claim 29, further comprising the step of linearly positioning, in order, the fluid guide, the tubular element, a susceptor, and the combustible heat source.
Description
[0372] Reference will now be made to the drawings, which 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 of this disclosure. Like numbers used in the figures refer to like components, steps and the like. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number. In addition, the use of different numbers to refer to components in different figures is not intended to indicate that the different numbered components cannot be the same or similar to other numbered components. The figures are presented for purposes of illustration and not limitation. Schematic drawings presented in the figures are not necessarily to scale.
[0373] FIG. 1 shows a cross-sectional view of tubular element comprising a susceptor and a heat source.
[0374] FIG. 2 shows a cross-sectional view of another tubular element comprising a susceptor and heat source.
[0375] FIGS. 3-6 are schematic sectional views of various embodiments of aerosol generating articles.
[0376] FIG. 7 is a schematic side view of an aerosol generating article.
[0377] FIG. 8 is a schematic perspective view of an embodiment of the aerosol generating article depicted in FIG. 7 in which a section of the wrapper is removed for illustrative purposes.
[0378] FIG. 9 is a schematic side view of an aerosol generating article.
[0379] FIG. 10 is a schematic side view of an embodiment of the aerosol generating article depicted in FIG. 9 with a portion of wrapper removed.
[0380] FIG. 11 is a schematic view of a fluid guide of a sample aerosol generating article.
[0381] FIG. 12 is a schematic view of sample aerosol generating article in which the fluid guide depicted in FIG. 11 is inserted.
[0382] FIG. 13 shows a cross-sectional view, sectioned along the length of an aerosol generating article.
[0383] FIGS. 14, 15 and 16 show a perspective view and two cross-sectional views of a tubular element for an aerosol generating article.
[0384] FIG. 17 shows part of a manufacturing process for the tubular element for an aerosol generating article.
[0385] FIG. 18 shows part of a further manufacturing process for the tubular element for an aerosol generating article.
[0386] FIG. 19 shows part of an alternative manufacturing process for the tubular element for an aerosol generating article.
[0387] FIG. 20 shows an aerosol generating system comprising an electrically heated aerosol generating device and an aerosol generating article.
[0388] FIGS. 21, 22 and 23 show cross-sectional views of further tubular elements for an aerosol generating article.
[0389] FIG. 24 shows a cross-sectional view along the length of an aerosol generating article.
[0390] FIGS. 25-29 show schematic cross-sectional views of various tubular elements.
[0391] FIG. 30-34 show schematic cross-sectional views of various tubular elements.
[0392] FIG. 35 shows a schematic cross-sectional view (cut proximal to distal) of an aerosol generating article of the present invention.
[0393] FIG. 36 shows a cross-sectional view of a fluid guide, suitable for use in the present invention.
[0394] FIG. 37 shows a cross-sectional view (cut proximal to distal) of an aerosol generating article.
[0395] FIGS. 38-44 show schematic cross-sectional views (cut proximal to distal) of various fluid guides of the present invention.
[0396] FIG. 45 shows a cross-sectional view of a tubular element comprising a susceptor.
[0397] FIG. 46 shows a cross-sectional view of a tubular element comprising a susceptor arranged differently to the susceptor illustrated in the FIG. 45 example.
[0398] FIG. 47 is a schematic sectional view of an aerosol generating device and a schematic side view of an aerosol generating article that may be inserted into the aerosol generating device.
[0399] FIG. 48 is a schematic sectional view of the aerosol generating device depicted in FIG. 47 and a schematic side view of the article depicted in FIG. 47 inserted into the aerosol generating device.
[0400] FIGS. 1 to 6 show a longitudinal cross-sectional cut away view of an aerosol generating articles 100. In other words the FIGS. 1 to 6 show a view of an aerosol generating article 100 cut in half longitudinally. In the FIGS. 1 to 6 embodiments the aerosol generating article is tubular. If one viewed a whole end face of the aerosol generating article 100 of FIGS. 1 to 6, either the proximal end 101 or distal end 103 it would be circular. The tubular element 500, if used or shown in the embodiments of FIGS. 1 to 6 is also tubular. The tubular element 500 is a, possible, tubular component of the tubular aerosol generating article 100 of the FIGS. 1 to 6 embodiments. If one viewed a whole end face of the tubular element 500, used in or shown in the FIGS. 1 to 6 embodiment, whether the proximal end or distal end, the face of the tubular element would be circular. As FIGS. 1 to 6 are a two dimensional longitudinal cross-sectional cut away view, the side curvature of the aerosol generating article and of the tubular element 600, among other components, cannot be seen. The drawings are for illustrative purposes to explain the invention and may not be to scale. The tubular element 500 if shown in FIGS. 1 to 6 is to illustrate the tubular element 500 in an aerosol generating article 100 but the features of the aerosol generating article 100 are optional to the embodiment shown of the tubular element 500 and should not be seen as essential features of the tubular element 500, and the features of the tubular element 500 are optional to the aerosol generating article 100 and should not be seen to be limiting features.
[0401] The example illustrated in FIG. 1 shows a combustible heat source 550 at the distal end 103 of an aerosol generating article 100 of the present invention. In this example instead of requiring an aerosol generating device to transfer heat to the aerosol generating article 100 the aerosol generating article 100 has its own heat source in the form of the combustible heat source 550. This example also has a tubular element 500, a fluid guide 400 and a mouthpiece 170 (which is also a filter), a susceptor 552, apertures 150, a wrapper 110 and tipping paper 111 over a portion of the wrapper 110 at the proximal end of the aerosol generating article 100. The fluid guide 400 in this example does not have a restrictor but has a long section 405 with a wide cross-sectional area, that aids cooling of the aerosol. The susceptor 552 in this example is aluminium. The susceptor 552, or a portion thereof, is positioned between the combustible heat source 550 and the tubular element 500 to act as a barrier between the combustible heat source 550 and the tubular element 500. The susceptor 552 in this example extends across the inner diameter of the aerosol generating article 100 as seen at point 554. This helps to prevent the tubular element 500 from being exposed to excessive thermal energy when the combustible heat source 550 is combusting. It also helps transfer heat from the combustible heat source 550 to the tubular element 100. In this example the tubular element comprises a combination of gel 124, porous medium loaded with gel 125 and threads loaded with gel 125 (not shown). The gel, and porous medium loaded with gel and the threads loaded with gel if present respectively all comprise active agents, the active agent includes nicotine.
[0402] The susceptor 552 in this example also has peripheral portions 553 that extend along the longitudinal length of the aerosol generating article 100. In this example the peripheral portions 553 extend in both the proximal direction and the distal direction along the length of the aerosol generating article 100, under the wrapper 110.
[0403] The example illustrated in FIG. 2 is similar to the example of FIG. 1 where the fluid guide 400 has a restrictor on the distal side of the mouth piece 170.
[0404] On ignition of the combustible heat source 550 heat is transferred, aided by the susceptor 552 to the tubular element 500. Heating the tubular element assists in releasing material from the gel 124, or porous material loaded with gel 125, or thread loaded with gel 125 (or combinations thereof). When a negative pressure is applied to the proximal end 101 of the aerosol generating article 100 fluid, ambient air (in this example), enters the apertures 150 and can combine with materials released from the tubular element before passing to and out of the proximal end of the aerosol generating article 100.
[0405] In both illustrated examples of FIG. 1 and FIG. 2:
[0406] the total proximal to distal length of the aerosol generating article 100 is 70 millimetres;
[0407] the wrapper 110 is metalized aluminium white coated;
[0408] the tubular element 500 proximal to distal length is 7 millimetres;
[0409] the combustible heat source 550 length, proximal to distal, is 9 millimetres;
[0410] the mouth piece 170 is a crimped polylactic acid filter;
[0411] the apertures 150 are 1.6 millimetres from the tubular element;
[0412] the susceptor 552 between the combustible heat source 550 and the tubular element 100 (at point 554) is 20 micrometres in length along the longitudinal axis of the aerosol generating article.
[0413] the tubular element comprises gel, or porous medium loaded with gel, or threads loaded with gel or combinations of gel, or porous medium loaded with gel, or threads loaded with gel, all comprise active agent, and the active agent includes nicotine.
[0414] FIGS. 3a and 3b depicts an embodiment of an aerosol generating article 100 including a wrapper 110 and a fluid guide 400. FIGS. 3a and 3b are a longitudinal cross-sectional cut away view of an aerosol generating article 100. In other words the FIG. 3a and FIG. 3b view is of an aerosol generating article 100 cut in half longitudinally. In the FIG. 3a and
[0415] FIG. 3b embodiment the aerosol generating article is tubular. If one viewed a whole end face of the aerosol generating article 100 of FIG. 3a or 3b, either the proximal end 101 or distal end 103 it would be circular. The tubular element 500 in FIG. 3a or FIG. 3b is also tubular. The tubular element 500 is a tubular component of the tubular aerosol generating article 100 of the FIG. 3a and FIG. 3b embodiments. If one viewed a whole end face of the tubular element 500 of the FIG. 3a or FIG. 3b embodiment, whether the proximal end or distal end, the face of the tubular element would be circular. As FIG. 3a and FIG. 3b are a two dimensional longitudinal cross-sectional cut away view, the side curvature of aerosol generating article and of the tubular element 600, among other components, cannot be seen. In FIG. 3a the proximal end of the tubular element 500 is not shown with a straight edge. FIG. 3b shows the proximal end of the tubular element 500 as a straight line across the width of the aerosol generating article. The drawings are for illustrative purposes to explain the invention and may not be to scale. The tubular element 500 is shown in FIG. 3a and FIG. 3b to illustrate the tubular element in an aerosol generating article but the features of the aerosol generating article 100 are optional to the embodiment shown of the tubular element and should not be seen as essential features of the tubular element 500. Likewise the features of the tubular element 500 in these figures may be optional and are not limiting to the aerosol generating article.
[0416] The fluid guide 400 has a proximal end 401, a distal end 403 and an inner longitudinal passageway 430 from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410 and a second portion 420. The first portion 410 defines a first portion of the passageway 430, which extends from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the passageway 430, which extends from the distal end 423 of the second portion 420 to the proximal end 421 of the second portion 420. The first portion 410 of the passageway 430 has a constricted cross-sectional area moving from the distal end 413 to the proximal end 411 of the first portion 410 to cause fluid, for example air, to accelerate through this first portion 410 of the inner longitudinal passageway 430 when negative pressure is applied at the proximal end 101 of the aerosol generating article 100. The cross-sectional area of the first portion 410 of the inner longitudinal passageway 430 narrows from the distal end 413 to the proximal end 411 of the first portion 410. The second portion 420 of the inner longitudinal passageway 430 has an expanding cross-sectional area from the distal end 423 to the proximal end 421 of the second portion 420 of the fluid guide 400. In the second portion 420 of the inner longitudinal passageway 430, fluid may decelerate.
[0417] The wrapper 110 defines an open, proximal end 101 of the aerosol generating article 100 and a distal end 103. A tubular element 500 comprising gel comprising an active agent (not shown), is disposed in the distal end 103 of the aerosol generating article 100. The aerosol generating article 100 comprises a combustible heat source 550 at its extreme distal end 103. The combustible heat source 550 comprises carbon. A susceptor 552 (not shown) separates the combustible heat source 550 and the tubular element 500. The susceptor helps to prevent aerosol entering the tubular element 500 from the combustible heat source 550, hence biasing fluid to enter the aerosol generating article 100 though the apertures 150 when a negative pressure is applied to the proximal end 101 of the aerosol generating article 100. Aerosol generated or released from the tubular element 500 comprising an active agent, when heated may enter the cavity 140 in the aerosol generating article 100 downstream from the tubular element 500, to be carried through the inner longitudinal passageway 430.
[0418] Apertures 150 extend through the wrapper 110. At least one aperture 150 is in communication with an outer longitudinal passageway 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the apertures 150 and the proximal end 101.
[0419] When a negative pressure is applied to the proximal end 101 of the aerosol generating article 100, fluid enters the apertures 150, flows through the outer longitudinal passageways 440 into the cavity 140 and to the tubular element 500 comprising a gel comprising an active agent, where the fluid may entrain aerosol when the tubular element 500 comprising a gel comprising an active agent, is heated (for example, by combustion of the combustible heat source 550. The fluid then flows through the inner longitudinal passageway 430, and through the proximal end 101 of the aerosol generating article 100. As fluid flows through the first portion 410 of the inner longitudinal passageway 430, the fluid accelerates. As fluid flows through the second portion of the inner longitudinal passageway 430, the fluid decelerates. In the depicted embodiment, the wrapper 110 defines a proximal cavity 130 between proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which could serve to decelerate the fluid prior to exiting the mouth end 101.
[0420] FIG. 4 depicts another embodiment of an aerosol generating article 100 including a wrapper 110 and a fluid guide 400.
[0421] The fluid guide 400 has a proximal end 401, a distal end 403 and an inner longitudinal passageway 430 from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410, a second portion 420, and a third portion 435. The first portion 410 is between the second 420 and third 435 portions. The first portion 410 defines a first portion of the inner longitudinal passageway 430, which extends from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the inner longitudinal passageway 430, which extends from the distal end 423 of the second portion 420 to the proximal end 421 of the second portion 420. The third portion 435 defines a third portion of the inner longitudinal passageway 430, which extends from the distal end 433 of the third portion to the proximal end 431 of the third portion. The third portion 435 has a substantially constant inner diameter from the proximal end 431 to the distal end 433. The first portion 410 of the inner longitudinal passageway 430 has a constricted cross-sectional area moving from the distal end 413 to the proximal end 411, of the first portion 410, to cause fluid to accelerate through this first portion 410 of the inner longitudinal passageway 430 when a negative pressure is applied at the proximal end 101 of the aerosol generating article 100. The cross-sectional area of the first portion 410 of the inner longitudinal passageway 430 narrows from the distal end 413 to the proximal end 411, of the first portion 410. The second portion 420 of the inner longitudinal passageway 430 has an expanding cross-sectional area from the distal end 423 to the proximal end 421 of the second portion 420 of the inner fluid passageway 430. In the second portion 420 of the inner longitudinal passageway 430, fluid may decelerate as it travels distal to proximal in direction.
[0422] Like the aerosol generating article 100 depicted in FIG. 3, the aerosol generating article 100 depicted in FIG. 4 includes a wrapper 110 that defines an open, proximal end 101 and a distal end 103, with a combustible heat source 550 at the extreme distal end 103, and a susceptor 552 (not shown) position between the combustible heat source 550 and the tubular element 500. The susceptor 552 is in contact with both the combustible heat source 550 and the tubular element 500 in this example. A tubular element 500 comprising a gel comprising an active agent, is disposed in the distal end 103 of the aerosol generating article. Aerosol released from the gel comprising an active agent, when heated may enter the cavity 140 in the aerosol generating article 110, to be carried through the inner longitudinal passageway 430.
[0423] While not shown in FIG. 4, the aerosol generating article 100 includes at least one aperture (such as apertures 150 shown in FIG. 3) that extends through the wrapper 110 and is in communication with an outer longitudinal passageway 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the apertures and the proximal end 101. Although the seal need not be fluid impermeable, it is advantageous that the seal here does have a high resistance to draw or some degree of impermeability, to bias the fluid entering the apertures 150 along the outer longitudinal passageways in the distal direction towards the tubular element 500. The third portion 435 of the fluid guide 400 extends the length of the fluid guide 400 and outer longitudinal passageway 440 to provide additional distance between the apertures (not shown in FIG. 4, which may be located in proximity to a proximal end 401 of the inner longitudinal passageway) and the tubular element 500 comprising a gel comprising an active agent, so that leakage of the gel comprising an active agent, through the apertures 150 is not likely.
[0424] When a negative pressure is applied at the proximal end 101 of the aerosol generating article 100 depicted in FIG. 4, fluid enters the apertures 150, flows through the outer longitudinal passageway 440 into the cavity 140 and to the tubular element 500 comprising gel comprising an active agent, where the fluid may entrain material from the gel 124 comprising an active agent is heated. The fluid may then flow through the inner longitudinal passageway 430, and through the proximal end 101 of the aerosol generating article 100. As fluid flows through the inner longitudinal passageway 430, the fluid flows through the third portion 435, the first portion 410, and then the second portion 420 of the aerosol generating article 100. As fluid flows through the first portion 410 of the inner longitudinal passageway 430, the fluid accelerates. As fluid flows through the second portion 420 of the inner longitudinal passageway 430, the fluid decelerates. In alternative specific embodiments the second portion 420 and third portion 435 of the inner longitudinal passageway 430 are optional. In the depicted embodiment, the wrapper defines a proximal cavity 130 between proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which could serve to decelerate the fluid prior to exiting the proximal end 101.
[0425] FIG. 5 and FIG. 6 depict additional embodiments of aerosol generating articles 100 that include a wrapper 110, a combustible heat source 550, a susceptor 552 (not shown), a tubular element 500 that comprises a gel comprising an active agent, a proximal cavity 130, a cavity 140, and a fluid guide 400. The susceptor 552 is positioned between the combustible heat source and the tubular element 500. The fluid guide 400 has a proximal end 401, a distal end 403 and an inner longitudinal passageway 430 from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410 and a third portion 435. The first portion 410 defines a first portion 410 of the inner longitudinal passageway 430, which extends from the distal end 413 of the first portion 410 to the proximal end 411 of the first portion 410. The third portion 435 defines a third portion of the inner longitudinal passageway 430, which extends from the proximal end 433 of the third portion 435 to the distal end 431 of the third portion 435. The third portion 435 has a substantially constant inner diameter from the proximal end 433 to the distal end 431.
[0426] In FIG. 5, the first portion 410 of the inner longitudinal passageway 430 has a substantially constant inner diameter from the distal end 413 to the proximal end 411 of the first portion 410. The inner diameter of the inner longitudinal passageway 430 at the first portion 410 is smaller than the inner diameter of the inner longitudinal passageway 430 at the third portion 435. The restricted inner diameter of the inner longitudinal passageway 430 at the first portion 410, relative to at the third portion 435, may cause fluid to accelerate as it flows from the third portion 435 to the first portion 410.
[0427] In FIG. 6, the first portion 410 of the fluid guide 400 includes multiple segments 410A, 410B, 410C, with stepped internal diameters. The most distal segment 410A has the largest inner diameter, and the most proximal segment 410C has the smallest inner diameter. As fluid flows through the inner longitudinal passageway 430 from the first segment 410A to the second segment 401B and from the second segment 410B to the third segment 410C, the fluid may accelerate as the inner longitudinal passageway 430 cross-sectional area constricts in a stepped manner.
[0428] The first portions 410 in FIG. 5 and FIG. 6 provide examples of a construction that may be beneficial when the material employed to form the first portion 410 is not readily moldable. For example, the first portion 410 or the segments 410A, 410B, 410C of the first portion 410 may be formed from cellulose acetate tow. In contrast, the first portions 410 of the fluid guide 400 depicted in FIG. 3 and FIG. 4 provide examples of construction that may be beneficial when the material employed to form the first portion 410 is moldable, such as when the first portion is formed from, for example, polyether ether ketone (PEEK).
[0429] Like the aerosol generating article 100 depicted in FIG. 3 and FIG. 4, the aerosol generating articles depicted in FIG. 5 and FIG. 6 include a wrapper 110 that defines an open, proximal end 101 and a distal end 103. A tubular element 500, in these examples, comprising gel 124 comprising an active agent, is disposed in the distal end 103 of the aerosol generating article 100, to the proximal side of the susceptor 552. Aerosol released from the tubular element 500 comprising gel 124 comprising an active agent when heated may enter the cavity 140 in the aerosol generating article 100 to be carried through the inner longitudinal passageway 430. The tubular element 500 is heated when the combustible heat source is ignited, and thermal energy passes via the susceptor 552 to the tubular element. The thermal energy generated generally travels in a proximal direction.
[0430] While not shown in FIG. 5 and FIG. 6, the aerosol generating article 100 includes at least one aperture (such as apertures 150 shown in FIG. 3) that extends through the wrapper 110 and is in communication with an outer longitudinal passageway 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrapper 110 at a location between the aperture or apertures 150 and the proximal end 101. This helps to bias the fluid entering through the apertures 150 along the outer longitudinal passageways 440 in the tubular element 500 or distal direction. The third portion 435 of the inner longitudinal passageway 430, among other things, serves to extend the length of the fluid guide 400 and outer longitudinal passageway 440 to provide additional distance between the apertures 150 (not shown in FIG. 5 and FIG. 6, which may be located in proximity to a proximal end of the outer longitudinal passageway 440) and the tubular element 500 comprising gel 124 comprising an active agent so that leakage of the gel 124 comprising an active agent through the apertures 150 is not likely.
[0431] When a negative pressure is applied at the proximal end 101 of the aerosol generating article 100 depicted in FIG. 5 and FIG. 6, fluid enters the apertures 150, flows through the outer longitudinal passageway 440 into the cavity 140 to the tubular element 500 comprising gel 124 comprising an active agent, where the fluid may entrain material from the gel when the tubular element 500 is heated. The fluid may then flow through the inner longitudinal passageway 430, and through the proximal end 101. As fluid flows through the inner longitudinal passageway 430, the fluid flows through the third portion 435 and then the first portion 410 of the aerosol generating article 100. As fluid flows into the first portion 410 of the inner longitudinal passageway 430, the inner longitudinal passageway 430 may accelerate because the inner diameter of the inner longitudinal passageway 430 at the first portion 410 is less than at the third portion 435. In the aerosol generating article 100 depicted in FIG. 6, the fluid may accelerate as it passes each segment 410A, 410B, 410C of the first portion 410.
[0432] In the embodiments depicted in FIG. 4 and FIG. 5, the wrapper defines a cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the aerosol generating article 100, which could serve to decelerate the fluid that exits the inner longitudinal passageway 430 at the proximal end 401 of the fluid guide 400 prior to exiting the proximal end 101.
[0433] FIGS. 7-8 illustrate an embodiment of an aerosol generating article 100. The aerosol generating article 100 includes a wrapper 110 and apertures 150 through the wrapper 110. The aerosol generating article includes a combustible heat source 550 that forms the distal end 103 of the aerosol generating article 100. To the proximal side of the combustible heat source 550 is a susceptor 552 (not shown). The susceptor 552 (not shown) is positioned between the combustible heat source and the tubular element 500. The susceptor 552 while allowing heat transfer to the tubular element 500, helps prevent aerosol, from the combustible heat source 550, from entering the tubular element 500. When heated, the tubular element 500 may form or release an aerosol that enters a cavity 140 to the proximal side of the tubular element 500.
[0434] FIG. 7 shows a side view of a tubular aerosol generating article 100. If one were to view a face of either the proximal end 101 or the distal end 103, the end face would be circular. FIG. 7 is a two dimensional drawing and thus the curvature of the tubular aerosol generating article cannot be seen. FIG. 8 is a partially cut away perspective view of the same embodiment as shown and described by FIG. 7. It can be seen that the face of the distal end, although partly blocked is circular. It can be seen that the face of the proximal end 101, although partly cut away will also be circular. Also from FIG. 8 it can be seen that the tubular element 500 is tubular in shape. Also from FIG. 8 it can be seen that the end cap 600 is also tubular in shape, for this embodiment.
[0435] At least one of the apertures 150 is in communication with at least one outer longitudinal passageway 440 formed between the fluid guide 400 and the wrapper 110 and between sidewalls 450. The fluid guide 400 has a rim 460 that presses against an inner surface of the wrapper 110 to form a seal. The seal is formed between the proximal end 101 and the apertures 150.
[0436] When a negative pressure is applied at the proximal end 101, fluid, for example air, may enter the apertures 150, and flow through the outer longitudinal passageways 440 to the cavity 140, and then through the tubular element 500 where material from the gel 124 is released into the fluid. The fluid then travels through the inner longitudinal passageway 430 through the fluid guide 400, into cavity 130 defined by the wrapper 110, and through (and exit) the proximal end 101 of the aerosol generating article 100. The inner longitudinal passageway 430 of the fluid guide 400 may be configured in any suitable manner, such as examples shown in FIGS. 3-6.
[0437] FIGS. 9-10 illustrate an embodiment of an aerosol generating article 100 that includes a mouthpiece 170 that forms a portion of the wrapper 110 and the fluid guide 400 of the aerosol generating article 100. The aerosol generating article 100 include a distal end 103 that forms the distal end 103 of the aerosol generating article 100 and also forms a portion of the wrapper 110. The distal end 103 is configured to be received by a distal portion of the mouthpiece 170, such as by interference fit. The tubular element comprising gel 124 comprising an active agent (not shown) may be disposed in the distal end 103. The aerosol generating article 100 comprises a combustible heat source 550 at the extreme distal end 103. A susceptor 550 (not shown) is positioned between the combustible heat source 550 and the tubular element 500.
[0438] FIG. 9 shows part of a cut away side view of a tubular aerosol generating article 100. If one were to view a whole face of either the proximal end 101 or the distal end 103, the end face would be circular. FIG. 9 is a two dimensional drawing and thus the curvature of the tubular aerosol generating article cannot be seen. FIG. 10 is a partially cut away perspective view of the same partly cut away, part of an aerosol generating article 100 as shown and described by FIG. 9. It can be seen that the face of the distal end, although partly blocked is circular. It can be seen that the face of the proximal end 101, although partly cut away will also be circular. Also from FIG. 10 it can be seen that the tubular element 500 is tubular in shape. Also from FIG. 10 it can be seen that the end cap 600 is also tubular in shape, for this embodiment.
[0439] The fluid guide 400 includes an inner longitudinal passageway 430 (not shown) that includes a portion that accelerates fluid, and, may include a portion that decelerates fluid. A seal is formed between the wrapper 110 and the fluid guide 400 because the wrapper 110 and the fluid guide 400 are formed from a single part. An aperture 150 is formed in the wrapper 110 and is in communication with an outer longitudinal passageway 640 that is formed at least in part by an inner surface of the wrapper 110. Part of the outer longitudinal passageway 640 is generally formed between the inner surface of the wrapper 110 and an exterior of the fluid guide 400. The outer longitudinal passageway 640 extends less than the full distance around the article 100. In this embodiment, the outer longitudinal passageway 640 extends around 50 percent of the distance around the circumference of the aerosol generating article 100. The outer longitudinal passageway 640 directs fluid, for example air, from the aperture 150 towards the tubular element 500 (not shown) in proximity of the distal end 103.
[0440] When a negative pressure is applied at the proximal end 101, fluid, for example ambient air, enters the aerosol generating article 100 through the aperture 150. The fluid flows through the outer longitudinal passageway 640 towards a tubular element 500, comprising gel 124 comprising an active agent, disposed at the distal end 103. The fluid then flows through an inner longitudinal passageway 430 of the fluid guide 400, where the fluid is accelerated and optionally decelerated. The fluid, for example air, may then exit the proximal end 101 of the aerosol generating article 100.
[0441] In FIG. 9, a distal end portion of the outer wrapper 110 of the aerosol generating article 100 is circumscribed by a band of tipping paper (not shown).
[0442] FIG. 11 is an illustration of a fluid guide 400 formed from polyetheretherketone (PEEK) material by computer numeric control (CNC) machining. The fluid guide 400 depicted in FIG. 11 has a length of 25 millimetres, an outer diameter at the proximal end of 6.64 millimetres, and an outer diameter at the distal end of 6.29 millimetres. The outer diameter at the distal end is the diameter of the distal end from the base of the sidewalls. The fluid guide 400 has 12 outer longitudinal passageways 640 formed around its exterior surface, each sidewall having a substantially semi-circular transverse cross-sectional area. The outer longitudinal passageways 640 have a radius of 0.75 millimetres and a length of 20 millimetres. The fluid guide 400 has an inner longitudinal passageway 430 (not shown) comprising three portions, a first portion (a fluid accelerating portion) a second portion (fluid decelerating portion) downstream or proximal to the first portion and a third portion upstream or distal to the first portion. The third portion of the inner longitudinal passageway 430 of the fluid guide 400 extends from the distal end 103 of the aerosol generating article 100 and has an inner diameter at the distal end of 5.09 millimetres, which tapers down to a diameter of 4.83 millimetres at a proximal end of the first portion of the inner longitudinal passageway 430. The length of the first portion of the inner longitudinal passageway is 15 millimetres. The first portion of the inner longitudinal passageway 430 extends from a distal end at the proximal end of the third portion to a proximal end. The first portion of the inner longitudinal passageway 430 has an inner diameter of 2 millimetres at its distal end, which constricts to 1 millimetre at the proximal end. The length of the first portion of the inner longitudinal passageway is 5.5 millimetres. The second portion of the inner longitudinal passageway 430 extends from a distal end at the proximal end of the first portion to a proximal end at the proximal end of the article. The second portion of the inner longitudinal passageway 430 has an inner diameter of 1 millimetre at its distal end, which is the same as the inner diameter at the proximal end of the first portion. The inner diameter of the second portion increases at a decreasing rate (in a curve) to the proximal end, which has an inner diameter of 5 millimetres. The length of the second portion is 4.5 millimetres. Accordingly, fluid drawn through the interior passageway of the fluid guide, from the distal end to the proximal end, encounters a chamber with a substantially constant inner diameter (the third portion), a constricted section configured to accelerate the fluid (the first portion), and an expanded section configured to decelerate the fluid (the second portion). It has been found that providing such an inner longitudinal passageway 430 for the aerosol released from the heated tubular element 500 (not shown) may enable aerosol volume and droplet size to be controlled such that a satisfactory aerosol is released. FIG. 11 is a side view of a tubular shaped fluid guide 400. The FIG. 11 is a two dimensional drawing and therefore the curvature of the tubular shape, of the fluid guide 400, in this embodiment, cannot be seen. If one were to view an end face of the fluid guide 400, of this embodiment, the face would be circular.
[0443] FIG. 12 is an illustration of an assembled aerosol generating article 100. The aerosol generating article 100 includes a wrapper 110 into which the fluid guide 400 of FIG. 11 is inserted. The wrapper depicted in FIG. 12 is generally a cylindrical paper tube having a length of 45 millimetres. One end of the wrapper 110 is distal to provide the distal end of the wrapper for holding the tubular element 500 (not shown). The proximal portion of the exterior of the fluid guide 400, above the outer longitudinal passageways, has a diameter of 6.64 millimetres. This diameter is substantially identical to the inner diameter of the wrapper, such that an interference fit seal may be formed between the proximal portion of the exterior of the fluid guide 400 and the interior of the wrapper 110. The distal portion of the exterior of the fluid guide 400, extending the length of the outer longitudinal passageways, may have a diameter that is slightly less than the diameter of the proximal portion of the exterior of the fluid guide 400, such that the fluid guide may be easily inserted into the wrapper 110 up to the proximal portion of the exterior, where the interference fit is made. FIG. 12 is a side view of an aerosol generating article 100. The FIG. 12 is a two dimensional drawing and therefore the curvature of the tubular shape, of the aerosol generating article 100, in this embodiment, cannot be seen. If one were to view an end face of the aerosol generating article 100, of this embodiment, the face would be circular.
[0444] FIG. 13 illustrates an aerosol generating article 100 manufactured with a tubular element 500 comprising gel 124 which is illustrated further in FIGS. 14, 15 and 16. FIG. 13 is a longitudinal cross-section, cut away, view of an aerosol generating article 100. The FIG. 13 is a two dimensional drawing and therefore the curvature of the tubular shape, of the fluid guide 100, and its components, for example, the tubular element 500, in this embodiment, cannot be seen. If one were to view a whole end face of the aerosol generating article 100, of this embodiment, the face would be circular. Likewise, if one were to view a whole end face of the tubular element 500, of this embodiment, the face would be circular.
[0445] The aerosol generating article 100, of FIG. 13, comprises five elements arranged in coaxial alignment: at the distal end 103 a combustible heat source 550, comprising carbon in this example, a susceptor 552 on the proximal side of the combustible heat source 550, a tubular element 500 which comprises gel 124, a fluid guide 400 and a mouthpiece 170 at the proximal end 101. These five elements are arranged sequentially and are circumscribed by a wrapper 110 to form the aerosol generating article 100. (In a similar but alternative embodiment there is a cavity 140 between the fluid guide 400 and the tubular element 500. Likewise in other examples there may be a cavity between the tubular element 500 and the susceptor 552.) The aerosol-generating article 100 has a proximal or mouth end 101, and a distal end 103 located at the opposite end of the aerosol-generating article 100 from the proximal end 101. Not all components of the tubular element 500 are necessarily shown or labelled in FIG. 13.
[0446] In use, fluid, for example air, is drawn through the aerosol generating article 100, via the apertures 150 (not shown but similar to those described for the examples of FIGS. 1 to 10) when a negative pressure is applied at proximal end 101.
[0447] The combustible heat source 500 is located at the extreme distal 103 end of the aerosol generating article 100 and has a susceptor 552 on its proximal side. The susceptor 552 is in contact with the combustible heat source 550 on its distal side and in contact with the tubular element 500 on its proximal side. In this example the susceptor 552 is a disc like shape between the combustible heat source 550 and the tubular element 550 (position 554 in FIG. 1), between the combustible heat source 550 and the tubular element 500. The susceptor 552 also comprises peripheral portions 553 (not shown) that extend under the wrapper 110 in the proximal direction for the full longitudinal length of the tubular element 500. The peripheral portion 553 of the susceptor 552 in this example substantially covers the wrapper side of the tubular element, under the wrapper 110. In operation, in this example, the combustible heat source 550 is ignited by, for example, a lit match. The combustion of the combustible heat source 550 heats the susceptor and tubular element. When a negative pressure is applied at the proximal end 101 of the aerosol generating article ambient air is drawn in through the apertures 150 (not show) to the outer longitudinal passageways 440 and passes to the tubular element where the ambient air mixes with material from the gel 124 from the tubular element 550. The aerosol travels through the fluid guide 400 and exits the aerosol generating article 100 at the proximal end 101.
[0448] As is illustrated further in FIGS. 14, 15 and 16, the tubular element 500 is a cellulose acetate tube 122 containing gel 124 in the core, for example the core is filled with gel 124. In this example gel 124 comprises an active, the active agent is nicotine and an aerosol former. Other examples similar to this example comprise different active agents, or none. Not all components of the tubular element 500 of FIGS. 14, 15 and 16 are necessarily shown or labelled.
[0449] FIG. 14 shows a perspective view of the tubular element 500, FIG. 15 shows a cross-sectional view coplanar with the central axis of the tubular element 500, and FIG. 16 shows a cross-sectional view perpendicular to the central axis. FIG. 16 shows an end face of a tubular element 500.
[0450] The tubular element 500 is located in the aerosol generating article 100 (FIG. 13) at the distal end 103 of the aerosol generating article 100 so that tubular element 500 can be heated by the combustible heat source 550.
[0451] The gel 124 comprises an active agent that is released into the fluid, for example ambient air, flowing from apertures 150 along outer longitudinal passageways (not shown) in the fluid guide 400 to the tubular element 500 near the distal end 103, then to the proximal end 101 via the inner longitudinal passageway 430 (not shown). In this illustrated example the active agent is nicotine. Optionally the gel 124 further comprises a flavour, for example, menthol.
[0452] The tubular element 500 may additionally comprise a plasticizer.
[0453] The fluid guide 400 is located immediately downstream of the tubular element 500 and abuts the tubular element 500. (In a similar but alternative specific example, for example FIG. 24, there is cavity between the fluid guide 400 and the tubular element 500, thus the fluid guide does not contact the tubular element). In use, material released from the tubular element 500 comprising gel 124, passes along the fluid guide 400 towards the proximal end 101 of the aerosol generating article 100.
[0454] In the example of FIG. 13 the mouthpiece 170 is located immediately downstream of the fluid guide 400 and abuts the fluid guide 400. In the example of FIG. 13, the mouthpiece 170 comprises a conventional cellulose acetate tow filter of low filtration efficiency.
[0455] To assemble the aerosol-generating article 100, the five elements described above are aligned and wrapped within the outer wrapper 110. In FIG. 13, the outer wrapper is a conventional cigarette paper.
[0456] The tubular element 500 may be formed by an extrusion process, for example as illustrated in FIG. 17. The cellulose acetate 122 longitudinal sides of the tubular element 500 may be formed by extruding a cellulose acetate material along a die 184 and around a mandrel 180 that projects rearwardly with respect to the direction of travel T of the extruded cellulose acetate material. The rearward projection of the mandrel 180 is shaped like a pin and is a cylindrical member having an external diameter of 3 to 7 millimetres, with a length of 55 to 100 millimetres. (To assist explanation, it is not illustrated to scale in the figures).
[0457] The cellulose acetate material 122, in this example, is thermoset, by exposure to steam S, which be at a pressure of greater than 1 bar.
[0458] The mandrel 180 is provided with a conduit 182, along which the gel 124 is extruded into the core of the set cellulose acetate material 122 that forms the longitudinal sides of the tubular element 500 in this example. In other examples the cellulose acetate material 122 is thermoset prior to extruding the gel 124 into the core of the of cellulose acetate material 122.
[0459] The composite cylindrical rod is cut into lengths, to form the individual tubular elements 500.
[0460] The composite cylindrical rod is formed by a hot extrusion process in this example. The composite cylindrical rod is allowed to cool, or subject to a cooling process, prior to processing into lengths. Alternatively, in other examples the composite cylindrical rod may be formed by a cold extrusion process.
[0461] In the illustrated tubular elements 500 of this example, the cellulose acetate 122 is shown as the longitudinal sides of the tubular element 500 with a core, the core to be filled with gel 124. However, alternatively in other examples, the cellulose acetate 122 longitudinal sides may have any shape, with a core (or more than one core) for receiving the gel 124 that extends generally along the tubular rod. In alternative specific examples the core is filled with porous medium loaded with gel 125.
[0462] In the present example the celluloses acetate 122 longitudinal sides, of the tubular element have a minimum thickness of 0.6 millimetres.
[0463] In the manufacturing process illustrated in FIG. 17, the gel 124 is extruded continuously.
[0464] In the alternative example as illustrated in FIG. 18, the gel 124 may be extruded in bursts, separated by gaps 128, as shown in FIG. 18. In alternative specific examples the porous medium loaded with gel 125 is extruded in bursts, to have separating gaps in the core of the tubular rod.
[0465] The gel 124 may be heated above room temperature before injection into the mandrel 180. The mandrel 180 may be thermally conductive (for example, a metal mandrel), and some externally applied heat (for example, from the steam S) applied to thermoset the cellulose acetate. This may transfer heat energy to the gel, heating the gel may reduce its viscosity and facilitate its extrusion.
[0466] In an alternative specific example as illustrated in FIG. 19, the mandrel 180 is configured to reduce heating of the gel 124 prior to extrusion. In some of these specific examples the mandrel 180 is formed from a substantially thermally insulating material. Alternatively, or additionally, the mandrel 180 is cooled, for example by having a liquid-cooled jacket 186 (for example a water-cooled jacket), having a circulating layer of cooled liquid forming a thermal barrier between externally applied heat (for example steam S) and the gel 124. Maintaining the gel 124 at a cool temperature may facilitate shaping the gel 124 within the cellulose acetate 122 longitudinal sides of the tubular element 500.
[0467] In this example the tubular elements 500 are formed by cutting through the gaps 128, of the composite rod, which aids prevention of contamination of the cutting machinery with the gel 124, thus improving cutting performance. The composite rod, in this example, is cooled prior to cutting, by a period of resting until it reaches a suitable temperature for cutting. After cutting, the cut lengths have hollow ends if cut in the gaps 128, which in some examples are trimmed off to form the tubular element, and before assembly into an aerosol generating article 100. The bursts of gel 124, in this example is 60 millimetres long, and separated by 10 millimetres gaps. In other examples the hollow ends are not trimmed at both ends in order to create a cavity 140 between the gel 124 and the fluid guide 400.
[0468] Alternatively, to the illustrated examples here, in specific examples, the gel 124 may be extruded at room temperature. Also, in alternatively specific examples the cellulose acetate is replaced with other materials, for example, polylactic acid.
[0469] In the FIG. 19 embodiment the mandrel has a cylindrical shape to aid in the manufacturing of a tubular shaped, tubular element.
[0470] FIG. 20 illustrates a portion of an aerosol generating device 200 with partially inserted aerosol generating article 100, as described above and illustrated in FIG. 13.
[0471] The preferred manner of using the aerosol generating article 100 as illustrated in FIG. 13 and described above, is as mentioned above, to ignite the combustible heat source 550 to generate the heat to heat the tubular element 500. This means of heating is not however the only manner of use. It is possible to use the aerosol generating article 100 with a combustible heat source 550 with an aerosol generating device 200 that provides all or part of the heat desired to heat the tubular element 500. It is even possible to use the heating element 230 of a device 200 to provide heat to an aerosol generating article 100 when the combustible heat source 550 is ignited.
[0472] The aerosol generating device 200 comprises a heating element 230. As shown in FIG. 20, the heating element 230 is mounted within an aerosol generating article 100 receiving chamber of the aerosol generating device 200. In use, the aerosol generating article 100 is inserted into the aerosol generating article receiving chamber of the aerosol generating device 200 such that the heating element 230 is inserted, into the heat source 550 such that, when actuated, heat is transferred via the heat source and via the susceptor 552 to the tubular element 500 of the aerosol generating article 100 as shown in FIG. 20. In FIG. 20, the heating element 230 of the aerosol-generating device 200 is a heater blade. In the FIG. 20 example the combustible heat source 550 is not ignited, but is heated by the heater blade.
[0473] The aerosol-generating device 200 comprises a power supply and electronics that allow the heating element 230 to be actuated. Such actuation may be manually operated or may occur automatically in response to insertion of an aerosol generating article 100 into the aerosol generating article receiving chamber of the aerosol-generating device 200. A plurality of openings is provided in the aerosol-generating device to allow air to flow to the aerosol-generating article 100; the direction of fluid, for example air, flow in the aerosol generating device 200 is illustrated by arrows in FIG. 20. The fluid can then enter the aerosol generating article 100 via the apertures 150 not shown.
[0474] Once the internal heating element 230 is inserted into the combustible heat source 550 of the aerosol-generating article 100, and actuated, the tubular element 500 comprising gel 124 comprising an active agent is heated to a temperature of 375 degrees Celsius by the heating element 230 of the aerosol-generating device 200. At this temperature, material from the tubular element 500 of the aerosol generating article 100 leaves the gel. When negative pressure is applied to the proximal end 101 of the aerosol generating article 100, this material from the tubular element 500 is drawn downstream through the aerosol-generating article 100, in particular drawn through the fluid guide 400 towards the proximal end and out of the proximal end 101 of the aerosol generating article 100.
[0475] As the aerosol passes downstream thorough the aerosol generating article 100, the temperature of the aerosol is reduced due to transfer of thermal energy from the aerosol to the fluid guide 400. In this example, when the aerosol enters the fluid guide 400, the temperature of the aerosol is about 150 degrees Celsius. Due to cooling within the fluid guide 400, the temperature of the aerosol as it exits the fluid guide 400 is 40 degrees Celsius. This leads to the formation of aerosol droplets.
[0476] In the illustrated example of FIG. 20 the tubular element 500 comprises cellulose acetate forming the longitudinal sides 122 of the cylindrical rod, with gel 124 in the core or central portion of the tubular element 500. Alternatively in other specific examples, the longitudinal sides of the tubular element 500 may be cardboard; crimped paper, such as crimped heat resistant paper or crimped parchment paper; or a polymeric material, for example low density polyethylene (LDPE).
[0477] In FIGS. 14, 15, 16, the tubular element 500 has a single core provided with a single gel 124, with the gel 124 filling the core, surrounded by cellulose acetate along the longitudinal sides of the tubular element 500. However, in alternative specific examples, the tubular element 500 comprises more than one core. In specific embodiments the tubular element comprises more than one gel 124. Not all components of the tubular element 500 are necessarily shown or labelled in the FIG. 21 embodiment.
[0478] As illustrated in the example of FIG. 21 the tubular element 500 comprises a plurality of gels 524A, 524B extending along the axial length of the core of tubular element 500, as shown in cross-section in FIG. 21. The tubular element 550, in this FIG. 21 embodiment, comprises cellulose acetate longitudinal sides 522, 622, 722.
[0479] The plurality of gels 524A, 524B may be extruded into the cellulose acetate 522 through separate conduits in the mandrel (not shown) forming the core of the tubular element 500. The use of gels 124 with different volatilities may facilitate optimisation of delivery of the active agent.
[0480] In the example illustrated in FIG. 22 the tubular element 500 comprises cellulose acetate longitudinal sides 622, the tubular element 500 additionally comprises a plurality of cores 624A, 624B, 624C, as shown in cross-section in FIG. 22.
[0481] Not all components of the tubular element 500 are necessarily shown or labelled in this FIG. 22 embodiment.
[0482] In this specific example, the plurality of cores is provided with different gels 624A, 624B, 624C, the gels having different active agents, for example different nicotine and flavouring, as shown in FIG. 22. The use of gels with different volatilities may facilitate optimisation of delivery of the active ingredient, in particular delivery over time of a heating cycle of an aerosol generating device.
[0483] In other specific examples (not shown) each of the plurality of cores 624A, 624B, 624C is provided with the same gel 124 (not shown). The use of a plurality of cores facilitates optimising air flow performance through the tubular element 500.
[0484] The plurality of cores may be formed by use of a mandrel (not shown) with a corresponding plurality of projections extending rearwardly with respect to the direction of travel T of the extruded cellulose acetate material. The gel may be extruded through respective conduits in the plurality of rearwardly extending mandrel projections.
[0485] In FIGS. 14, 15, 16, the tubular element 500 comprises cellulose acetate 122 longitudinal sides filled with gel 124 in the core. However, alternatively, in specific examples in combination with other features, the core of the tubular element 500 is only partially filled with gel 124 across the cross-section perpendicular to the axial length. Advantageously this facilitates axial air flow through the length of the tubular element 500. For example, as shown in FIG. 23, the gel 724 may be provided as a coating on the internal face of the longitudinal sides of the tubular element 500.
[0486] In this illustrated example, FIG. 23 embodiment, the tubular element 500 has a hollow conduit 726 extending axially along its length, by use of a mandrel (not shown) with a central rod extending further downstream from where the gel 724 is extruded into the tube during manufacturing, to form the hollow conduit within the extruded gel 724.
[0487] Although FIG. 20 illustrates an aerosol generating article 100 that is used with a blade-like heating element 230 of the aerosol generating device 200, the tubular element 500 may, alternatively, be used in other aerosol generating articles 100 that are heated differently.
[0488] For example, FIG. 24 illustrates, a cut away view, of an example of an aerosol generating article 100 that is suitable for induction heating as well as for heating with a blade like heating element. FIG. 24 illustrates an example of an aerosol generating article 100 suitable for use with a tubular element of the present invention. FIG. 24 is a cross-sectional, cut away, view of a tubular aerosol generating article and its components, for example a tubular element 500, and thus does not show the curvature of the tubular shapes. Not all components of the tubular element 500 are necessarily shown or labelled in this FIG. 24.
[0489] In the FIG. 24 example the aerosol generating article 100 comprises a mouthpiece 170 at the proximal end 101, a fluid guide 400, a cavity 700, a tubular element 500, a combustible heat source 550 in the order proximal to distal. And a susceptor 552 position between the combustible heat source 550 and the tubular element 500. In this example the tubular element 500 comprises a gel 824 comprising an active agent and further comprises a susceptor (both not shown). Thus, there is a susceptor between the tubular element and the combustible heat source and a susceptor within the tubular element 500. The susceptor within the tubular element 500 in this example is a single aluminium strip centrally located along the longitudinal axis of the tubular element 500. On insertion of the distal end 103 of the aerosol generating article 100 into an aerosol generating device 200 (not shown) such that the portion of the aerosol generating article 100 comprising the tubular element 500 is positioned to be in proximity to induction heating elements 230 (not shown) of the aerosol generating device 200 (not shown). Electromagnetic radiation produced by the induction heating elements 230 is absorbed by the susceptor within the tubular element 500 and aids heating of the gel 824 in the tubular element 500. Preferably the heating of the tubular element is from combustion of the combustible heat source 550.
[0490] Heating of the tubular element 500 in turn aids the release of material from the gel 824, for example the active agent is entrained into the passing aerosol when a negative pressure is applied at the proximal end 101 of the aerosol generating article 100. Fluid, for example ambient air, enters the outer longitudinal passageways 834 via apertures 150 (not shown) to transfer to the cavity 700 and then to the tubular element 500 where the fluid mixes with the gel 824 and is entrained with active agents before returning to the cavity and then via the inner longitudinal passageway (not shown) of the fluid guide 400 before exiting at the proximal end 101. In this example the longitudinal sides 822 of the tubular element 500 comprise paper. The aerosol generating article comprises an outer wrapper 850. This aerosol generating article 100 illustrated in FIG. 24 and as described can be used with the aerosol generating device 200 as illustrated in FIGS. 47-48 and as described. However preferably the thermal transfer to the tubular element 500 is from combusting the combustible heat source 550.
[0491] The tubular element 500 may have numerous different combinations of, among other things; gel 124, porous medium loaded with gel 125, active agent, inner longitudinal elements, void space, filling material (preferably porous) and wrapper. A desired aerosol may be created by the particular combination and arrangement of its ingredients.
[0492] For example:
[0493] FIG. 25 illustrates an example wherein the tubular element 500 comprises: a wrapper 110; a second tubular element 115, the second tubular element 115 comprising gel 124, the second tubular element 115 comprises a paper wrapper, the second tubular element is located centrally along the longitudinal axis of the tubular element 500; porous filler material 132 located between the second tubular element 115 and the wrapper 110. The porous filler material 132 helps to hold the second tubular element centrally within the tubular element 500. The gel 124 in this example is located within the central portion of the second tubular element 115.
[0494] FIG. 26 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising gel 124, the second tubular element comprises a paper wrapper, the second tubular element is located centrally along the longitudinal axis of tubular element 500; gel 124 located between the second tubular element 115 and the wrapper 110. The gel located between the second tubular element 115 and the wrapper 110 helps to hold the second tubular element 115 centrally within the tubular element 500. The gel 124 in this example is located within the central portion of the second tubular element 115 as well as between the second tubular element 115 and the wrapper 110.
[0495] FIG. 27 illustrates an example where the tubular element 500 comprises: a wrapper 110; an inner longitudinal element comprising porous medium loaded with gel 125, the inner longitudinal element comprising porous medium loaded with gel 125, is centrally located along the longitudinal axis of the tubular element 500; gel 124 located between the inner longitudinal element comprising porous medium loaded with gel 125 and the wrapper 110. The gel 124 may assist in holding the inner longitudinal element comprising porous medium loaded with gel 124 centrally within the tubular element 500. In this example the inner longitudinal element is a cross shape, in its longitudinal cross-section, and parts of the inner longitudinal element contact the inner surface of the wrapper 110. Other examples may use inner longitudinal elements of other shapes and sizes, and thus may not necessarily contact the inner surface off the wrapper 110. Other specific examples may also use inner longitudinal elements of different materials.
[0496] FIG. 28 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising gel 124, the second tubular element 115 comprises a paper wrapper, the second tubular element is located centrally along the longitudinal axis of the tubular element 500; porous medium loaded with gel 124 located between the second tubular element 115 and the wrapper 110. In this example the porous medium loaded with gel 124 helps to hold the second tubular element 115 centrally within the tubular element 500.
[0497] FIG. 29 illustrates an example where the tubular element 500 comprises: a wrapper 110; porous medium loaded with gel 125; and gel 124; wherein the porous medium loaded with gel 125 is located adjacent the inner surface of the wrapper 110, and, surrounding the gel 124. In this example there is both gel 124 and porous medium loaded with gel 125. The porous medium loaded with gel 125 coating the inside surface of the wrapper, although the shape of the porous medium loaded with gel 125 may have been formed first and then wrapped by the wrapper 110. In this example the porous medium loaded with gel 125 is surrounding the gel 124, that is held centrally along the longitudinal axis of the tubular element 500. The porous medium loaded with gel may assist in holding the gel 125 along the central position.
[0498] FIG. 30 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous medium loaded with gel 125, the second tubular element 115 comprises a paper wrapper; the second tubular element 115 is located centrally along the longitudinal axis of the tubular element 500; porous filler material 132 located between the second tubular element 115 and the wrapper 110. The porous filler material 132 helps to hold the second tubular element centrally within the tubular element 500. The porous medium loaded with gel 125 in this example is located within the central portion of the second tubular element 115. In this example the paper wrapper of the second tubular element 115 surrounds the porous medium loaded with gel.
[0499] FIG. 31 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous medium loaded with gel 125, the second tubular element 115, is centrally located along the longitudinal axis of the tubular element 500, the second tubular element further comprises a paper wrapper; porous medium loaded with gel 125, located between the second tubular element 115 and the wrapper 110. In this example the porous medium loaded with gel 125 is in two locations, within the second tubular element 115 and between the second tubular element and the wrapper 110. These may have the same or different, porous medium, gel, or active agent.
[0500] FIG. 32 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous filler material 132, the second tubular element 115 is centrally located along the longitudinal axis of the tubular element 500, the second tubular element 115 further comprises a paper wrapper; porous medium loaded with gel 125 located between the second tubular element 115 and the wrapper 110. The porous medium loaded with gel may assist in holding the second tubular element 115 centrally along the longitudinal axis of the tubular element 500. In this example the porous medium loaded with gel 125 is adjacent the inner surface of the wrapper 110. The porous medium loaded with gel 125 coats the inner surface of the wrapper 110.
[0501] FIG. 33 illustrates an example where the tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising porous medium loaded with gel 125, the second tubular element 115 is centrally located along the longitudinal axis of the tubular element 500, the second tubular element 115 further comprises a paper wrapper; gel 124, located between the second tubular element 115 and the wrapper 110. In this example the gel 124 may assist in holding the second tubular element 115 centrally along the longitudinal axis of the tubular element 500. In this example the gel 124 is adjacent the inner surface of the wrapper 110. In this example the porous medium loaded with gel 124 is centrally located within the second tubular element 115, surrounded by the paper wrapper of the second tubular elements 115.
[0502] FIG. 34 illustrates an example where the tubular element 500 comprises: a wrapper 110; an inner longitudinal element comprising porous medium loaded with gel 125, the inner longitudinal element comprising porous medium loaded with gel 125, is cylindrical and centrally located along the longitudinal axis of the tubular element 500; gel 124 located between the inner longitudinal element comprising porous medium loaded with gel 125 and the wrapper 110. The gel 124 may assist in holding the inner longitudinal element comprising porous medium loaded with gel 124 centrally within the tubular element 500. In this example the inner longitudinal element is a cylindrical in shape, in its longitudinal cross-section, and is held apart from the inner surface of the wrapper 110 by gel 124. Other examples may use inner longitudinal elements of other shapes and sizes, and materials.
[0503] FIG. 35 illustrate an example of an aerosol generating article 100 according to the present invention, that comprises a combustible heat source 550 at the proximal end of the aerosol generating article. This example is suitable for heating by igniting the combustible heat source 550. There is also shown an optional protective cap 559 that may cover the distal end of the aerosol generating article 100. The protective cap 559 is to be removed before igniting the combustible heat source 550. There is also illustrated the apertures 150, and the direction of fluid flow by the arrows. Ambient air may enter the apertures 150, and travel towards the tubular element 500, before travelling through the fluid guide 400 and exiting the aerosol generating article 100 at the proximal end 101. The apertures 150 in the example illustrated are laser perforated holes and are located 22 millimetres from the proximal end. The fluid guide in this example comprises crimped polylactic acid. The wrapper 110 is a high porous plug wrap paper. There is however an additional wrapper over the tubular element which is water-resistant. In this particular example the fluid guide 400 is approximately 25 millimetres in length.
[0504] As illustrated in FIG. 36 the apertures 150 are made using a precise laser beam 555 from a laser unit (not shown). By adjusting the power of the laser beam 555 and the pulse number and the focus point of the laser a desired hole size and depth can be obtained, through the wrapper 110 and through the side of the fluid guide 400 to the outer longitudinal passageway 440. The depth 556 of the laser beam 555 is illustrated in FIG. 36 for this example. In this example the laser beam 55 depth 556 is approximately 0.7 millimetres. This ensures that the laser beam does not cut through the barrier between the outer longitudinal passageway 440 and the inner longitudinal passageway 430. Any number of apertures 150 can be made, however, in this example there are 8 apertures, evenly spaced around the circumference of the aerosol generating article, 22 millimetres from the proximal end.
[0505] FIG. 37 illustrates another aerosol generating article 100 of the present invention, showing the three sections of the fluid guide 400A, 400B and 400C.
[0506] FIGS. 38 to 44 show various fluid guide designs of the present invention. These designs can be used proximal to distal or distal to proximal depending on the desired flow required. The fluid guides can also be used in combination with any other fluid guide.
[0507] FIG. 38 illustrates a fluid guide 400 having two sections 400A and 400B, both sections have an abrupt increase or decrease in the cross-sectional area in comparison to each other.
[0508] FIG. 39 illustrates one section of a fluid guide, or a section of a fluid guide, having a gradual increase or decrease in the cross-sectional area of the passageway.
[0509] FIG. 40 illustrates a two section fluid guide 400A and 400B. Section 400A has a gradual increase or decrease in the cross-sectional area of the passageway depending on the direction of fluid flow. The section 400B has a consistent cross-sectional area along its length. This may give distance to allow cooling of an aerosol.
[0510] FIG. 41 also illustrates a section of a fluid guide, or a complete fluid guide that also has a consistent cross-sectional area along it length. In comparison to section 400B of FIG. 40 however, the cross-sectional area of the passageway of the FIG. 41 example is much smaller.
[0511] FIG. 42 shows a single section or a complete fluid guide where there is again a gradual increase or decrease in the cross-sectional area. Gradual increasing or decreasing of the cross-sectional area of the passageway allows smooth aerosol flow.
[0512] FIG. 43 and FIG. 44 show more than one inner longitudinal passageway 430 that all have a constant cross-sectional area along the length of the fluid guide. FIG. 43 has three inner longitudinal passageways 430 and FIG. 44 has two inner longitudinal passageways.
[0513] FIGS. 45 and 46 show cross-sectional views of a tubular element 100 with a susceptor 552. In the FIG. 45 example the susceptor 552 is located in the middle of the tubular element 100. The susceptor 552 appears as a long thin strip, the width of the susceptor 552 is almost the inner diameter of the tubular element 100 under the wrapper 110. The susceptor 552 appears to divide the tubular element 100 longitudinally with gel 124 on both sides of the susceptor 552.
[0514] In the FIG. 46 illustrated example the susceptor 552 is on the inner surface of the wrapper 110 surrounding the gel 124.
[0515] Both examples enable heat to be transferred to the gel 124. The susceptor 552 assist heat transfer to the gel 124 in both illustrated examples FIGS. 45 and 46. The heat may be from the combustion of the combustible heat source 550 as explained in the example of FIG. 35 where the combustible heat source comprises carbon and is ignited, for example, by a lit match or lighter.
[0516] FIGS. 47-48 illustrate an example of an aerosol generating article 100 and aerosol generating device 200. The aerosol generating article 100 has a proximal or mouth end 101 and a distal end 103. In FIG. 47, the distal end 103 of the aerosol generating article 100 is received in a receptacle 220 of the aerosol generating device 200. The aerosol generating device 200 includes a wrapper 110 defining the receptacle 220, which is configured to receive the aerosol generating article 100. The aerosol generating device 200 also includes a heating element 230 that forms a cavity 235 configured to receive the aerosol generating article 100, preferably by interference fit. The heating 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 element 230.
[0517] The heating element 230 may heat the distal end 103 of the aerosol generating article 100, which contains a tubular element 500 (not shown). In this example the tubular element 500 comprises a gel 124 comprising an active agent, and the active agent comprises nicotine. Heating of the aerosol generating article 100 causes the tubular element 500 comprising a gel 124 comprising an active agent to generate an aerosol containing the active agent, which can transfer out of the aerosol generating article 100 at the proximal end 101. The aerosol generating device 200 comprises a housing 210.
[0518] FIGS. 47-48 do not show the exact heating mechanism.
[0519] Where a combustible heat source is present it is preferred to heat the tubular element by igniting the combustible heat source. An advantage of this means of heating is that it does not require an additional device and power source. Using an aerosol generating article comprising a combustible heat source 550 does not prevent heating by other means. Therefore, having a combustible heat source 550 allows options of how to transfer thermal energy to the tubular element.
[0520] In some examples the heating mechanism could be by conduction heating where the heat is transferred from the heating element 230 of the aerosol generating device 200 to the aerosol generating article 100. This can take place easily when the aerosol generating article 100 is positioned in the receptacle 220 of the aerosol generating device 200 and the distal end 103 (which is preferably the end where the tubular element 500 comprising gel is located) and thus the aerosol generating article 100 is in contact with the heating element 230 of the aerosol generating device 200. In specific examples the heating element 230 comprises a heating blade that protrudes from the aerosol generating device 200 and is suitable for penetrating into the aerosol generating article 100 to make direct contact with the combustible heat source 550 or the combustible heat source 550 and the susceptor 552, to transfer heat to the gel 124 of the tubular element 500. In specific embodiments the heating 230 element may penetrate though the combustible heat source 550 to contact and heat the tubular element 500.
[0521] In other examples the heating element 230 may partially surround a portion of the distal end of the aerosol generating article 100 (preferably a portion in proximity to the tubular element) that enables thermal energy to be transferred to the combustible heat source 550 or susceptor 552 or the tubular element 500 or any combination thereof.
[0522] In other examples the heating may be by induction where the heating element partially surrounds a portion of the distal end of the aerosol generating article 100 (preferably a portion in proximity to the susceptor 552 and tubular element 500) that enables induction energy to be transferred to the susceptor 552 that converts the induction energy to thermal energy and heats the tubular element 500. In this example the heating mechanism is by induction where the heating element emits radio-magnetic radiation which is absorbed by the susceptor 552 when the aerosol generating article 100 is positioned in the receptacle 220 of the aerosol generating device 200. Using an aerosol generating article comprising a combustible heat source 550 does not prevent heating by other means.
Examples
[0523] 1. An aerosol generating article for generating an aerosol, the aerosol generating article comprising; [0524] a fluid guide to allow movement of fluid; the fluid guide having a proximal end and a distal end, the fluid guide having an inner longitudinal region and an outer longitudinal region separated by a barrier; where the inner longitudinal region comprises an inner longitudinal passageway between the distal end and the proximal end thereof, and the outer region comprises an outer longitudinal passageway which communicates external fluid through at least one aperture to the distal end of the fluid guide, such that external fluid can travel along the outer longitudinal passageway to the distal end of the fluid guide; [0525] a tubular element, that comprises gel; in which the gel comprises an active agent; [0526] the tubular element having a proximal end and a distal end and is located at the distal end of the fluid guide; [0527] a combustible heat source located at the distal end of the tubular element; and [0528] a susceptor located between the tubular element and the combustible heat source.
2. An aerosol generating article as exemplified in example 1 in which the aerosol generating article further comprises a wrapper, to secure the fluid guide, tubular element, susceptor and combustible heat source together.
3. An aerosol generating article as exemplified in example 1 or 2 in which the aerosol generating article comprises a cavity between the distal end of the fluid guide and the proximal end of the tubular element.
4. An aerosol generating article as exemplified in example 2 in which the wrapper comprises paper.
5. An aerosol generating article as exemplified in any one of examples 2 or 4 in which at least a portion of the wrapper is water-resistant.
6. An aerosol generating article as exemplified in any preceding example in which the at least one aperture is a plurality of apertures able to allow the flow of fluid into the fluid guide.
7. An aerosol generating article as exemplified in any preceding example in which the susceptor comprises peripheral portions that extend in the longitudinal length of the aerosol generating article.
8. An aerosol generating article as exemplified in any preceding example in which the fluid guide comprises a restrictor.
9. An aerosol generating article as exemplified in anyone of the preceding examples in which the tubular element comprises a water-resistant wrapper
[0529] 10. An aerosol generating article as exemplified in any preceding example in which the tubular element comprises a susceptor, such that heat may be transferred to the gel within the tubular element.
11. An aerosol generating article as exemplified in example 10 in which the susceptor is positioned centrally within the tubular element.
12. An aerosol generating article as exemplified in preceding example in which the susceptor comprises metal.
13. An aerosol generating article as exemplified in example 12 in which the heat source comprises carbon.
14. An aerosol generating article as exemplified in any preceding example in which the tubular element further comprises a porous medium loaded with gel.
[0530] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein.
[0531] As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.
[0532] As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0533] As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open-ended sense, and generally mean “including, but not limited to”. It will be understood that “consisting essentially of”, “consisting of”, and the like are subsumed in “comprising,” and the like.
[0534] The words “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and, is not intended to exclude other embodiments from the scope of the disclosure, including the claims.
[0535] Any direction referred to herein, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions or orientations are described herein for clarity and brevity are not intended to be limiting of an actual device or system. Devices and systems described herein may be used in a number of directions and orientations.
[0536] The embodiments exemplified above are not limiting. Other embodiments consistent with the embodiments described above will be apparent to those skilled in the art.
