WO2025114156A2

WO2025114156A2 - Inhaler article with support element

Info

Publication number: WO2025114156A2
Application number: PCT/EP2024/083281
Authority: WO
Inventors: Carmelo GARZIA
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2023-11-27
Filing date: 2024-11-22
Publication date: 2025-06-05
Anticipated expiration: 2026-05-27
Also published as: WO2025114156A3

Abstract

There is provided an inhaler article (100) comprising a longitudinal body (105), a sensorial element (106) within the longitudinal body (105), and a downstream section located downstream of the sensorial element (106). The downstream section comprises a support element (107) within the longitudinal body (105). The support element comprises a first short edge (301) and an opposing second short edge (302). The first short edge (301) is fixed to the inner surface of the longitudinal body (105), and is aligned with the longitudinal axis of the longitudinal body (105). The second short edge (302) is able to move relative to the longitudinal body (105). The length of the support element (107) between the first (301) and second (302) opposing short edges is at least 15 millimetres. There is also provided a method for manufacturing an inhaler article (100) comprising steps of attaching an end of a bulk portion of planar material (503) to a conical spiral forming device (501), applying torsion to the conical spiral forming device (501) to wind a portion of the bulk planar material (503) into a spiral shape (508), and cutting the bulk portion of planar material to form a support element having a spiral shape.

Description

INHALER ARTICLE WITH SUPPORT ELEMENT

The present invention relates to an inhaler article for generating an inhalable product. In particular, the present invention relates to an inhaler article comprising a sensorial element and a support element. The present invention also relates to a method of manufacturing an inhaler article.

Inhaler articles are known which may provide an alternative to conventional cigarettes. One type of known inhaler article are aerosol-generating articles. Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than combusted, are known in the art. Typically, in such aerosol-generating articles an aerosol is generated by 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, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

A number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosolgenerating devices in which an aerosol is generated by the transfer of heat from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of a heated aerosol-generating article. For example, electrically heated aerosol-generating devices have been proposed that comprise an internal heater blade which is adapted to be inserted into the aerosol-generating substrate. As an alternative, inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor arranged within the aerosolgenerating substrate have been proposed by WO 2015/176898. A further alternative has been described in WO 2020/1 15151 , which discloses an aerosol-generating article used in combination with an external heating system comprising one or more heating elements arranged around the periphery of the aerosol-generating article.

Where the aerosol-generating article is intended to be used with an aerosol-generating device which includes a heater blade, the heater blade may be inserted into the upstream end of the aerosol-generating substrate and pushed in a downstream direction. When this occurs, the aerosol-generating substrate may be pushed downstream in the aerosol-generating article. Because of this, the aerosol-generating article may include a support element downstream of the aerosol-generating substrate to prevent the aerosol-generating substrate from moving downstream when the heater blade is inserted into the aerosol-generating substrate. Where the aerosol-generating article includes a susceptor arranged within the aerosolgenerating substrate, a support element may also be used to ensure the susceptor remains in the aerosol-generating substrate and does not move further downstream in the aerosol-generating article.

In both cases, the support element may also act to cool and condense the aerosol generating in the aerosol-generating substrate. This may advantageously improve the aerosoldelivery of the aerosol-generating article and ensure that the aerosol is sufficiently cool to be inhaled by a user.

A further type of inhaler article may deliver dry powder to a user. Such articles may comprise a capsule containing a dry powder. These capsules may be activated by piercing the capsule wall. Typically, these capsule containing inhaler articles may be activated by inserting a piercing element in a downstream direction to pierce the upstream end of the capsule to allow the dry power to be released. As the piercing element pierces the upstream end of the capsule, the capsule may be pushed in a downstream direction. When this occurs, the capsule may be pushed downstream in the inhaler article. Because of this, the inhaler article may include a support element downstream of the capsule to prevent the capsule from moving downstream when the piercing element pierces the capsule.

In the inhaler articles of the prior art, the support element is typically provided by a tube formed from polymeric material, for example a hollow acetate tube. These tubes are selected such that the inner diameter of the tube prevents the substrate, susceptor, or capsule from moving downstream when pushed. The inner diameter also provides space for the aerosol to cool and condense. However, tubes formed from a polymeric material may not be biodegradable and so may lead to pollution when the inhaler article is discarded. In addition, while recycling of the hollow acetate tube may be theoretically possible, material recovery from a used inhaler article may not be practical. In a similar way, it may be desirable to provide a support element which requires less material overall. This may advantageously reduce the overall weight of the inhaler article and may reduce the environmental impact of manufacturing the inhaler article.

In addition, even though tubes formed from polymeric material of the prior art typically include a hollow lumen, the polymeric material still acts to filter the aerosol passing though the support element. While this may be advantageous in some articles, other articles do not require the filtration provided by the polymeric material of the support element.

In addition, even though tubes formed from polymeric material of the prior art typically include a hollow lumen, the restricted airflow path may still increase the resistance to draw of the inhaler article. This may not be desirable in some applications. Similarly, in support elements of the prior art, most of the airflow is forced through the central lumen of the support element. This may cause turbulence since the airflow is forced from a wide airflow channel to a narrower airflow channel.

Accordingly, there is a need to provide an inhaler article which is more readily disposed of without the risk of pollution. In particular, there is a need to provide a support element which is more sustainable and is less likely to lead to plastics pollution.

At the same time, the support element must also provide adequate support to upstream components such as aerosol-generating substrate, susceptor, or capsule. The support element must also allow sufficient air flow through the inhaler article to deliver an aerosol or powder to a user. The support element must have a low resistance to draw. The support element must also cool and condense the aerosol.

According to a first aspect of the present disclosure, there is provided an inhaler article. The inhaler article may comprise a longitudinal body. The inhaler article may comprise a sensorial element within the longitudinal body. The inhaler article may comprise a downstream section located downstream of the sensorial element. The downstream section may comprise a support element within the longitudinal body. The support element may comprise a first short edge and an opposing second short edge. The first short edge may be fixed to the inner surface of the longitudinal body. The first short edge may be aligned with the longitudinal axis of the longitudinal body. The second short edge may be able to move relative to the longitudinal body.

According to a first aspect of the present invention, there is provided an inhaler article. The inhaler article comprises a longitudinal body. The inhaler article comprises a sensorial element within the longitudinal body. The inhaler article comprises a downstream section located downstream of the sensorial element. The downstream section comprises a support element within the longitudinal body. The support element comprises a first short edge and an opposing second short edge. The first short edge is fixed to the inner surface of the longitudinal body. The first short edge is aligned with the longitudinal axis of the longitudinal body. The second short edge is able to move relative to the longitudinal body.

The provision of a support element having a first short edge and an opposed second short edge allows the support element to be formed from a planar portion of material. This in turn may allow the support element to be formed from a paper or cardboard material which may advantageously be biodegradable. The provision of such a planar support element in which the first short edge is aligned with the longitudinal axis of the longitudinal body may also allow a relatively unobstructed passageway through which the mainstream aerosol or powder may pass from the sensorial element to a user. In this way, the resistance to draw of the support element may advantageously be low. In addition, aligning the first short edge of the support element with the longitudinal axis of the longitudinal body may advantageously ensure that the support element is sufficiently strong in the longitudinal direction and able to support components such as aerosol- generating substrate, susceptor, or capsule. This may be because such an alignment may prevent the support element from buckling when a force is applied to the support element along the longitudinal axis of the longitudinal body due to the column effect. The provision of the first short edge being fixed to the inner surface of the longitudinal body may also help to support components such as aerosol-generating substrate, susceptor, or capsule since doing so may prevent these components from moving downstream relative to the longitudinal body. The provision that the second short edge is able to move relative to the longitudinal body may prevent the support element from dividing the airflow into two separate airflow pathways which do not mix. This may advantageously improve the delivery of a consistent aerosol to a user.

As used herein with reference to the invention, the term “longitudinal” is used to describe the direction between the opposed upstream and downstream ends of the inhaler article, or of a component of the inhaler article such as the longitudinal body. The “longitudinal axis” is therefore the axis which is aligned with the longitudinal direction of the inhaler article, or of a component of the inhaler article.

As used herein with reference to the invention, the terms “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the inhaler article in relation to the direction in which airflows through the inhaler article during use thereof. Inhaler articles according to the invention comprise a proximal end through which, in use, air exits the article. The proximal end of the inhaler article may also be referred to as the mouth end or the downstream end. The mouth end is downstream of the distal end. Components, or portions of components, of the inhaler article may be described as being upstream or downstream of one another based on their relative positions between the proximal end of the inhaler article and the distal end of the aerosol generating article.

As used herein with reference to the invention, the term “sensorial element” is used to refer to an element comprising a material configured to generate a solid or liquid aerosol for delivery to a user. For example, the sensorial element may comprise an aerosol-generating substrate which is configured to generate a liquid aerosol when heated. The aerosols generated from aerosol-forming substrates of aerosol generating articles according to the invention may be visible or invisible and may include vapours (for example, fine particles of substances, which are in a gaseous state, that are ordinarily liquid or solid at room temperature) as well as gases and liquid droplets of condensed vapours. Alternatively or in addition, the sensorial element may comprise a capsule containing a dry powder for delivery to a user in the absence of heat. The powder delivered may be sufficiently fine that it may be delivered as a solid aerosol.

The support element may have any length between the first and second opposing short edges. The length of the support element between the first and second opposing short edges may be less than the inner diameter of the longitudinal body at the position where the support element is fixed to the inner surface of the longitudinal body.

Preferably, the length of the support element between the first and second opposing short edges may be greater than the inner diameter of the longitudinal body at the position where the support element is fixed to the inner surface of the longitudinal body.

By providing a support element which has a length between the first and second opposing short edges may be greater than the inner diameter of the longitudinal body at the position where the support element is fixed to the inner surface of the longitudinal body, the support element may extend across the full inner diameter of the longitudinal body. This may help to provide improved support to upstream components. In addition, since the length of the support element between the first and second opposing short edges is greater than the inner diameter of the longitudinal body, the support element must bend or fold between its first and second opposing short edges. This may further improve the stiffness of the support element due to the column effect. This may in turn advantageously improve the strength of the support element.

Where the support element includes one or more bends or folds between the first and second opposing short edges, the length referred to herein is the length between the first and second opposing short edges when the support element is flat, i.e. the support element without any bends or folds. In other words, where the support element includes one or more bends or folds, the length referred to herein is the length between the first and second sort edges, along the corresponding long edge of the support element.

The support element also has a longitudinal length. The longitudinal length of the support element is the length of the support element in the longitudinal direction between an upstream end of the support element and the downstream end of the support element. The longitudinal length of the support element is perpendicular to the length of the support element between the first and second opposing short edges. The length of the support element between the first and second opposing short edges may be greater than the longitudinal length of the support element.

The first short edge may be fixed to the inner surface of the longitudinal body by any means. The first short edge may be fixed to the inner surface of the longitudinal body by an adhesive.

The adhesive may be any adhesive. The adhesive may be a biodegradable adhesive. This may advantageously help to reduce the plastics pollution caused when the inhaler article is discarded. The adhesive may comprise at least one of a water based adhesive, a starch based adhesive, a PVA adhesive, a cellulose based adhesive, and a natural rubber based adhesive.

The longitudinal body may comprise a support element tube. The first short edge of the support element may be fixed to the inner surface of the support element tube. The provision of a support element tube may advantageously provide a secure structure to which the first short edge of the support element may be fixed. In addition, the provision of a support element tube may also simplify the manufacturing process of the inhaler article.

The upstream end of the support element tube may be aligned with the upstream end of the support element. The downstream end of the support element tube may be aligned with the downstream end of the support element. The longitudinal length of the support element tube may be approximately the same as the longitudinal length of the support element. Support element may be integrally formed with the support element tube.

The support element tube may comprise any material. Preferably, the support element tube comprises a biodegradable material. The support element tube may comprise paper or cardboard. The support element tube may comprise a spirally wound paper tube.

The provision of a spirally wound paper tube may advantageously provide a tube having sufficient strength to support the support element.

According to a second aspect of the present disclosure, there is provided an inhaler article. The inhaler article may comprise a longitudinal body. The inhaler article may comprise a sensorial element within the longitudinal body. The inhaler article may comprise a downstream section located downstream of the sensorial element. The downstream section may comprise a support element within the longitudinal body. The support element may comprise a first short edge and an opposing second short edge. The length of the support element between the first and second opposing short edges may be at least 15 millimetres.

According to a second aspect of the present invention, there is provided an inhaler article. The inhaler article comprises a longitudinal body. The inhaler article comprises a sensorial element within the longitudinal body. The inhaler article comprises a downstream section located downstream of the sensorial element. The downstream section comprises a support element within the longitudinal body. The support element comprises a first short edge and an opposing second short edge. The length of the support element between the first and second opposing short edges is at least 15 millimetres.

The provision of a support element having a length between the first and second opposing short edges of at least 15 millimetres may increase the stiffness and strength of the support element. This may be because a length of 15 millimetres is greater than the inner diameter of the longitudinal body at the position where the support element is located within the longitudinal body. As a result, the support element must bend or fold between its first and second opposing short edges in order to fit within the longitudinal body. This may further improve the stiffness of the support element due to the column effect. This may in turn advantageously improve the strength of the support element. In addition, the provision of a support element having a length between the first and second opposing short edges of at least 15 millimetres provides a support element having a relatively large surface area. The provision of a support element having a relatively large surface area may increase the cooling effect of the support element.

The support element according to any aspect described above may have any shape. The support element may be arranged as a spiral which extends from the first short edge to the second short edge, the first short edge being the radially outer short edge, and the second short edge being the radially inner short edge.

In this way, the support edge may spiral inwardly from a first short edge to the second short edge. The spiral may be about the longitudinal axis of the longitudinal body such that the second short edge of the support element is located close to the longitudinal axis of the longitudinal body.

The provision of a spiral support element may advantageously allow the support element to have a length between the first and second opposing short edges greater than the inner diameter of the longitudinal body at the position where the support element is located within the longitudinal body. The provision of a spiral support element may also advantageously improve the strength and stiffness of the support element due to the column effect.

At the same time, the provision of a spiral support element may minimise the resistance to draw of the support element since the support element is aligned with the longitudinal axis of the longitudinal body.

The spiral support element may include any number of windings. For example, the spiral may include at least 2, or at least 3 windings. The provision of a spiral including at least 3 windings may advantageously ensure that the support element is sufficiently strong and able to provide effective cooling of the mainstream air.

The spiral support element may include no more than 6 windings, no more than 5 windings, or no more than 4 windings. The provision of a spiral including no move than 6 windings may advantageously not have an undesirably high resistance to draw.

The spiral support element may include 3.5 windings. The inventors have found that 3.5 windings provides the optimal balance between strength and resistance to draw.

As used herein with reference to the invention, the term “winding” refers to a complete turn about the longitudinal axis of the coil. Where the support element includes 3.5 windings, the support element fully encircles the longitudinal axis three and a half times.

The support element may have any spacing between adjacent windings. For example, the spacing between any two adjacent windings may be no more than 4 millimetres, no more than 3 millimetres, or no more than 2.5 millimetres.

The spacing between any two adjacent windings may be at least 0.5 millimetres, at least 1 millimetre, or at least 1.5 millimetres. The spacing between two adjacent windings may be between about 0.5 millimetres and about 4 millimetres, between about 1 millimetres and about 3 millimetres, or between about 1 .5 millimetres and about 2.5 millimetres.

The spacing between any two adjacent windings may be about 2 millimetres.

The windings may be substantially evenly spaced. In this way, the spacing between any two adjacent windings described above may apply to the spacing between all adjacent windings.

The second short edge of the support element may be within 1 millimetre of the central longitudinal axis of the longitudinal body. The second short edge of the support element may be within 0.5 millimetres of the central longitudinal axis of the longitudinal body. The second short edge of the support element and the central longitudinal axis of the longitudinal body may be colinear.

The central longitudinal axis of the longitudinal body is the longitudinal axis of the longitudinal body which runs along the centre of the longitudinal body. Locating the second short edge of the support element on or close to the central longitudinal axis of the longitudinal body may advantageously support to upstream components such as aerosol-generating substrate, susceptor, or capsule across the entire inner diameter of the longitudinal body. In addition, this provision may prevent upstream components or portions of upstream components from passing along the centre of the longitudinal body.

The support element may have any longitudinal length. For example, the support element may have a length of at least 2 millimetres, at least 4 millimetres, or at least 5 millimetres.

The support element may have a length of no more than 15 millimetres, no more than 13 millimetres, no more than 10 millimetres.

The support element may have a length of between about 2 millimetres and about 15 millimetres, between about 4 millimetres and about 13 millimetres, or between about 5 millimetres and about 10 millimetres.

The support element may have a length of about 7.9 millimetres.

The provision of a support element having this length may advantageously provide sufficient cooling for the mainstream airflow.

The longitudinal body may be any body. The longitudinal body may comprise at least one paper wrapper. The at least one paper wrapper may be in the form of a cylinder. The longitudinal body may comprise a plurality of paper wrappers. The longitudinal body may comprise a paper overwrap. The longitudinal body may comprise tipping paper. The longitudinal body may comprise both paper overwrap and tipping paper. The tipping paper may be disposed upstream of the paper overwrap.

The support element may have any shape. The support element may be planar. The support element may be a portion of planar material. The provision of a planar support element may allow it to be easily coiled into a spiral shape. The provision of a planer support element may advantageously allow the support element to have a relatively low resistance to draw since the long edges of the planer support element may be arranged along the longitudinal direction of the inhaler article. In this way, the support element may provide as little resistance to draw as possible.

The support element may be rectangular. Where the support element is rectangular, the first short edge may have the same length as the second short edge. The support element may further comprise a first long edge and an opposing second long edge extending between the first and second short edges. The first long edge may have the same length as the second long edge.

The support element may include a first surface and an opposed second surface. The first and second surfaces may be a planar. The first and second planar surfaces may be defined on two opposing sides by the first and second short edges. The first and second planar surfaces may be defined on two opposing sides by the first and second long edges. The support element may have any thickness. The thickness of the support element is defined as the distance between the first and second surfaces. The thickness of the support element may be not more than 0.5 millimetres, no more than 0.1 millimetres, or no more than 0.05 millimetres. This may advantageously allow the support element to be easily coiled into a spiral shape. This may also advantageously allow the support element to have a relatively low resistance to draw.

The support element may be formed from any material. The support element may be formed from a resiliently deformable material. The support element may be formed from a cardboard or a paper material. This may advantageously allow the support element to be biodegradable. This may also allow the support element to be easily coiled into a spiral shape.

The support element may have any basis weight. The support element may have a basis weight of at least 100 grams per square metre, at least 200 grams per square metre, or at least 300 grams per square metre.

The support element may have a basis weight of no more than 700 grams per square metre, no more than 600 grams per square metre, or no more than 500 grams per square metre.

The support element may have a basis weight of between about 100 grams per square metre and about 700 grams per square metre, between about 200 grams per square metre and about 600 grams per square metre, or between about 300 grams per square metre and about 500 grams per square metre.

The provision of a support element having a basis weight within this range may advantageously provide an optimal balance between strength and resistance to draw of the support element.

The downstream section may have any resistance to draw (RTD). The resistance to draw of the downstream section may be no more than 20 millimetres H2O. The resistance to draw of the downstream section may be no more than 15 millimetres H2O, no more than 10 millimetres H2O, or no more than 5 millimetres H2O.

Values of RTD from about 10 millimetres H₂O to about to about 15 millimetres H₂O are particularly preferred because a downstream section having one such RTD is expected to contribute minimally to the overall RTD of the inhaler article and substantially does not exert a filtration action on the mainstream air being delivered to the consumer.

Unless otherwise specified, the resistance to draw (RTD) of a component or the inhaler article is measured in accordance with ISO 6565-2015. The RTD refers the pressure required to force air through the full length of a component. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements in accordance with ISO 6565-2015 are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

The sensorial element may comprise a capsule containing a dry powder.

The capsule may hold or contain at least about 5 mg of a dry powder or at least about 10 mg of a dry powder. The capsule may hold or contain less than about 900 mg of a dry powder, or less than about 300 mg of a dry powder, or less than about 150 mg of a dry powder. The capsule may hold or contain from about 5 mg to about 300 mg of a dry powder, or from about 10 mg to about 200 mg of a dry powder, or from about 25 mg to about 100 mg of a dry powder.

The capsule may contain pharmaceutically active particles comprising nicotine (also referred to as “nicotine powder” or “nicotine particles”) and optionally particles comprising flavour (also referred to as “flavour particles). The capsule may contain a predetermined amount of nicotine particles and optional flavour particles. The capsule may contain enough nicotine particles to provide at least 2 inhalations or “puffs”, or at least about 5 inhalations or “puffs”, or at least about 10 inhalations or “puffs”. The capsule may contain enough nicotine particles to provide from about 5 to about 50 inhalations or “puffs”, or from about 10 to about 30 inhalations or “puffs”. Each inhalation or “puff” may deliver from about 0.1 mg to about 3 mg of nicotine particles to the lungs of the user or from about 0.2 mg to about 2 mg of nicotine particles to the lungs of the user or about 1 mg of nicotine particles to the lungs of the user.

The sensorial element may comprise a rod of aerosol-generating substrate.

The aerosol-generating substrate may be a solid aerosol-generating substrate.

In certain preferred embodiments, the aerosol-generating substrate comprises homogenised plant material, preferably a homogenised tobacco material.

As used herein with reference to the invention, the term “homogenised plant material” encompasses any plant material formed by the agglomeration of particles of plant. For example, sheets or webs of homogenised tobacco material for the aerosol-generating substrates of the present invention may be formed by agglomerating particles of tobacco material obtained by pulverising, grinding or comminuting plant material and optionally one or more of tobacco leaf lamina and tobacco leaf stems. The homogenised plant material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

The homogenised plant material can be provided in any suitable form.

The aerosol-generating substrate may comprise tobacco. The aerosol-generating substrate may comprise at least one of reconstituted tobacco, cut filler, and homogenised tobacco material.

In some embodiments, the homogenised plant material may be in the form of one or more sheets. As used herein with reference to the invention, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof.

In some preferred embodiments, the aerosol-generating substrate comprises cut filler. Within the context of the present specification, the term “cut filler” is used to describe to a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

The cut filler may also comprise other after-cut, filler tobacco or casing.

Preferably, the cut filler is soaked with aerosol former. Soaking the cut filler can be done by spraying or by other suitable application methods. The aerosol former may be applied to the blend during preparation of the cut filler. For example, the aerosol former may be applied to the blend in the direct conditioning casing cylinder (DCCC). Conventional machinery can be used for applying an aerosol former to the cut filler. The aerosol former may be any suitable known compound or mixture of compounds that, in use, facilitates formation of a dense and stable aerosol. The aerosol former may be facilitating that the aerosol is substantially resistant to thermal degradation at temperatures typically applied during use of the aerosol-generating article. Suitable aerosol formers are for example to: polyhydric alcohols such as, for example, triethylene glycol, 1 ,3-butanediol, propylene glycol and glycerine; esters of polyhydric alcohols such as, for example, glycerol mono-, di- or triacetate; aliphatic esters of mono-, di- or polycarboxylic acids such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

Preferably, the aerosol former comprises one or more of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

Preferably, the amount of aerosol former is between 6 percent and 20 percent by weight on a dry weight basis of the cut filler, more preferably, the amount of aerosol former is between 8 percent and 18 percent by weight on a dry weight basis of the cut filler, most preferably the amount of aerosol former is between 10 percent and 15 percent by weight on a dry weight basis of the cut filler. When aerosol former is added to the cut filler in the amounts described above, the cut filler may become relatively sticky. This advantageously help retain the cut filler at a predetermined location within the article, as the particles of cut filler display a tendency to adhere to surrounding cut filler particles as well as to surrounding surfaces (for example, the internal surface of a wrapper circumscribing the cut filler).

For some embodiments the amount of aerosol former has a target value of about 13 percent by weight on a dry weight basis of the cut filler. The most efficient amount of aerosol former will depend also on the cut filler, whether the cut filler comprises plant lamina or homogenized plant material. For example, among other factors, the type of cut filler will determine to which extent the aerosol-former can facilitate the release of substances from the cut filler.

In certain embodiments of the invention, the homogenised plant material is a homogenised tobacco material comprising tobacco particles. Sheets of homogenised tobacco material for use in such embodiments of the invention may have a tobacco content of at least about 40 percent by weight on a dry weight basis, more preferably of at least about 50 percent by weight on a dry weight basis more preferably at least about 70 percent by weight on a dry weight basis and most preferably at least about 90 percent by weight on a dry weight basis.

The aerosol-generating substrate may further comprise one or more aerosol formers. Upon volatilisation, an aerosol former can convey other vaporised compounds released from the aerosol-generating substrate upon heating, such as nicotine and flavourants, in an aerosol. Suitable aerosol formers for inclusion in the homogenised plant material are known in the art and include, but are not limited to: polyhydric alcohols, such as triethylene glycol, propylene glycol, 1 ,3-butanediol and glycerol; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

The aerosol-generating substrate may have an aerosol former content of between about 5 percent and about 30 percent by weight on a dry weight basis, such as between about 10 percent and about 25 percent by weight on a dry weight basis, or between about 15 percent and about 20 percent by weight on a dry weight basis.

For example, if the substrate is intended for use in an aerosol-generating article for an electrically-operated aerosol-generating system having a heating element, it may preferably include an aerosol former content of between about 5 percent to about 30 percent by weight on a dry weight basis. If the substrate is intended for use in an aerosol-generating article for an electrically-operated aerosol-generating system having a heating element, the aerosol former is preferably glycerol. In other embodiments, the aerosol-generating substrate may have an aerosol former content of about 1 percent to about 5 percent by weight on a dry weight basis. For example, if the substrate is intended for use in an aerosol-generating article in which aerosol former is kept in a reservoir separate from the substrate, the substrate may have an aerosol former content of greater than 1 percent and less than about 5 percent. In such embodiments, the aerosol former is volatilised upon heating and a stream of the aerosol former is contacted with the aerosolgenerating substrate so as to entrain the flavours from the aerosol-generating substrate in the aerosol.

The inhaler article may further comprise a susceptor element in the rod of aerosolgenerating substrate. The susceptor element is preferably in contact with the aerosol-generating substrate.

As used herein with reference to the invention, the term “susceptor element” refers to an element comprising a material that is capable of converting electromagnetic energy into heat. When a susceptor element is located in an alternating electromagnetic field, the susceptor is heated. Heating of the susceptor element may be the result of at least one of hysteresis losses and eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material.

The susceptor element may be arranged such that, when the aerosol-generating article is received in the cavity of the aerosol-generating device, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element, causing the susceptor element to heat up. In these embodiments, the aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of between 1 and 5 kilo amperes per metre (kA m), preferably between 2 and 3 kA/m, for example about 2.5 kA/m. The electrically-operated aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field having a frequency of between 1 and 30 MHz, for example between 1 and 10 MHz, for example between 5 and 7 MHz.

The susceptor element may comprise any suitable material. The susceptor element may be formed from any material that can be inductively heated to a temperature sufficient to release volatile compounds from the aerosol-forming substrate. Suitable materials for the elongate susceptor element include graphite, molybdenum, silicon carbide, stainless steels, niobium, aluminium, nickel, nickel containing compounds, titanium, and composites of metallic materials. Some susceptor elements comprise a metal or carbon. Advantageously the susceptor element may comprise or consist of a ferromagnetic material, for example, ferritic iron, a ferromagnetic alloy, such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. A suitable susceptor element may be, or comprise, aluminium. The susceptor element preferably comprises more than about 5 percent, preferably more than about 20 percent, more preferably more than about 50 percent or more than about 90 percent of ferromagnetic or paramagnetic materials. Some elongate susceptor elements may be heated to a temperature in excess of about 250 degrees Celsius.

The susceptor element may comprise a non-metallic core with a metal layer disposed on the non-metallic core. For example, the susceptor element may comprise metallic tracks formed on an outer surface of a ceramic core or substrate.

The downstream section may comprise at least one additional component. The at least one additional component may be contained within the longitudinal body.

The downstream section may comprise a hollow tubular element. The hollow tubular element may be disposed downstream of the support element. The hollow tubular element may be disposed immediately downstream of the support element.

As used herein with reference to the invention, the term "hollow tubular element" denotes a generally elongate element defining a lumen or airflow passage along a longitudinal axis thereof. In particular, the term "tubular" will be used in the following with reference to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit establishing an uninterrupted fluid communication between an upstream end of the tubular element and a downstream end of the tubular element. However, it will be understood that alternative geometries (for example, alternative cross-sectional shapes) of the tubular element may be possible.

In the context of the present invention, a hollow tubular element provides an unrestricted flow channel. This means that the hollow tubular element provides a negligible level of resistance to draw (RTD). The term “negligible level of RTD” is used to describe an RTD of less than 1 millimetres H2O per 10 millimetres of length of the hollow tubular element, preferably less than 0.4 millimetres H2O per 10 millimetres of length of the hollow tubular element, more preferably less than 0.1 millimetres H2O per 10 millimetres of length of the hollow tubular element.

The RTD of a hollow tubular element is preferably less than or equal to 10 millimetres H2O. More preferably, the RTD of a hollow tubular element is less than or equal to 5 millimetres H2O. Even more preferably, the RTD of a hollow tubular element is less than or equal to 2.5 millimetres H2O. Even more preferably, the RTD of the hollow tubular element is less than or equal to 2 millimetres H2O. Even more preferably, the RTD of the hollow tubular element is less than or equal to 1 millimetre H₂O.

The RTD of a hollow tubular element may be at least 0 millimetres H₂O, or at least 0.25 millimetres H2O or at least 0.5 millimetres H2O or at least 1 millimetre H2O.

The hollow tubular element may comprise a paper-based material. The hollow tubular element may comprise at least one layer of paper. The paper may be very rigid paper. The paper may be crimped paper, such as crimped heat resistant paper or crimped parchment paper. Preferably, the hollow tubular element may comprise cardboard. The hollow tubular element may be a cardboard tube. The hollow tubular element may be formed from cardboard.

The downstream section may comprise a ventilation zone. The ventilation zone may be at a location along the hollow tubular element.

As such, a ventilated cavity is provided downstream of the support element. This provides several potential technical benefits.

First of all, the inventors have found that one such ventilated hollow tubular element provides a particularly efficient cooling of the aerosol. Thus, a satisfactory cooling of the aerosol can be achieved.

Secondly, the inventors have surprisingly found that such rapid cooling of the volatile species released upon heating the aerosol-generating substrate promotes enhances nucleation of aerosol particles.

The ventilation zone may typically comprise a plurality of perforations through the peripheral wall of the hollow tubular element. Preferably, the ventilation zone comprises at least one circumferential row of perforations. In some embodiments, the ventilation zone may comprise two circumferential rows of perforations. For example, the perforations may be formed online during manufacturing of the aerosol-generating article. Preferably, each circumferential row of perforations comprises from 8 to 30 perforations.

An aerosol-generating article in accordance with the present invention may have a ventilation level of at least 25 percent.

The term “ventilation level” is used throughout the present specification to denote a volume ratio between of the airflow admitted into the aerosol-generating article via the ventilation zone (ventilation airflow) and the sum of the aerosol airflow and the ventilation airflow. The greater the ventilation level, the higher the dilution of the aerosol flow delivered to the consumer. The aerosolgenerating article preferably has a ventilation level of at least 25 percent, more preferably at least 30 percent, even more preferably at least 40 percent, even more preferably at least 50 percent.

An aerosol-generating article in accordance with the present invention may have a ventilation level of up to 90 percent. Preferably, an aerosol-generating article in accordance with the present invention has a ventilation level of less than or equal to 80 percent, more preferably less than or equal to 70 percent, even more preferably less than or equal to 60 percent.

The downstream section may further comprise a downstream filter segment. The downstream filter segment may be located at the downstream end of the inhaler article. The downstream end of the downstream filter segment may define the downstream end of the inhaler article. The downstream filter segment may be located downstream of a hollow tubular element, which is described above. The downstream filter segment may be located downstream of the support element. The downstream filter segment may be located within the longitudinal body.

The downstream filter segment is preferably a solid plug, which may also be described as a ‘plain’ plug and is non-tubular. The filter segment therefore preferably has a substantially uniform transverse cross section.

The downstream filter segment is preferably formed of a fibrous filtration material. The fibrous filtration material may be for filtering the aerosol that is generated from the aerosolgenerating substrate. Suitable fibrous filtration materials would be known to the skilled person.

The fibrous filtration material may comprise a plurality of natural fibres. The plurality of natural fibres may comprise one or more of flax fibres, hemp fibres, jute fibres, kenaf fibres, ramie fibres, abaca fibres, phormium fibres, sisal fibres, coir fibres, cotton fibres, and kapok fibres.

The fibrous filtration material may comprise a plurality of regenerated cellulose fibres. The regenerated cellulose fibres may comprise one or more of viscose fibres, modal fibres, Lyocell fibres and viscose rayon fibres.

The fibrous filtration material may comprise a paper material.

The fibrous filtration material may further comprise an additive coating provided on the plurality of natural fibres. The additive coating may comprise at least 5 percent by weight of exogenous lignin on a dry weight basis.

Particularly preferably, the at least one downstream filter segment comprises a cellulose acetate filter segment formed of cellulose acetate tow.

Preferably, the downstream filter segment has a low particulate filtration efficiency.

The inhaler article may further comprise an upstream element upstream of the sensorial element within the longitudinal body.

The upstream element advantageously prevents direct physical contact with the upstream end of the sensorial element. For example, where the sensorial element comprises a susceptor element, the upstream element may prevent direct physical contact with the upstream end of the susceptor element. This helps to prevent the displacement or deformation of the susceptor element during handling or transport of the inhaler article. This in turn helps to secure the form and position of the susceptor element. Furthermore, the presence of an upstream element helps to prevent any loss of the substrate, which may be advantageous, for example, if the sensorial element contains particulate plant material.

For inhaler articles that are intended to be inserted into a heating chamber in an aerosolgenerating device such that the sensorial element can be externally heated within the heating chamber, the upstream element may advantageously facilitate the insertion of the upstream end of the article into the heating chamber. The inclusion of the upstream element may additionally protect the end of the sensorial element during the insertion of the article into the heating chamber such that the risk of damage to the substrate is minimised.

An upstream element may be a porous plug element. Preferably, an upstream element has a porosity of at least 50 percent in the longitudinal direction of the aerosol-generating article. More preferably, an upstream element has a porosity of between 50 percent and 90 percent in the longitudinal direction. The porosity of an upstream element in the longitudinal direction is defined by the ratio of the cross-sectional area of material forming the upstream element and the internal cross-sectional area of the aerosol-generating article at the position of the upstream element.

An upstream element may be made of a porous material or may comprise a plurality of openings. This may, for example, be achieved through laser perforation. Preferably, the plurality of openings is distributed homogeneously over the cross-section of the upstream element.

The porosity or permeability of an upstream element may advantageously be designed in order to provide an aerosol-generating article with a particular overall resistance to draw (RTD) without substantially impacting the filtration provided by other portions of the article.

An upstream element may be formed from a material that is impermeable to air. In such embodiments, the aerosol-generating article may be configured such that air flows into at least one of the first aerosol-generating segment and the second aerosol-generating segment through suitable ventilation means provided in a wrapper.

In certain preferred embodiments of the invention, it may be desirable to minimise the RTD of an upstream element. For example, this may be the case for articles that are intended to be inserted the heating chamber of an aerosol-generating device such that the aerosol-generating substrate is externally heated, as described herein. For such articles, it is desirable to provide the article with as low an RTD as possible, so that the majority of the RTD experience by the consumer is provided by the aerosol-generating device and not the article.

According to a third aspect of the present disclosure, there is provided a method for manufacturing an inhaler article. The method may comprise the step of attaching an end of a bulk portion of planar material to a conical spiral forming device. The method may comprise the step of applying torsion to the conical spiral forming device to wind a portion of the bulk planar material into a spiral shape. The method may comprise the step of cutting the bulk portion of planar material to form a support element having a spiral shape.

According to a third aspect of the present invention, there is provided a method for manufacturing an inhaler article. The method comprises the step of attaching an end of a bulk portion of planar material to a conical spiral forming device. The method comprises the step of applying torsion to the conical spiral forming device to wind a portion of the bulk planar material into a spiral shape. The method comprises the step of cutting the bulk portion of planar material to form a support element having a spiral shape.

Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

Example 1. An inhaler article comprising a longitudinal body, a sensorial element within the longitudinal body, and a downstream section located downstream of the sensorial element, the downstream section comprising a support element within the longitudinal body, the support element comprising a first short edge and an opposing second short edge, wherein the first short edge is fixed to the inner surface of the longitudinal body, and is aligned with the longitudinal axis of the longitudinal body, and the second short edge is able to move relative to the longitudinal body.

Example 2. An inhaler article according to Example 1 , wherein the length of the support element between the first and second opposing short edges is greater than the inner diameter of the longitudinal body at the position where the support element is fixed to the inner surface of the longitudinal body.

Example 3. An inhaler article according to Example 1 or Example 2, wherein the first short edge is fixed to the inner surface of the longitudinal body by an adhesive.

Example 4. An inhaler article according to Example 3, wherein the adhesive comprises at least one of a water based adhesive, a starch based adhesive, a PVA adhesive, a cellulose based adhesive, and a natural rubber based adhesive.

Example 5. An inhaler article according to any preceding Example, wherein the longitudinal body further comprises a support element tube , the first short edge of the support element being fixed to the inner surface of the support element tube.

Example 6. An inhaler article according to Example 5, wherein the support element tube comprises a spirally wound paper tube.

Example 7. An inhaler article comprising: a longitudinal body, a sensorial element within the longitudinal body, and a downstream section located downstream of the sensorial element, the downstream section comprising a support element within the longitudinal body, the support element comprising a first short edge and an opposing second short edge, wherein the length of the support element between the first and second opposing short edges is at least 15 millimetres.

Example 8. An inhaler article according to any preceding Example, wherein the support element is arranged as a spiral which extends from the first short edge to the second short edge, the first short edge being the radially outer short edge, and the second short edge being the radially inner short edge. Example 9. An inhaler article according to Example 8, wherein the spiral includes at least three windings.

Example 10. An inhaler article according to Example 9, wherein the spacing between any two adjacent windings is no more than 4 millimetres.

Example 11 . An inhaler article according to Example 9 or Example 10, wherein the spacing between any two adjacent windings is at least 0.5 millimetres.

Example 12. An inhaler article according to any preceding Example, wherein the second short edge of the support element is within 1 millimetre of the central axis of the longitudinal body.

Example 13. An inhaler article according to any preceding Example, wherein the support element has a longitudinal length of at least 2 millimetres.

Example 14. An inhaler article according to any preceding Example, wherein the support element has a longitudinal length of no more than 15 millimetres.

Example 15. An inhaler article according to any preceding Example, wherein the longitudinal body comprises a paper overwrap.

Example 16. An inhaler article according to any preceding Example, wherein the longitudinal body comprises a tipping paper.

Example 17. An inhaler article according to any preceding Example, wherein the support element comprises a portion of planar material.

Example 18. An inhaler article according to any preceding Example, wherein the support element is rectangular.

Example 19. An inhaler article according to any preceding Example, wherein the support element is formed from at least one of paper or cardboard.

Example 20. An inhaler article according to any preceding Example, wherein the support element has a basis weight of at least 100 grams per square metre.

Example 21. An inhaler article according to any preceding Example, wherein the support element has a basis weight of no more than 700 grams per square metre.

Example 22. An inhaler article according to any preceding Example, wherein the resistance to draw of the downstream section is no more than 20 millimetres H2O.

Example 23. An inhaler article according to any preceding Example, wherein the sensorial element comprises a capsule containing a dry powder.

Example 24. An inhaler article according to any preceding Example, wherein the sensorial element comprises a rod of aerosol-generating substrate.

Example 25. An inhaler article according to Example 24, wherein the aerosol-generating substrate comprises tobacco. Example 26. An inhaler article according to Example 25, wherein the aerosol-generating substrate comprises at least one of reconstituted tobacco, cut filler, and homogenised tobacco material.

Example 27. An inhaler article according to any one of Example 24 to 26, wherein the inhaler article further comprises a susceptor element in the rod of aerosol-generating substrate.

Example 28. An inhaler article according to any preceding Example, wherein the downstream section further comprises a downstream filter segment downstream of the support element and within the longitudinal body.

Example 29. An inhaler article according to any preceding Example, further comprising an upstream element upstream of the sensorial element within the longitudinal body.

Example 30. A method of manufacturing an inhaler article, the method comprising steps of, attaching an end of a bulk portion of planar material to a conical spiral forming device, applying torsion to the conical spiral forming device to wind a portion of the bulk planar material into a spiral shape, cutting the bulk portion of planar material to form a support element having a spiral shape.

In the following, the invention will be further described with reference to the drawings of the accompanying Figures, in which:

Figure 1 shows a schematic side sectional view of a first inhaler article according to the present invention comprising an aerosol-generating substrate;

Figure 2 shows a schematic side sectional view of a second inhaler article according to the present invention comprising a capsule;

Figure 3 shows a schematic longitudinal sectional view of the inhaler article shown in Figure 1 taken along direction ‘A’;

Figure 4 shows a schematic perspective view of portion of the inhaler article according to the present invention; and

Figure 5 shows a schematic perspective view of an apparatus for carrying out a method for manufacturing an inhaler article, the method being in accordance with the present disclosure.

The inhaler article 100 shown in Figure 1 extends from a downstream end 101 to an upstream end 102. The inhaler article 100 comprises a longitudinal body 105. The longitudinal body 105 comprises a downstream tipping paper 103, an upstream overwrap 104, and a support element tube 108. The support element tube 108 is disposed within the overwrap 104. The inhaler article 100 comprises a sensorial element 106 within the longitudinal body 105. The inhaler article 100 comprises a downstream section located downstream of the sensorial element 106. The downstream section comprises a support element 107. The upstream end of the support element 107 is in contact with the downstream end of the sensorial element 106.

The support element 107 comprises a rectangular, planar portion of cardboard material. The cardboard material has a basis weight of about 500 grams per square metre. The support element has a first short edge, a second opposed short edge, a first long edge, and a second opposed long edge. The first and second short edges are aligned with the longitudinal axis of the inhaler article 100. The length between the first and second short edges of the support element 107 is about 15 millimetres.

The first short edge of the support element 107 is fixed to the inner surface of the longitudinal body 105, specifically to the inner surface of the support element tube 108. The second short edge of the support element 107 is able to move relative to the longitudinal body 105.

As described in more detail below, the support element 107 is arranged as a spiral which extends from the first short edge to the second short edge, the first short edge being the radially outer short edge, and the second short edge being the radially inner short edge.

The support element 107 has a longitudinal length of about 7.9 millimetres.

In the inhaler article 100 shown in Figure 1 , the sensorial element 106 comprises a rod of aerosol-generating substrate 109 comprising homogenised tobacco material. The sensorial element 106 further comprises a susceptor element 1 10 comprising a portion of steel foil disposed within the aerosol-generating substrate 109 and aligned with the longitudinal axis of the inhaler article 100. The sensorial element 106 has a length of about 12.3 millimetres.

The downstream section of the inhaler article 100 shown in Figure 1 further comprises a hollow tubular element 11 1. The hollow tubular element 1 11 is disposed immediately downstream of the support element 107 such that the upstream end of the hollow tubular element 11 1 is in direct contact with the downstream end of the support element 107. The hollow tubular element 111 is formed from paper. The hollow tubular element 1 11 has an inner diameter of about 4.8 millimetres. The hollow tubular element 1 11 has a length of about 7.7 millimetres.

The hollow tubular element comprises a ventilation zone 1 12. The ventilation zone 112 comprises a circumferential row of perforations through the peripheral wall of the hollow tubular element 11 1.

The downstream section of the inhaler article 100 shown in Figure 1 further comprises a downstream filter segment 113. The downstream filter segment 113 is disposed immediately downstream of the hollow tubular element 11 1 such that the upstream end of the downstream filter segment 1 13 is in direct contact with the downstream end of the hollow tubular element 11 1. The downstream end of the downstream filter segment 113 defines the downstream end 101 of the inhaler article 100. The downstream filter segment 1 13 comprises a plug of cellulose acetate tow. The downstream filter segment 1 13 has a length of about 11 .9 millimetres.

The inhaler article 100 shown in Figure 1 further comprises an upstream element 114 upstream of the sensorial element 106. The upstream element 114 is disposed immediately upstream of the sensorial element 106 such that the upstream end of the sensorial element 106 is in direct contact with the downstream end of the upstream element 1 14. The upstream end of the upstream element 114 defines the upstream end 102 of the inhaler article 100. The upstream element 1 14 comprises a porous plug element. The upstream element 114 has a length of about 5.3 millimetres.

A second example inhaler article 200 according to the present invention is shown in Figure 2. Components which the second inhaler article 200 has in common with the first inhaler article 100 are identified by similar reference numerals. The first inhaler article 200 differs from the first inhaler article 100 since the sensorial element 206 is a capsule comprising a dry powder. The capsule contains about 50 milligrams of dry powder. The dry powder comprises nicotine particles. The second inhaler article 200 does not include a downstream filter segment or an upstream element.

Figure 3 shows a schematic longitudinal sectional view of the inhaler article 100 shown in Figure 1 taken along direction ‘A’. It will be appreciated that Figure 3 is equally applicable to the second inhaler article 200.

As described above, the support element 107 extends between a first short edge 301 and a second opposed short edge 302. The first short edge 301 is adhered to the inner surface of the support element tube 108 of the longitudinal body 105. The adhesive is a biodegradable, PVA based adhesive.

The support element 107 is arranged as a spiral. The spiral includes three windings. The spacing between each adjacent winding 304 is substantially the same. The spacing between adjacent windings 304 is about 2 millimetres.

The second short edge 302 of the support element 107 is 1 millimetre of the central axis of the longitudinal body.

A schematic perspective view of portion of the inhaler article 100 according to the present invention is shown in Figure 4.

The perspective view in Figure 4 allows the first long edge 401 of the support element 107 to be seen. The first long edge 401 and second long edge (not shown) extend between the first short edge 301 and the second short edge 302. The example shown in Figure 4 does not include a support element tube.

In use, the support element 107 provides support to upstream components such as aerosol-generating substrate 109, susceptor 110, or capsule. In particular, where the sensorial element 206 comprises a capsule as shown in Figure 2, the support element 207 prevents the capsule from moving further downstream in the inhaler article 200 when the capsule is pierced by a piercing element. In addition, the support element 107 acts to cool the mainstream airflow in the case where the sensorial element 106 comprises an aerosol-generating substrate 109 which is intended to be heated. The apparatus 500 shown in Figure 5 comprises a conical spiral forming device 501 which is configured to rotate about an axle 502. The method for manufacturing an inhaler article comprises steps of attaching an end of a bulk portion of planar material 503. The bulk portion of planar material 503 is fed into the conical spiral forming device 501 at angle x°- Angle x° is preferably 84°. The conical spiral forming device 501 comprises a series of four tapered steps 504, 505, 506, 507 which decrease in diameter. The four tapered steps 504, 505, 506, 507 rotate and progressively coil the planar material 503 into a spiral shape 508 to form the support element. An overwrap 509 may be applied about the spiral shape 508 to form a rod. The overwrap 509 forms the support element tube of the longitudinal body described above. The rod comprising the support element and the support element tube is then cut to length by a rotating knife 510.

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.

While a number of example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. It will be understood that features described above in relation to one aspect of the invention or disclosure are equally applicable to other aspects of the invention or disclosure.

Claims

CLAIMS:

1 . An inhaler article comprising: a longitudinal body, a sensorial element within the longitudinal body, and a downstream section located downstream of the sensorial element, the downstream section comprising a support element within the longitudinal body, the support element comprising a first short edge and an opposing second short edge, wherein the first short edge is fixed to the inner surface of the longitudinal body, and is aligned with the longitudinal axis of the longitudinal body, and the second short edge is able to move relative to the longitudinal body, and wherein the support element is arranged as a spiral which extends from the first short edge to the second short edge, the first short edge being the radially outer short edge, and the second short edge being the radially inner short edge.

2. An inhaler article according to claim 1 , wherein the length of the support element between the first and second opposing short edges is greater than the inner diameter of the longitudinal body at the position where the support element is fixed to the inner surface of the longitudinal body.

3. An inhaler article according to claim 1 or claim 2, wherein the first short edge is fixed to the inner surface of the longitudinal body by an adhesive.

4. An inhaler article according to claim 3, wherein the adhesive comprises at least one of a water based adhesive, a starch based adhesive, a PVA adhesive, a cellulose based adhesive, and a natural rubber based adhesive.

5. An inhaler article according to any preceding claim, wherein the longitudinal body further comprises a support element tube , the first short edge of the support element being fixed to the inner surface of the support element tube.

6. An inhaler article according to claim 5, wherein the support element tube comprises a spirally wound paper tube.

7. An inhaler article comprising: a longitudinal body, a sensorial element within the longitudinal body, and a downstream section located downstream of the sensorial element, the downstream section comprising a support element within the longitudinal body, the support element comprising a first short edge and an opposing second short edge, wherein the length of the support element between the first and second opposing short edges is at least 15 millimetres.

8. An inhaler article according to claim 7, wherein the support element is arranged as a spiral which extends from the first short edge to the second short edge, the first short edge being the radially outer short edge, and the second short edge being the radially inner short edge.

9. An inhaler article according to any one of claims 1 to 6, or 8, wherein the spiral includes at least three windings.

10. An inhaler article according to any one of claims 1 to 6, 8, or 9, wherein the spacing between any two adjacent windings is no more than 4 millimetres.

11. An inhaler article according to claim 9 or claim 10, wherein the spacing between any two adjacent windings is at least 0.5 millimetres.

12. An inhaler article according to any preceding claim, wherein the second short edge of the support element is within 1 millimetre of the central axis of the longitudinal body.

13. An inhaler article according to any preceding claim, wherein the support element has a longitudinal length of no more than 15 millimetres.

14. An inhaler article according to any preceding claim, wherein the support element comprises a portion of planar material.

15. An inhaler article according to any preceding claim, wherein the support element is formed from at least one of paper or cardboard.