WO2026002892A1 - Aerosol-generating article with extruded or injection moulded element - Google Patents

Abstract

The invention relates to an aerosol-generating article. The aerosol- generating article comprises a longitudinal axis extending between an upstream end and a downstream end of the aerosol-generating article. The aerosol-generating article comprises an aerosol¬ forming substrate portion (16). The aerosol-forming substrate portion (16) comprises an aerosol-forming substrate. The aerosol- generating article comprises a downstream element (14,12) arranged downstream of the aerosol-forming substrate portion (16). The downstream element (14,12) comprises an extruded or injection moulded mixture of polymers. The mixture of polymers comprises starch and cellulose. The invention further relates to an aerosol- generating system. The invention further relates to a method for manufacturing an aerosol-generating article.

Description

AEROSOL-GENERATING ARTICLE WITH EXTRUDED OR INJECTION MOULDED

ELEMENT

The present disclosure relates to an aerosol-generating article. The present disclosure further relates to an aerosol-generating system. The present disclosure further relates to a method for manufacturing an aerosol-generating article.

It is known to provide an aerosol-generating device for generating an inhalable vapor. Such devices may heat an aerosol-forming substrate contained in an aerosol-generating article without burning the aerosol-forming substrate. The aerosol-generating article may have a rod shape for insertion of the aerosol-generating article into a heating chamber of the aerosol-generating device.

The aerosol-generating device may comprise a heating arrangement. The heating arrangement may be an induction heating arrangement and may comprise an induction coil configured to inductively heat a susceptor. The susceptor may be part of the device or may be part of the aerosol-generating article.

It would be desirable to provide an aerosol-generating article that is environmentally more friendly. It would be desirable to improve biodegradability of an aerosol-generating article. It would be desirable to improve biodegradability of an aerosol-generating article without need of major reconstruction of production machinery. It would be desirable to improve biodegradability of an aerosol-generating article without significant rise in production costs. It would be desirable to improve biodegradability of an aerosol-generating article without adversely affecting product performance.

According to an embodiment of the invention there is provided an aerosol-generating article. The aerosol-generating article may comprise a longitudinal axis extending between an upstream end and a downstream end of the aerosol-generating article. The aerosolgenerating article may comprise an aerosol-forming substrate portion comprising an aerosolforming substrate. The aerosol-generating article may comprise a downstream element arranged downstream of the aerosol-forming substrate portion. The downstream element may comprise a mixture of polymers. The mixture of polymers may be a mixture of natural polymers. The mixture of polymers may comprise one or both of starch and cellulose. The mixture of polymers may be an extruded mixture of polymers. The mixture of polymers may be an injection moulded mixture of polymers.

According to an embodiment of the invention there is provided an aerosol-generating article. The aerosol-generating article comprises a longitudinal axis extending between an upstream end and a downstream end of the aerosol-generating article. The aerosolgenerating article comprises an aerosol-forming substrate portion. The aerosol-forming substrate portion comprises an aerosol-forming substrate. The aerosol-generating article comprises a downstream element arranged downstream of the aerosol-forming substrate portion. The downstream element comprises a mixture of polymers. The mixture of polymers comprises starch and cellulose. The mixture of polymers is extruded or injection moulded.

An aerosol-generating article that is environmentally more friendly may be provided. An aerosol-generating article with improved biodegradability may be provided. An aerosolgenerating article with improved biodegradability without the need for major reconstructions of the production machinery may be provided. An aerosol-generating article with improved biodegradability without significant rise in production costs may be provided. An aerosolgenerating article with improved biodegradability without adversely affecting product performance may be provided.

By the downstream element of the aerosol-generating article of the invention, a more environmentally friendly alternative compared to existing downstream elements, for example hollow acetate tubes, may be provided. The article of the invention may be produced in existing manufacturing apparatuses for producing aerosol-generating articles with conventional downstream elements without the need for major reconstructions of the production machinery. The article of the invention may show comparative product performance as conventional aerosol-generating articles with conventional downstream elements as regards; for example, smoking experience and mechanical stability.

A weight ratio of starch to cellulose in the mixture of polymers may be between 10 to 90 and 90 to 10, preferably between 20 to 80 and 80 to 20, on a dry weight basis.

The weight ratio of starch to cellulose in the mixture of polymers may be between 60 to 40 and 80 to 20, preferably between 65 to 35 and 75 to 25, more preferably may be about 70 to 30, on a dry weight basis. In other embodiments, the weight ratio of starch to cellulose in the mixture of polymers may be between 40 to 60 and 60 to 40, preferably between 45 to 55 and 55 to 45, more preferably may be about 50 to 50, on a dry weight basis.

The mixture of polymers may be a mixture of natural polymers. The term “natural polymers” refers to polymers which are not chemically modified.

The starch may be obtained from various sources, for example corn, potato, or cassava. The cellulose may be obtained from various sources, for example wood pulp, cotton, or other plant-based materials. The starch may be provided to the mixture of polymers in a finely powdered form.

The mixture of polymers may comprise water. The amount of water may be below 10 percent by weight based on the weight of the dry material in the mixture.

The mixture of polymers may comprise one or more of polysaccharides, microcrystalline cellulose, cellulose nanofibrils, alginate, ligno-cellulosic products, pectins, chitosan, chitin, gums, proteins, lipids, gelatin, gluten, keratin, and beeswax. The mixture of polymers may comprise one or more plasticizers. The one or more plasticizers may improve the flexibility and workability of the mixture.

The one or more plasticizers may be added in an amount of 10 to 30 weight percent, preferably 15 to 22 weight percent, more preferably about 20 weight percent, based on the dry weight of the polymers in the mixture of polymers.

The plasticizer may be derived from one or more of epoxidized triglyceride vegetable oils, linseed oil, castor-oil, sunflower oil, fatty acid esters, polyols, mono-, di- and oligosaccharides.

The plasticizer may be selected from one or more of polyols, lactic acid esters, citric acid esters, acetylated monoglycerides, and diacetyl tartaric acid esters.

The plasticizer may be selected from one or more polyols. The one or more polyols may be selected from one or more of glycerol, sorbitol, propylene glycol, mannitol and xylitol.

The plasticizer may be glycerol. The plasticizer may be glycerol and the glycerol may be added in the range of 20 to 40 weight percent based on the weight of the starch in the mixture of polymers.

The plasticizer may be propylene glycol. The plasticizer may be propylene glycol and the propylene glycol may be added in the range of 10 to 30 weight percent based on the weight of the starch in the mixture of polymers.

The plasticizer may be selected from one or more lactic acid esters. The one or more lactic acid esters may be selected from one or both of ethyl lactate and butyl lactate.

A density of the mixture of polymers may be more than 0.90 grams per cubic centimeter, preferably more than 1.70 grams per cubic centimeter. A density of the material of the downstream element may be more than 0.90 grams per cubic centimeter, preferably more than 1.70 grams per cubic centimeter.

The downstream element may be a hollow tubular element.

The downstream element may be a hollow tubular element and a density of the walls of the hollow tubular downstream element may be more than 0.90 grams per cubic centimeter, preferably more than 1.70 grams per cubic centimeter.

An inner diameter of the hollow tubular downstream element may vary along a longitudinal axis of the hollow tubular downstream element.

As used herein, the “inner diameter of a hollow tubular element” refers to the diameter of the hollow inner core of the hollow tubular element, i.e. the diameter extending between opposing inner sidewalls of the hollow tubular element.

A first longitudinal portion of the hollow tubular downstream element may have a larger inner diameter than a second longitudinal portion of the hollow tubular downstream element. One or both of the first and second portions may comprise perforations. The first portion may comprise perforations. The first portion may be located downstream or upstream of the second portion. Preferably, the first portion comprises perforations and is located downstream of the second portion. This may advantageously provide vortices in the airflow. This may particularly advantageously improve homogenization.

The inner diameter of the hollow tubular downstream element may constantly increase in a direction from the downstream end towards the upstream end. The inner diameter of the hollow tubular downstream element may constantly increase in a direction from the upstream end towards the downstream end. The inner diameter of the hollow tubular downstream element may linearly increase in a direction from the downstream end towards the upstream end. The inner diameter of the hollow tubular downstream element may linearly increase in a direction from the upstream end towards the downstream end.

The inner diameter of the hollow tubular downstream element may increase stepwise in a direction from the downstream end towards the upstream end. The inner diameter of the hollow tubular downstream element may increase stepwise in a direction from the upstream end towards the downstream end.

The downstream element may be a monolithic piece. The downstream element may be a monolithic downstream element.

The downstream element may comprise one or more perforations. The perforations may be provided in form of one or more circumferentially arranged rows of perforations.

The downstream element may be configured as a hollow tube. The hollow tube may have an inner diameter of between 2.8 millimeters and 3.8 millimeters, preferably about 3.3 millimeters. The hollow tube may have an outer diameter of between 7.0 millimeters and 7.2 millimeters, preferably about 7.1 millimeters. The hollow tube may have a length of between 2 millimeters and 15 millimeters, preferably between 5 millimeters and 11 millimeters, more preferably between 7 millimeters and 9 millimeters.

The downstream element may be configured as a fine hollow tube. The fine hollow tube may have an inner diameter of between 4.8 millimeters and 5.2 millimeters, preferably about 5 millimeters. The fine hollow tube may have an outer diameter of between 7.0 millimeters and 7.2 millimeters, preferably about 7.1 millimeters. The fine hollow tube may have a length of between 2 millimeters and 15 millimeters, preferably between 5 millimeters and 11 millimeters, more preferably between 7 millimeters and 9 millimeters. The fine hollow tube may comprise one or more perforations.

The downstream element may be configured as the hollow tube and the fine hollow tube. The fine hollow tube may be arranged downstream of the hollow tube. The fine hollow tube and the hollow tube may be configured as two separate elements. The fine hollow tube and the hollow tube may be configured as a monolithic piece.

The aerosol-generating article may comprise a mouthpiece filter arranged downstream of the downstream element. The mouthpiece filter may comprise or may be made of a filter material. Suitable filter materials are known to those skilled in the art. Suitable filter materials may include cellulose acetate or polylactic acid.

The aerosol-generating article may comprise a front plug located upstream of the aerosol-forming substrate portion. The front plug may prevent movement of the aerosolforming substrate portion towards an upstream direction. The front plug may be provided at the upstream end of the article. The front plug may be a filled cylinder. The front plug may comprise or may be made of filter material. Suitable filter materials are known to those skilled in the art. Suitable filter materials may include cellulose acetate or polylactic acid.

The aerosol-forming substrate portion may comprise aerosol-forming substrate and a susceptor. The susceptor may be a sheet-like element. The susceptor may extend along a longitudinal center axis of the aerosol-forming substrate portion.

The aerosol-generating article may comprise a front plug located at the upstream end of the article, an aerosol-forming substrate portion located downstream of the front plug, a downstream element arranged downstream of the aerosol-forming substrate portion and comprising a mixture of polymers comprising starch and cellulose, and a mouthpiece filter arranged downstream of the downstream element at the downstream end of the article.

The aerosol-generating article may comprise one or more wrappers surrounding part or all of the article. The wrappers may be made of a paper-based material.

The aerosol-generating article may comprise a substrate wrapper surrounding only the aerosol-forming substrate portion. The aerosol-generating article may comprise a mouthpiece wrapper surrounding a proximal portion of the article. The aerosol-generating article may comprise a distal wrapper surrounding a distal portion of the article. The aerosolgenerating article may comprise an overlapping portion surrounded by both the mouthpiece wrapper and the distal wrapper.

The downstream element may prevent movement of the aerosol-forming substrate portion towards a downstream direction. The downstream element may prevent movement of the susceptor of the aerosol-forming substrate portion towards a downstream direction. The downstream element may function as a cooling section. The cooling section may allow evaporated components travelling downstream from the aerosol-forming substrate portion to cool down. The downstream element may serve as a homogenization chamber.

According to an embodiment of the invention there is provided an aerosol-generating system comprising the aerosol-generating article as described herein and an aerosolgenerating device. The aerosol-generating device may comprise a cavity configured for at least partly inserting the aerosol-generating article into the cavity. The aerosol-generating article may comprise a susceptor and the aerosol-generating device may comprise an inductor for inductively heating the susceptor. According to an embodiment of the invention there is provided a method for manufacturing an aerosol-generating article comprising a downstream element. The method comprises forming the downstream element by extruding or injection moulding a mixture of polymers comprising starch and cellulose. The method may comprise forming the downstream element by extruding or injection moulding a mixture of polymers comprising starch and cellulose at a temperature between 100 and 250 degrees Celsius, preferably between 100 and 250 degrees Celsius, more preferably between 120 and 180 degrees Celsius.

The mixture of polymers may comprise between 30 to 70 parts by weight of starch and between 70 to 30 party by weight of cellulose.

The cellulose may be pre-mixed with water. The cellulose may be pre-mixed with water at a range of 20 to 80 percent by weight of water with respect to the cellulose, preferably at a range of 40 to 60 percent by weight of water with respect to the cellulose, more preferably at a range of 45 to 55 percent by weight of water with respect to the cellulose.

One or more plasticizers as described herein may be incorporated. The one or more plasticizers may be incorporated to yield a viscosity range of the mixture of polymers from 0.1 Pascal-second to 10 Pascal-seconds before the extrusion or injection moulding.

The one or more plasticizers may be incorporated to yield a pH value between 6 and 10 of the mixture of polymers before the extrusion or injection moulding.

Before the extrusion or injection moulding, the mixture of polymers may comprise water. The amount of water in the mixture of polymers before the extrusion or injection moulding may be between 5 percent and 40 percent, preferably between 10 percent and 30 percent, based on the weight of the dry material in the mixture of polymers.

Water may be added to form a dough-like consistency with the starch. The amount of water may vary depending on the type of starch and the desired moisture content of the mixture. For example, the water content in starch-cellulose mixtures, for example extrusion mixtures, may be around 15% to 30% water based on the weight of dry materials.

The method may comprise a step of arranged the downstream element downstream of an aerosol-forming substrate portion.

As used herein, the term “mixture of polymers”, “polymer mixture”, and “polymer blend” may be used synonymously.

The mixture of polymers may be a mixture of natural polymers. The mixture of polymers may be a mixture of starch and cellulose. The mixture of natural polymers may be a mixture of starch and cellulose. The mixture of polymers may consist of a mixture of starch and cellulose and, optionally, one or both of water and plasticizers. At least 90 percent by weight, preferably at least 95 percent by weight, more preferably at least 99 percent by weight of the mixture of polymers may be provided by starch and cellulose and, optionally, one or both of water and plasticizers.

At least 90 percent by weight, preferably at least 95 percent by weight, more preferably at least 99 percent by weight of the downstream element may be provided by starch and cellulose and, optionally, one or both of water and plasticizers.

As used herein, the term ‘aerosol-forming substrate’ relates to a substrate capable of releasing volatile compounds that can form an aerosol or a vapor. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be in solid form or may be in liquid form. The aerosol-forming substrate may be solid or liquid or may comprise both solid and liquid components. An aerosol-forming substrate may be part of an aerosol-generating article. The terms ‘aerosol’ and ‘vapor’ are used synonymously.

The aerosol-forming substrate may comprise nicotine. The nicotine-containing aerosol-forming substrate may be a nicotine salt matrix.

The aerosol-forming substrate may comprise plant-based material. The aerosolforming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material including volatile tobacco flavour compounds which are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise homogenised plant-based material. The aerosol-forming substrate may comprise homogenised tobacco material. Homogenised tobacco material may be formed by agglomerating particulate tobacco. In a particularly preferred embodiment, the aerosolforming substrate may comprise a gathered crimped sheet of homogenised tobacco material. As used herein, the term 'crimped sheet' denotes a sheet having a plurality of substantially parallel ridges or corrugations.

The aerosol-forming substrate may comprise at least one aerosol former. An aerosolformer is any suitable known compound or mixture of compounds that, in use, facilitates formation of a dense and stable aerosol and that is substantially resistant to thermal degradation at the temperature of operation of the device. Suitable aerosol formers are well known in the art and include, but are not limited to: polyhydric alcohols, such as triethylene glycol, 1 ,3-butanediol and glycerine; 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. Preferred aerosol formers are polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1, 3-butanediol. Preferably, the aerosol former is glycerine. Where present, the homogenised tobacco material may have an aerosol former content of equal to or greater than 5 percent by weight on a dry weight basis, and preferably from 5 percent to 30 percent by weight on a dry weight basis. The aerosolforming substrate may comprise other additives and ingredients, such as flavourants.

Preferably, the aerosol-forming substrate comprises plant material and an aerosol former. Preferably, the plant material is a plant material comprising an alkaloid, more preferably a plant material comprising nicotine, and more preferably a tobacco-containing material.

Preferably, the aerosol-forming substrate comprises at least 70 percent of plant material, more preferably at least 90 percent of plant material by weight on a dry weight basis. Preferably, the aerosol-forming substrate comprises less than 95 percent of plant material by weight on a dry weight basis, such as from 90 to 95 percent of plant material by weight on a dry weight basis.

Preferably, the aerosol-forming substrate comprises at least 5 percent of aerosol former, more preferably at least 10 percent of aerosol former by weight on a dry weight basis. Preferably, the aerosol-forming substrate comprises less than 30 percent of aerosol former by weight on a dry weight basis, such as from 5 to 30 percent of aerosol former by weight on a dry weight basis.

As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. An aerosol-generating article may be disposable. An aerosol-generating article comprising an aerosol-forming substrate comprising tobacco may be referred to herein as a tobacco stick.

As used herein, the term “aerosol-generating device” refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. An aerosol-generating device may interact with one or both of an aerosol-generating article comprising an aerosol-forming substrate, and a cartridge comprising an aerosol-forming substrate. In some examples, the aerosol-generating device may heat the aerosol-forming substrate to facilitate release of volatile compounds from the substrate. An electrically operated aerosol-generating device may comprise an atomiser, such as an electric heater, to heat the aerosol-forming substrate to form an aerosol.

As used herein, the term "aerosol-generating system" refers to the combination of an aerosol-generating device with an aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol-generating article, the aerosol-generating system refers to the combination of the aerosol-generating device with the aerosol-generating article. In the aerosol-generating system, the aerosol-forming substrate and the aerosol-generating device cooperate to generate an aerosol.

As used herein, the term "tubular element" is used to denote an elongate element defining a lumen or airflow passage along a longitudinal axis thereof. In particular, the term "tubular" is used herein to encompass any tubular element having a substantially cylindrical cross-section and defining at least one airflow passage 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 of the tubular element may be possible. The terms “tubular element” and “hollow tubular element” may be used synonymously.

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

As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article.

The term “length” denotes the dimension of a component of the aerosol-generating article in the longitudinal direction. For example, it may be used to denote the dimension of the rod or of the elongate tubular elements in the longitudinal direction.

As used herein with reference to the present invention, the term “transverse” is used to describe the direction perpendicular to the longitudinal direction. Unless otherwise stated, references to the “cross-section” of the aerosol-generating article or a component of the aerosol-generating article refer to the transverse cross-section.

As used herein, the term “proximal” refers to a user-end, or mouth-end of the aerosolgenerating article, and the term “distal” refers to the end opposite to the proximal end.

Components of aerosol-generating articles according to the present invention may be described as being upstream or downstream of one another based on their relative positions between the proximal end of the aerosol-generating article and the distal end of the aerosolgenerating article. The aerosol-generating device suitable for use with an aerosol-generating article as described herein may comprise a cavity for receiving at least part of the aerosol-generating article and a heater for heating the aerosol-forming substrate portion of the aerosolgenerating article when the aerosol-generating article is received within the cavity. The cavity may be a heating chamber.

At least 25 percent of the length of the downstream section may be inserted or received within the device cavity, when the aerosol-generating article is received within the device. At least 30 percent of the length of the downstream section may be inserted or received within the device cavity, when the aerosol-generating article is received within the device.

The aerosol-generating device may comprise a heater for heating the aerosolgenerating article. The heater may be any suitable type of heater. Preferably, in the present invention, the heater is an external heater. Preferably, the heater externally heats the aerosol-forming substrate portion when the aerosol-generating article is received within the aerosol-generating device. Such an external heater may circumscribe the aerosol-generating article when inserted in or received within the aerosol-generating device.

In some embodiments, the heater is arranged for insertion into an aerosol-forming substrate when the aerosol-forming substrate is received within the cavity.

The heater may be positioned within the device cavity, or heating chamber.

The heater may comprise at least one heating element. The at least one heating element may be any suitable type of heating element. In some embodiments, the device comprises only one heating element. In some embodiments, the device comprises a plurality of heating elements.

The heater may comprise a resistive heating arrangement.

In some embodiments, the heater comprises an inductive heating arrangement. The inductive heating arrangement may comprise an inductor coil and a power supply configured to provide high frequency oscillating current to the inductor coil. As used herein, a high frequency oscillating current means an oscillating current having a frequency of between about 500 kHz and about 30 MHz. The heater may advantageously comprise a DC/AC inverter for converting a DC current supplied by a DC power supply to the alternating current. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field on receiving a high frequency oscillating current from the power supply. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field in the device cavity. In some embodiments, the inductor coil may substantially circumscribe the device cavity. The inductor coil may extend at least partially along the length of the device cavity. The heater may comprise an inductive heating element. The inductive heating element may be a susceptor element. A 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 meter (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.

In these embodiments, the susceptor element is preferably located in contact with the aerosol-forming substrate. In some embodiments, a susceptor element is located in the aerosol-generating device. In these embodiments, the susceptor element may be located in the cavity. The aerosol-generating device may comprise only one susceptor element. The aerosol-generating device may comprise a plurality of susceptor elements. In some embodiments, the susceptor element is preferably arranged to heat the outer surface of the aerosol-forming substrate.

The susceptor element may be part of the aerosol-generating device. The susceptor element may be part of the aerosol-generating article.

The susceptor element of the device may comprise any suitable material, as described above in relation to a susceptor element incorporated within the aerosol-forming substrate portion.

During use, the heater may be controlled to operate within a defined operating temperature range, below a maximum operating temperature. An operating temperature range between about 150 degrees Celsius and about 300 degrees Celsius in the heating chamber (or device cavity) is preferable. The operating temperature range of the heater may be between about 150 degrees Celsius and about 250 degrees Celsius.

The aerosol-generating device may comprise a power supply. The power supply may be a DC power supply. In some embodiments, the power supply is a battery. The power supply may be a nickel-metal hydride battery, a nickel cadmium battery, or a lithium based battery, for example a lithium-cobalt, a lithium-iron-phosphate or a lithium-polymer battery. However, in some embodiments the power supply may be another form of charge storage device, such as a capacitor. The power supply may require recharging and may have a capacity that allows for the storage of enough energy for one or more user operations, for example one or more aerosol-generating experiences. As used herein, a ‘susceptor’ or ‘susceptor element’ means an element that heats up when subjected to an alternating magnetic field. This may be the result of eddy currents induced in the susceptor element, hysteresis losses, or both eddy currents and hysteresis losses. During use, the susceptor element is located in thermal contact or close thermal proximity with an aerosol-forming substrate received in the aerosol-generating device or cartridge. In this manner, the aerosol-forming substrate is heated by the susceptor such that an aerosol is formed.

The susceptor material may be any material that can be inductively heated to a temperature sufficient to aerosolize an aerosol-forming substrate. The following examples and features concerning the susceptor may apply to one or both of the susceptor element of the cartridge, a susceptor of an aerosol-generating device, and a susceptor of an aerosolgenerating article. Suitable materials for the susceptor material include graphite, molybdenum, silicon carbide, stainless steels, niobium, aluminium, nickel, nickel containing compounds, titanium, and composites of metallic materials. Preferred susceptor materials comprise a metal or carbon. Advantageously the susceptor material may comprise or consists of a ferromagnetic or ferri-magnetic material, for example, ferritic iron, a ferromagnetic alloy, such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. A suitable susceptor material may be, or comprise, aluminium. The susceptor material may comprise more than 5 percent, preferably more than 20 percent, more preferably more than 50 percent, or more than 90 percent of ferromagnetic, ferri-magnetic or paramagnetic materials. Preferred susceptor materials may be heated to a temperature in excess of 250 degrees Celsius without degradation.

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 E1 : An aerosol-generating article, comprising a longitudinal axis extending between an upstream end and a downstream end of the article; an aerosol-forming substrate portion comprising an aerosol-forming substrate; and a downstream element arranged downstream of the aerosol-forming substrate portion, wherein the downstream element comprises a mixture of polymers, wherein the mixture of polymers comprising starch and cellulose, and preferably wherein the mixture of polymers is extruded or injection moulded.

Example E2: The aerosol-generating article according to Example E1, wherein a weight ratio of starch to cellulose in the mixture of polymers is between 10 to 90 and 90 to 10, preferably between 20 to 80 and 80 to 20, on a dry weight basis. Example E3: The aerosol-generating article according to Example E2, wherein the weight ratio of starch to cellulose in the mixture of polymers is between 60 to 40 and 80 to 20, preferably between 65 to 35 and 75 to 25, more preferably is about 70 to 30, on a dry weight basis.

Example E4: The aerosol-generating article according to Example E3, wherein the weight ratio of starch to cellulose in the mixture of polymers is between 40 to 60 and 60 to 40, preferably between 45 to 55 and 55 to 45, more preferably is about 50 to 50, on a dry weight basis.

Example E5: The aerosol-generating article according to any of the preceding examples, wherein the mixture of polymers comprises water, preferably wherein the amount of water is below 10 percent, based on the weight of the dry material in the mixture.

Example E6: The aerosol-generating article according to any of the preceding examples, wherein the mixture of polymers comprises one or more of polysaccharides, microcrystalline cellulose, cellulose nanofibrils, alginate, ligno-cellulosic products, pectins, chitosan, chitin, gums, proteins, lipids, gelatin, gluten, keratin, and beeswax.

Example E7: The aerosol-generating article according to any of the preceding examples, wherein the mixture of polymers comprises a plasticizer.

Example E8: The aerosol-generating article according to Example E7, wherein the plasticizer is added in an amount of 10 to 30 weight percent, preferably 15 to 22 weight percent, more preferably about 20 weight percent, based on the dry weight of the polymers in the mixture of polymers.

Example E9: The aerosol-generating article according to Example E8, wherein the plasticizer is derived from one or more of epoxidized triglyceride vegetable oils, linseed oil, castor-oil, sunflower oil, fatty acid esters, polyols, mono-, di- and oligosaccharides.

Example E10: The aerosol-generating article according to any of Examples E7 to E9, wherein the plasticizer is selected from one or more of polyols, lactic acid esters, citric acid esters, acetylated monoglycerides, and diacetyl tartaric acid esters.

Example E11: The aerosol-generating article according to Example E10, wherein the plasticizer is selected from one or more polyols, preferably wherein the plasticizer is selected from one or more of glycerol, sorbitol, propylene glycol, mannitol and xylitol.

Example E12: The aerosol-generating article according to Example E11 , wherein the plasticizer is glycerol, preferably, wherein the plasticizer is glycerol and the glycerol is added in the range of 20 to 40 weight percent based on the weight of the starch in the mixture of polymers.

Example E13: The aerosol-generating article according to Example E11 , wherein the plasticizer is propylene glycol, preferably, wherein the plasticizer is propylene glycol and the propylene glycol is added in the range of 10 to 30 weight percent based on the weight of the starch in the mixture of polymers.

Example E14: The aerosol-generating article according to Example E10, wherein the plasticizer is selected from one or more lactic acid esters, preferably wherein the plasticizer is selected from one or both of ethyl lactate and butyl lactate.

Example E15: The aerosol-generating article according to any of the preceding examples, wherein a density of the mixture of polymers is more than 0.90 grams per cubic centimeter, preferably more than 1:70 grams per cubic centimeter.

Example E16: The aerosol-generating article according to any of the preceding examples, wherein the downstream element is a hollow tubular element.

Example E17: The aerosol-generating article according to Example E16, wherein an inner diameter of the hollow tubular downstream element varies along its longitudinal axis.

Example E18: The aerosol-generating article according to Example E17, wherein the inner diameter of the hollow tubular downstream element constantly, preferably linearly, increases in a direction from the downstream end towards the upstream end or vice versa.

Example E19: The aerosol-generating article according to Example E17, wherein the inner diameter of the hollow tubular downstream element increases stepwise in a direction from the downstream end towards the upstream end or vice versa.

Example E20: The aerosol-generating article according to any of the preceding examples, wherein the downstream element is a monolithic piece.

Example E21: The aerosol-generating article according to any of the preceding examples, comprising a mouthpiece filter arranged downstream of the downstream element.

Example E22: An aerosol-generating system comprising the aerosol-generating article according to any of the preceding examples and an aerosol-generating device comprising a cavity configured for at least partly inserting the aerosol-generating article into the cavity.

Example E23: A method for manufacturing an aerosol-generating article comprising a downstream element, the method comprising forming the downstream element by extruding or injection moulding a mixture of polymers comprising starch and cellulose at a temperature between 100 and 250 degrees Celsius, preferably between 100 and 250 degrees Celsius, more preferably between 120 and 180 degrees Celsius.

Example E24: The method according to Example E23, wherein the mixture of polymers comprises between 30 to 70 parts by weight of starch and between 70 to 30 party by weight of cellulose.

Example E25: The method according to Example E24, wherein the cellulose is premixed with water at a range of 20 to 80 percent by weight of water with respect to the cellulose, preferably at a range of 40 to 60 percent by weight of water with respect to the cellulose, more preferably at a range of 45 to 55 percent by weight of water with respect to the cellulose.

Example E26: The method according to any of Examples E23 to E25, wherein one or more plasticizers are incorporated to yield a viscosity range of the mixture of polymers from 0.1 Pascal-second to 10 Pascal-seconds before the extrusion or injection moulding.

Example E27: The method according to any of Examples E23 to E26, wherein one or more plasticizers are incorporated to yield a pH value between 6 and 10 of the mixture of polymers before the extrusion or injection moulding.

Features described in relation to one embodiment may equally be applied to other embodiments of the invention.

The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

Figs. 1a to 1c show an aerosol-generating article;

Fig. 2 shows the aerosol-generating article of Fig. 1; and

Figs. 3a and 3b show downstream elements.

Fig. 1a schematically shows an aerosol-generating article in a cross-sectional view. The article of Fig. 1a comprises a mouth-end filter 10 at a downstream end of the article, a fine hollow tube 12, a hollow tube 14, an aerosol-forming substrate portion 16 comprising an aerosol-forming substrate, and a front plug 18 at an upstream end of the article.

The aerosol-forming substrate portion 16 may comprise an optional susceptor 20. The aerosol-forming substrate portion 16 may be circumscribed by a substrate wrapper 22.

The front plug 18 may be a filter plug.

A proximal portion of the article is circumscribed by a mouthpiece wrapper 24. One or more, for example two, circumferential rows of ventilation holes 26 may be provided in an area where the mouthpiece wrapper 24 surrounds the fine hollow tube 12. The ventilation holes 26 may be provided in one or both of the fine hollow tube 12 and the mouthpiece wrapper 24.

A distal portion of the article is circumscribed by a distal wrapper 28.

One or both of the fine hollow tube 12 and the hollow tube 14 is configured as a downstream element comprising an extruded or injection moulded mixture of polymers, the mixture of polymers comprising starch and cellulose.

Fig. 1b shows a top view onto the aerosol-forming substrate portion 16 at position 102 as indicated in Fig. 1a.

Fig. 1c shows a top view onto the hollow tube 14 at position 104 as indicated in Fig. 1a. The hollow tube 14 is configured as a hollow cylindrical element. The fine hollow tube 12 is similarly configured as a hollow cylindrical element, but with thinner sidewalls. For example, an inner diameter of the fine hollow tube 12 may be about 4.8 millimeters to 5.2 millimeters and an inner diameter of the hollow tube 14 may be about 2.8 millimeters to 3.8 millimeters and an outer diameter of both the fine hollow tube 12 and the hollow tube 14 may be about 7.1 millimeters.

Fig. 2 shows the aerosol-generating article of Fig. 1. For sake of clarity, only the front plug 18 and the mouth-end filter 10 are indicated with reference numerals. Fig. 2 indicates preferred lengths “L” and preferred diameters “D” for the various elements of the aerosolgenerating article as listed in the below Table 1.

Table 1: Preferred dimensions of the aerosol-generating article as indicated in Fig. 2:

Fig. 3a shows a downstream element to be arranged downstream of the aerosolforming substrate portion 16 in an aerosol-generating article. The downstream element comprises an extruded or injection moulded mixture of polymers, the mixture of polymers comprising starch and cellulose. The downstream element is a hollow tubular element. An inner diameter of the hollow tubular downstream element varies along its longitudinal axis. The inner diameter of the hollow tubular downstream element linearly increases in a direction from an upstream end 30 of the hollow tubular downstream element towards a downstream end 32 of the hollow tubular downstream element. The inner diameter of the hollow tubular downstream element at the upstream end 30 may be between 2.8 and 3.8 millimeters, preferably about 3.3 millimeters. The inner diameter of the hollow tubular downstream element at the downstream end 32 may be between 4.8 and 5.2 millimeters, preferably about 5.0 millimeters. The outer diameter of the tubular downstream element may be between 7.0 and 7.2 millimeters, preferably about 7.1 millimeters.

The hollow tubular downstream element may be a monolithic piece.

The hollow tubular downstream element of Fig. 3a may substitute one or both of the fine hollow tube 12 and the hollow tube 14 in the aerosol-generating article of Figs. 1 and 2.

Fig. 3b shows a downstream element to be arranged downstream of the aerosolforming substrate portion 16 in an aerosol-generating article. The downstream element comprises an extruded or injection moulded mixture of polymers, the mixture of polymers comprising starch and cellulose. The downstream element is a hollow tubular element. An inner diameter of the hollow tubular downstream element varies along its longitudinal axis. The inner diameter of the hollow tubular downstream element increases stepwise in a direction from an upstream end 30 of the hollow tubular downstream element towards a downstream end 32 of the hollow tubular downstream element. In particular, an upstream portion 34 of the hollow tubular downstream element comprises a smaller inner diameter compared to a downstream portion 36 of the of the hollow tubular downstream element. The inner diameter of the hollow tubular downstream element at the upstream portion 34 may be between 2.8 and 3.8 millimeters, preferably about 3.3 millimeters. The inner diameter of the hollow tubular downstream element at the downstream portion 36 may be between 4.8 and 5.2 millimeters, preferably about 5.0 millimeters. The outer diameter of the tubular downstream element may be between 7.0 and 7.2 millimeters, preferably about 7.1 millimeters.

The hollow tubular downstream element may be a monolithic piece.

The hollow tubular downstream element of Fig. 3b may substitute one or both of the fine hollow tube 12 and the hollow tube 14 in the aerosol-generating article of Figs. 1 and 2.

Claims

1. An aerosol-generating article, comprising a longitudinal axis extending between an upstream end and a downstream end of the article; an aerosol-forming substrate portion comprising an aerosol-forming substrate; and a downstream element arranged downstream of the aerosol-forming substrate portion, wherein the downstream element comprises a mixture of polymers, the mixture of polymers comprising starch and cellulose, and the mixture of polymers being extruded or injection moulded, and wherein at least 90 percent by weight of the mixture of polymers are provided by starch and cellulose and, optionally, one or both of water and plasticizers.

2. The aerosol-generating article according to claim 1, wherein at least 90 percent by weight of the downstream element are provided by starch and cellulose and, optionally, one or both of water and plasticizers.

3. The aerosol-generating article according to claim 1 or claim 2, wherein a weight ratio of starch to cellulose in the mixture of polymers is between 10 to 90 and 90 to 10, preferably between 20 to 80 and 80 to 20, on a dry weight basis.

4. The aerosol-generating article according to claim 3, wherein the weight ratio of starch to cellulose in the mixture of polymers is between 60 to 40 and 80 to 20, preferably between 65 to 35 and 75 to 25, more preferably is about 70 to 30, on a dry weight basis.

5. The aerosol-generating article according to claim 3, wherein the weight ratio of starch to cellulose in the mixture of polymers is between 40 to 60 and 60 to 40, preferably between 45 to 55 and 55 to 45, more preferably is about 50 to 50, on a dry weight basis.

6. The aerosol-generating article according to any of the preceding claims, wherein the mixture of polymers comprises a plasticizer.

7. The aerosol-generating article according to claim 6, wherein the plasticizer is glycerol, preferably, wherein the plasticizer is glycerol and the glycerol is added in the range of 20 to 40 weight percent based on the weight of the starch in the mixture of polymers.

8. The aerosol-generating article according to claim 6, wherein the plasticizer is propylene glycol, preferably, wherein the plasticizer is propylene glycol and the propylene glycol is added in the range of 10 to 30 weight percent based on the weight of the starch in the mixture of polymers.

9. The aerosol-generating article according to any of the preceding claims, wherein the downstream element is a hollow tubular element.

10. The aerosol-generating article according to claim 9, wherein an inner diameter of the hollow tubular downstream element varies along its longitudinal axis.

11. The aerosol-generating article according to claim 10, wherein the inner diameter of the hollow tubular downstream element constantly, preferably linearly, increases in a direction from the downstream end towards the upstream end or vice versa, or wherein the inner diameter of the hollow tubular downstream element increases stepwise in a direction from the downstream end towards the upstream end or vice versa.

12. The aerosol-generating article according to any of the preceding claims, wherein the downstream element is a monolithic piece.

13. The aerosol-generating article according to any of the preceding claims, comprising a mouthpiece filter arranged downstream of the downstream element.

14. An aerosol-generating system comprising the aerosol-generating article according to any of the preceding claims and an aerosol-generating device comprising a cavity configured for at least partly inserting the aerosol-generating article into the cavity.

15. A method for manufacturing an aerosol-generating article comprising a downstream element, the method comprising forming the downstream element by extruding or injection moulding a mixture of polymers comprising starch and cellulose at a temperature between 100 and 250 degrees Celsius, preferably between 100 and 250 degrees Celsius, more preferably between 120 and 180 degrees Celsius, wherein at least 90 percent by weight of the mixture of polymers are provided by starch and cellulose and, optionally, one or both of water and plasticizers.