Smoking substitute consumable

Abstract

The present disclosure provides an aerosol-forming article comprising an aerosol-forming substrate and an axially adjacent, downstream filter arrangement. In some implementations, the filter arrangement comprises an upstream filter element, an intermediate filter element and a terminal filter element. The upstream and terminal filter elements may be independently selected from a solid filter element and a hollow bore filter element. The intermediate filter element may be a hollow bore filter element having a greater bore diameter than any other hollow bore filter element in the filter arrangement.

1 . An aerosol-forming article comprising: an aerosol-forming substrate; and an axially adjacent, downstream filter arrangement wherein the filter arrangement comprises an upstream filter element, an intermediate filter element and a terminal filter element, wherein the upstream and terminal filter elements are independently selected from a solid filter element and a hollow bore filter element, and wherein the intermediate filter element is a hollow bore filter element having a greater bore diameter than any other hollow bore filter element in the filter arrangement. 
     
     
         2 . An article according to  claim 1  wherein the article is a heat-not-burn (HNB) consumable. 
     
     
         3 . An article according to  claim 1  wherein the intermediate filter element comprises cellulose acetate or polypropylene tow. 
     
     
         4 . An article according to  claim 1  wherein the bore diameter in the intermediate filter element is greater than 3 mm. 
     
     
         5 . An article according to  claim 4  wherein the bore diameter in the intermediate filter element is greater than or equal to 5 mm. 
     
     
         6 . An article according to  claim 1  wherein the upstream filter element is a hollow bore filter element having a smaller bore diameter than the intermediate filter element. 
     
     
         7 . An article according to  claim 1  wherein the terminal filter element is a hollow bore filter element having a smaller bore diameter than the intermediate filter element. 
     
     
         8 . An article according to  claim 1  wherein both the upstream and terminal filter elements are hollow bore filter element and wherein the upstream filter element has a larger bore diameter than the terminal filter element. 
     
     
         9 . An article according to  claim 1  wherein the terminal filter element is a solid filter element. 
     
     
         10 . A system comprising a smoking substitute article according to  claim 1  and a device comprising a heating element. 
     
     
         11 . A system according to  claim 10  wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element. 
     
     
         12 . A method of using the system according to  claim 10 , the method comprising:
 inserting the article into the device; and   heating the article using the heating element.   
     
     
         13 . A method according to  claim 12  comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article. 
     
     
         14 . An aerosol-forming article comprising an aerosol-forming substrate and a hollow bore terminal filter element at a downstream axial end of an article/consumable wherein the article comprises at least one radial air flow path into the article/consumable interposed between the aerosol-forming substrate and the terminal filter element. 
     
     
         15 . An article according to  claim 14  wherein the article is a heat-not-burn (HNB) consumable. 
     
     
         16 . An article according to  claim 14  comprising a plurality of radial air flow paths circumferentially-arranged around the article. 
     
     
         17 . An article according to  claim 14  further comprising a spacer element or an aerosol-cooling element upstream and axially adjacent the terminal filter portion. 
     
     
         18 . An article according to  claim 17  wherein the or each radial air flow path is provided within the spacer/aerosol-cooling element proximal a join between the terminal filter element and the spacer/aerosol-cooling element. 
     
     
         19 . An article according to  claim 17  wherein the aerosol-forming substrate and the spacer/aerosol-cooling element are at least partly circumscribed by a wrapping layer and wherein the radial air flow path(s) are provided by one or more ventilation holes provided in the wrapping layer. 
     
     
         20 . An article according to  claim 19  wherein the terminal filter element is joined to the spacer/aerosol-cooling element by a circumscribing tipping layer that partly overlays the wrapping layer and wherein the radial air flow path(s) are provided by one or more ventilation holes provided in the tipping layer. 
     
     
         21 . An article according to  claim 20  wherein the ventilation hole(s) in the tipping layer are aligned or overlap with the ventilation hole(s) in the wrapping layer. 
     
     
         22 . An article according to  claim 17  comprising a spacer element having a tubular wall wherein the radial air flow path(s) are provided by one or more ventilation holes provided in the tubular wall of the spacer element. 
     
     
         23 . An article according to  claim 22  wherein the ventilation hole(s) in the tubular wall of the spacer element are aligned or overlap with the ventilation hole(s) in the wrapping layer and/or tipping layer. 
     
     
         24 . A system comprising a smoking substitute article according to  claim 1  and a device comprising a heating element. 
     
     
         25 . A system according to  claim 24  wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element. 
     
     
         26 . A method of using the system according to  claim 24 , the method comprising:
 inserting the article into the device; and   heating the article using the heating element.   
     
     
         27 . A method according to  claim 26  comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article. 
     
     
         28 . An aerosol-forming article comprising an aerosol-forming substrate and a terminal filter element at a downstream axial end of the article, wherein the article further comprises a spacer element interposed between the substrate and the terminal filter element, the spacer element being at least partly lined with a heat reflective material. 
     
     
         29 . An article according to  claim 28  wherein the article is a heat not burn consumable. 
     
     
         30 . An article according to  claim 28  wherein the spacer element is provided axially adjacent and upstream of the terminal filter element. 
     
     
         31 . An article according to  claim 28  wherein further comprising an upstream filter element and wherein the spacer element may be provided between the terminal filter element and the upstream filter element. 
     
     
         32 . An article according to  claim 28  wherein the spacer element is a tubular spacer element. 
     
     
         33 . An article according to  claim 32  wherein the spacer element comprises a tube formed of cardboard or extruded plastic material. 
     
     
         34 . An article according to  claim 28  wherein the heat reflective material is a metallic foil. 
     
     
         35 . A system comprising an article according to  claim 28  and a device comprising a heating element. 
     
     
         36 . A system according to  claim 35 , wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element. 
     
     
         37 . A method of using the system according to  claim 35 , the method comprising: inserting the article into the device; and heating the article using the heating element. 
     
     
         38 . A method according to  claim 37  comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article. 
     
     
         39 . A heat-not-burn (HNB) consumable comprising:
 an aerosol-forming substrate; and   a cooling element located downstream of the substrate, the cooling element comprising a sheet formed of a plastics material, and an additive applied to a surface of the sheet.   
     
     
         40 . A consumable according to  claim 39 , wherein the plastics material comprises polylactic acid (PLA). 
     
     
         41 . A consumable according to  claim 39 , wherein the additive comprises a flavourant. 
     
     
         42 . A consumable according to  claim 39 , wherein the additive comprises a phase change material. 
     
     
         43 . A consumable according to  claim 39 , wherein the additive is sprayed onto the surface of the sheet. 
     
     
         44 . A consumable according to  claim 39 , wherein the sheet is gathered and/or crimped so as to have a generally cylindrical shape. 
     
     
         45 . A consumable according to  claim 39 , further comprising a terminal hollow bore filter element at a downstream end of the consumable. 
     
     
         46 . A consumable according to  claim 45 , further comprising an upstream filter element located upstream of the terminal filter element. 
     
     
         47 . A cooling element for a heat-not-burn (HNB) consumable, the cooling element comprising a sheet formed of a plastics material, and an additive applied to a surface of the sheet. 
     
     
         48 . A cooling element according to  claim 47 , wherein the plastics material comprises polylactic acid (PLA). 
     
     
         49 . A cooling element according to  claim 47 , wherein the additive comprises a flavourant. 
     
     
         50 . A cooling element according to  claim 47 , wherein the additive comprises a phase change material. 
     
     
         51 . A cooling element according to  claim 47 , wherein the additive is sprayed or coated onto the surface of the sheet. 
     
     
         52 . A cooling element according to  claim 47 , wherein the sheet is gathered and/or crimped so as to have a generally cylindrical shape. 
     
     
         53 . A method of forming a cooling element, the method comprising:
 providing a sheet formed of a plastics material;   applying an additive to a surface of the sheet; and   gathering and/or crimping the sheet to form a cooling element.   
     
     
         54 . A method according to  claim 53 , wherein the step of applying an additive to the surface of the sheet is performed separately to the step of gathering and/or crimping the sheet. 
     
     
         55 . A method according to  claim 53 , wherein the step of applying the additive comprises spraying the additive onto the surface of the sheet. 
     
     
         56 . A system comprising a consumable according  claim 39 , and a device comprising a heating element. 
     
     
         57 . A system according to  claim 56 , wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element. 
     
     
         58 . A method of using the system according to  claim 56 , the method comprising:
 inserting the article into the device; and   heating the article using the heating element.   
     
     
         59 . An aerosol-forming article comprising a cooling element, the cooling element comprising a solid body, formed of a plastics material, defining one or more bores extending through the cooling element. 
     
     
         60 . An aerosol-forming article according to  claim 59 , wherein the body is one of injection moulded, extruded or additive manufactured. 
     
     
         61 . An aerosol-forming article according to  claim 59 , wherein the plastics material comprises polylactic acid (PLA). 
     
     
         62 . An aerosol-forming article according to  claim 59 , wherein the body is substantially tubular. 
     
     
         63 . An aerosol-forming article according to  claim 59 , wherein the body defines a plurality of bores arranged in a predetermined manner. 
     
     
         64 . An aerosol-forming article according to  claim 59 , wherein the cooling element comprises an additive. 
     
     
         65 . An aerosol-forming article according to  claim 59 , comprising an aerosol-forming substrate, the cooling element located downstream of the aerosol-forming substrate. 
     
     
         66 . An aerosol-forming article according to  claim 64 , comprising a hollow bore terminal filter element at a downstream end of the article, the cooling element located between the aerosol-forming substrate and the terminal filter. 
     
     
         67 . A method for forming a cooling element for an aerosol-forming article, the method comprising:
 providing an at least partially molten plastics material; and   forming the plastics material into a solid body defining one or more bores.   
     
     
         68 . A method according to  claim 67 , wherein the step of forming the plastics material comprises one of injection moulding, extrusion or additive manufacturing. 
     
     
         69 . A method according to  claim 68 , wherein the bores are formed in the injection moulding, extrusion, or additive manufacturing process. 
     
     
         70 . A system comprising an aerosol-forming article according to  claim 67 , and a device comprising a heating element. 
     
     
         71 . A system according to  claim 70 , wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element. 
     
     
         72 . A method of using the system according to  claim 70 , the method comprising:
 inserting the article into the device; and   heating the article using the heating element.   
     
     
         73 . A method according to  claim 72 , comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article. 
     
     
         74 . An aerosol-forming article comprising an aerosol-forming substrate and a filter element wherein the article comprises at least one radial air flow path into the filter element. 
     
     
         75 . An article according to  claim 74 , wherein the article is a heat-not-burn (HNB) consumable. 
     
     
         76 . An article according to  claim 74 , wherein the filter element is a solid filter element. 
     
     
         77 . An article according to  claim 76 , comprising a plurality of radial air flow paths circumferentially-arranged around the filter element. 
     
     
         78 . An article according to  claim 77 , comprising a plurality of axially spaced, circumferentially-extending rows of radial flow paths. 
     
     
         79 . An article according to  claim 74 , wherein the radial air flow path(s) is/are provided in a terminal filter element at the downstream axial end of the article/consumable and/or in an upstream filter element provided upstream from the downstream axial end of the article/consumable and downstream of the aerosol-forming substrate. 
     
     
         80 . An article according to  claim 79 , wherein the radial air flow path(s) is/are provided in the terminal filter element and the article further comprises an upstream filter element. 
     
     
         81 . An article according to  claim 80 , wherein the terminal filter element is at least partially circumscribed by a tipping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the tipping layer surrounding the terminal filter element. 
     
     
         82 . An article according to  claim 80 , wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the terminal filter element. 
     
     
         83 . An article according to  claim 79 , wherein the radial air flow path(s) is/are provided in the upstream filter element and the article further comprises a terminal filter element. 
     
     
         84 . An article according to  claim 83 , wherein the upstream filter element is at least partially circumscribed by a wrapping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the wrapping layer surrounding the upstream filter element. 
     
     
         85 . An article according to  claim 83 , wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the upstream filter element. 
     
     
         86 . An article according to  claim 80 , further comprising a spacer element or an aerosol-cooling element interposed between the upstream filter element and the terminal filter element. 
     
     
         87 . An aerosol-forming article comprising an aerosol-forming substrate and a hollow bore filter element wherein the article comprises at least one radial air flow path into the hollow bore filter element. 
     
     
         88 . An article according to  claim 87 , wherein the article is a heat-not-burn (HNB) consumable. 
     
     
         89 . An article according to  claim 88 , comprising a plurality of radial air flow paths circumferentially-arranged around the hollow bore filter element. 
     
     
         90 . An article according to  claim 89 , comprising a plurality of axially spaced, circumferentially-extending rows of radial flow paths. 
     
     
         91 . An article according to  claim 87 , wherein the radial air flow path(s) is/are provided in a terminal hollow bore filter element at the downstream axial end of the article/consumable and/or in an upstream hollow bore filter element provided upstream from the downstream axial end of the article/consumable and downstream of the aerosol-forming substrate. 
     
     
         92 . An article according to  claim 91 , wherein the radial air flow path(s) is/are provided in the terminal hollow bore filter element and the article further comprises an upstream hollow bore filter element. 
     
     
         93 . An article according to  claim 92 , wherein the terminal filter element is at least partially circumscribed by a tipping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the tipping layer surrounding the terminal hollow bore filter element. 
     
     
         94 . An article according to  claim 92 , wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the terminal hollow bore filter element. 
     
     
         95 . An article according to  claim 91 , wherein the radial air flow path(s) is/are provided in the upstream hollow bore filter element and the article further comprises a terminal hollow bore filter element. 
     
     
         96 . An article according to  claim 95 , wherein the upstream filter element is at least partially circumscribed by a wrapping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the wrapping layer surrounding the upstream hollow bore filter element. 
     
     
         97 . An article according to  claim 95 , wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the upstream hollow bore filter element. 
     
     
         98 . An article according to  claim 92 , further comprising a spacer element or an aerosol-cooling element interposed between the upstream filter element and the terminal filter element. 
     
     
         99 . A system comprising a smoking substitute article according to  claim 87 , and a device comprising a heating element. 
     
     
         100 . A system according to  claim 99 , wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element. 
     
     
         101 . A method of using the system according to  claim 99 , the method comprising:
 inserting the article into the device; and   heating the article using the heating element.   
     
     
         102 . A method according to  claim 101 , comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article. 
     
     
         103 . A filter element for an aerosol-forming article, the filter element comprising at least one radial bore. 
     
     
         104 . A filter element for an aerosol-forming article, the filter element comprising an axial bore and at least one radial bore. 
     
     
         105 . An aerosol-forming article comprising an aerosol-forming substrate and a downstream cooling element formed of a granular or foamed plastics material. 
     
     
         106 . An article according to  claim 105 , wherein the article is a HNB consumable. 
     
     
         107 . An article according to  claim 105 , wherein the plastics material comprises polylactic acid (PLA). 
     
     
         108 . An article according to  claim 105 , wherein the granular plastics material is combined to form a unitary structure or contained within a containment sleeve. 
     
     
         109 . An article according to  claim 105 , wherein the foamed plastic material is an open cell foam. 
     
     
         110 . An article according to  claim 105 , wherein the cooling element further comprises a flavourant additive. 
     
     
         111 . An article according to  claim 105 , wherein the cooling element comprises an axially-extending bore. 
     
     
         112 . An article according to  claim 105 , further comprising a terminal hollow bore filter element at a downstream end of the article. 
     
     
         113 . An article according to  claim 105 , further comprising an upstream filter element located upstream of cooling element. 
     
     
         114 . An article according to  claim 105 , comprising a terminal filter element and an upstream filter element axially spaced by the cooling element. 
     
     
         115 . A system comprising an article according to  claim 105 , and a device comprising a heating element. 
     
     
         116 . A system according to  claim 115 , wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element. 
     
     
         117 . A method of using the system according to  claim 115 , the method comprising:
 inserting the article into the device; and   heating the article using the heating element.   
     
     
         118 . A method according to  claim 117 , comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.