Aerosol-generating device having a porous mass

Abstract

An aerosol-generating device including an aerosol-generating article comprising an aerosol-forming substrate, a support element, an aerosol-cooling element, and a mouthpiece. At least one of the aerosol-cooling element and the filter comprise a porous mass comprising from 20 to 100 wt. % binder and from 0 to 80 wt. % active or inactive particles.

We claim: 
     
         1 . An aerosol-generating device comprising:
 an aerosol-generating article, wherein the aerosol-generating article comprises:
 an aerosol-forming substrate; 
 a support element; 
 an aerosol-cooling element; and 
 a mouthpiece, 
 wherein at least one of the support element, the aerosol cooling element, and the mouthpiece comprises a porous mass comprising from 20 to 100 wt. % binder and from 0 to 80 wt. % active or inactive particles. 
   
     
     
         2 . The device of  claim 1 , wherein the support element comprises the porous mass. 
     
     
         3 . The device of  claim 1 , wherein the aerosol-cooling element comprises the porous mass. 
     
     
         4 . The device of  claim 1 , wherein the mouthpiece comprises the porous mass. 
     
     
         5 . The device of  claim 1 , wherein the support element and the aerosol-cooling element comprise the porous mass. 
     
     
         6 . The device of  claim 1 , wherein the support element and the mouthpiece comprise the porous mass. 
     
     
         7 . The device of  claim 1 , wherein the aerosol cooling element and the mouthpiece comprise the porous mass. 
     
     
         8 . The device of  claim 1 , wherein the support element, the aerosol cooling element, and the mouthpiece comprise the porous mass. 
     
     
         9 . The device of  claim 1 , wherein the binder comprises a very high molecular weight polyethylene, an ultra high molecular weight polyethylene, or combinations thereof. 
     
     
         10 . The device of  claim 1 , wherein the binder is selected from the group consisting of polyolefins, polyesters, polyamides, polyacrylics, polystrenes, polyvinyls, cellulosics, and combinations thereof. 
     
     
         11 . The device of  claim 9 , wherein the binder further comprises polyolefins, polyesters, polyamides, polyacrylics, polystrenes, polyvinyls, cellulosics, or combinations thereof. 
     
     
         12 . The device of  claim 1 , wherein the active particles are selected from the group consisting of ion exchange resins, desiccants, silicates, molecular sieves, silica gels, activated alumina, perlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxides, activated carbon, activated charcoals, and combinations thereof. 
     
     
         13 . The device of  claim 1 , wherein the inactive particles comprise heat stable materials. 
     
     
         14 . The device of  claim 1 , wherein the inactive particles comprise adsorbent carbons selected from the group consisting of porous grade carbons, graphite, low activity carbons, and non-activated carbons. 
     
     
         15 . The device of  claim 1 , wherein the inactive particles comprise inorganic solids selected from the group consisting of ceramics, glass, alumina, vermiculite, clays, bentonite, and inert materials. 
     
     
         16 . The device of  claim 1 , wherein the porous mass has an encapsulated pressure drop of less than 3.0 mm water/mm length. 
     
     
         17 . The device of  claim 1 , wherein the binder is configured to undergo repeated heat cycles without structural deformation. 
     
     
         18 . The device of  claim 17 , wherein the binder is configured to undergo less than a 10% change in pressure drop. 
     
     
         19 . The device of  claim 1 , wherein the porous mass is configured to provide a multi-path air flow. 
     
     
         20 . The device of  claim 1 , wherein the support and the aerosol-cooling element are combined into a single unit and wherein the pressure drop is substantially the same as compared to the support and aerosol-cooling elements as separate units.