JP7550772B2 - Aerosol-generating systems and aerosol-generating articles including aerosol-forming substrates - Patents.com - Google Patents

Description

The present invention relates to an aerosol generating article, an aerosol generating device, and an aerosol generating system including the aerosol generating article and the aerosol generating device.

Aerosol-generating articles in which an aerosol-forming substrate, such as a tobacco-containing substrate, is heated rather than combusted are known in the art. The purpose of such heated aerosol-generating articles is to reduce harmful or potentially harmful by-products produced by the combustion and thermal decomposition of tobacco in conventional cigarettes.

In an aerosol-generating article, an inhalable aerosol is typically generated by heat transfer from a heating element to an aerosol-forming substrate. During heating, volatile compounds are released from the aerosol-forming substrate and entrained in the air. For example, the volatile compounds may be entrained in air that passes through, passes through, around, or is otherwise drawn near the aerosol-generating article. As the released volatile compounds cool, they condense to form an aerosol. The aerosol may be inhaled by a user. The aerosol may contain aromas, flavors, nicotine, and other desirable elements.

The heating element may be included in an aerosol generating device. The combination of the aerosol generating article and the aerosol generating device may form an aerosol generating system.

In one aspect of the invention, an aerosol generation system is provided, the system comprising:
1. An aerosol-generating article having an upstream end and a downstream end, the aerosol-generating article defining a longitudinal direction between the upstream end and the downstream end, the aerosol-generating article comprising:
an upstream segment disposed at an upstream end of the aerosol-generating article, the upstream segment comprising an aerosol-forming substrate, the aerosol-forming substrate comprising a substrate outer surface having a substrate outer diameter; and
an aerosol-generating article comprising: a downstream segment disposed at a downstream end of the aerosol-generating article, the downstream segment having a downstream segment outer diameter, the downstream segment outer diameter being greater than the substrate outer diameter;
An aerosol generating device, comprising:
an apparatus cavity including an apparatus cavity inner surface having an apparatus cavity inner diameter, the apparatus cavity configured to receive at least an aerosol-forming substrate of an aerosol-generating article; and
and an aerosol generating device including at least one heating element configured to heat the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity;
When the aerosol-forming substrate of the aerosol-generating article is received within the device cavity, an airflow passage is defined between the substrate exterior surface and the device cavity interior surface, the airflow passage extending longitudinally along the length of the aerosol-forming substrate.

The aerosol generating device comprises a device cavity. In use, an aerosol-forming substrate of an aerosol-generating article is received within the device cavity of the aerosol generating device. The aerosol-generating article is then heated by a heating element to release volatile compounds from the aerosol-forming substrate, which may condense to form an aerosol.

When the device cavity receives the aerosol-forming substrate, an airflow passage is defined by the outer surface of the substrate and the inner surface of the device cavity. A gap between the inner surface of the device cavity and the outer surface of the substrate at least partially bounds the airflow passage. The airflow passage is external to the aerosol-forming substrate and is contained within the device cavity of the aerosol generating device.

The airflow passages allow air drawn by a user to flow along the outer surface of the aerosol-forming substrate rather than through the aerosol-forming substrate, thus reducing or minimizing the amount of air moving through the aerosol-forming substrate. As a result, the airflow within the device primarily cools the outer surface of the substrate as it flows along the airflow passages, rather than cooling the substrate throughout its thickness. Advantageously, this may reduce fluctuations in the temperature of the substrate due to a user inhaling the aerosol-generating article.

Advantageously, providing an airflow passage between the outer diameter of the substrate and the inner diameter of the device cavity provides a space into which volatile compounds released from the heated aerosol-forming substrate may migrate. Such airflow passages may facilitate the release of volatile compounds from the heated substrate as air drawn through the article by the user is drawn across the outer surface of the substrate.

As used herein, the term "aerosol generating device" refers to a device that includes a heating element that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol.

According to yet another aspect of the present invention there is provided an aerosol-generating article suitable for the aerosol generating system described above, the article comprising:
The aerosol-generating article has an upstream end and a downstream end, defining a longitudinal direction between the upstream end and the downstream end, the aerosol-generating article comprising:
an upstream segment disposed at an upstream end of the aerosol-generating article, the upstream segment including an aerosol-forming substrate, the substrate including a substrate outer surface having a substrate outer diameter; and
A downstream segment is disposed at a downstream end of the aerosol-generating article, the downstream segment having a downstream segment outer diameter, the downstream segment outer diameter being greater than the substrate outer diameter.

The downstream segment has an outer diameter larger than the outer diameter of the aerosol-forming substrate. Providing an aerosol-generating article with segments having different outer diameters, as compared to an aerosol-generating article having a constant outer diameter along the length of the article, may allow the segment of the article including the aerosol-forming substrate to be thinner than other components of the article, such as a filter or cooling element. Advantageously, reducing the thickness of the aerosol-forming substrate allows heat applied to the substrate from the heating element to propagate more rapidly through the thickness of the substrate, reducing the time required to raise the temperature of the substrate in the region of the substrate furthest from the heating element. This may reduce the temperature variation across the thickness of the aerosol-forming substrate, reducing the likelihood that unused aerosol-forming substrate remains unheated in the region of the substrate furthest from the region heated by the heating element. Because the temperature variation across the thickness of the aerosol-forming substrate may be reduced, the composition and other properties of the aerosol generated from the substrate may be more uniform throughout the user experience and easier to control between user experiences with different substrates. Advantageously, this may create a more consistent experience for the user.

The aerosol generating article of this aspect of the invention is suitable for use in the aerosol generating system of the above-mentioned aspect of the invention, and therefore the advantages identified above for the system also apply to the article itself.

The term "aerosol-generating article" is used herein to denote an article that includes an aerosol-forming substrate that can be heated to generate and deliver an aerosol to a user. As used herein, the term "aerosol-generating substrate" refers to a substrate that has the ability to generate an aerosol by releasing a volatile compound upon heating.

The aerosol-generating article may be generally in the form of a rod. The article may have a central longitudinal axis extending longitudinally centrally through the rod from an upstream end to a downstream end. The upstream and downstream segments of the aerosol-generating article may be disposed in coaxial alignment with the central longitudinal axis of the aerosol-forming article. The upstream and downstream segments of the aerosol-generating article may be disposed end-to-end in coaxial alignment with the central longitudinal axis of the aerosol-forming article.

The aerosol-generating article may have a total length of about 30 millimeters to about 100 millimeters.

In a preferred embodiment, the aerosol-generating article has an overall length of about 40 millimeters to about 50 millimeters. Preferably, the aerosol-generating article has an overall length of about 45 millimeters.

The aerosol-generating article may comprise multiple components. For example, the aerosol-generating article may comprise an aerosol-forming substrate and any one or any combination of one or more of the following: a thermally conductive layer, a mouthpiece, a filter, a cooling element, a spacing element, and a flavoring element.

The downstream segment has a downstream segment outer diameter that is greater than the substrate outer diameter. The downstream segment outer diameter is greater than the substrate outer diameter at least at the upstream end of the downstream segment. As used herein, the term "upstream end" refers to the end of a feature or aspect of an article that is closest to the upstream end of the article, and the term "downstream end" refers to the end of a feature or aspect of an article that is closest to the downstream end of the article.

In some preferred embodiments, the downstream segment has a constant downstream segment outer diameter along the length of the downstream segment. However, in some embodiments, the downstream segment outer diameter varies along the length of the downstream segment from the upstream end to the downstream end of the article. The downstream segment outer diameter may increase from the upstream end of the downstream segment to the downstream end of the article. The downstream segment outer diameter may decrease from the upstream end of the downstream segment to the downstream end of the article.

The downstream segment may have a downstream segment outer diameter of about 5 millimeters to about 13 millimeters. Preferably, the downstream segment has a substantially constant outer diameter along the length of the segment.

The downstream segment may have a length of about 7 millimeters to about 25 millimeters.

The downstream segment may include one or more components. For example, the downstream segment may include any one of a mouthpiece, a filter, a spacing element, a cooling element, and a flavoring element, or any combination of any one or more of these.

The upstream segment may include a mouthpiece, which is a component configured to be sucked on by a user to receive aerosol from the aerosol-generating article when the aerosol-generating article is heated.

The upstream segment may include a filter. The term "filter" is used to denote a section of an aerosol generating article that is configured to at least partially remove gas phase or particulate phase components, or both gas phase and particulate phase components, from the mainstream aerosol drawn through the filter. The filter may thus be beneficial in minimizing the presence of undesirable components in the formed aerosol. The filter is preferably a cellulose acetate filter plug. The downstream segment preferably includes a mouthpiece in the form of a filter. The downstream segment preferably includes a mouthpiece in the form of a filter that is about 7 millimeters in length, but can have a length of about 5 millimeters to about 10 millimeters.

In some embodiments, the downstream segment consists of a filter. This can provide a compact aerosol-generating article in which the number of parts is reduced to a minimum.

In some embodiments, at least one of a cooling element and a spacing element may be disposed between the aerosol-forming substrate and the filter. Such additional components may be used to improve the thermal or mechanical properties of the aerosol-generating article.

As used herein, "cooling element" refers to a component of an aerosol-generating article that is located downstream of an aerosol-forming substrate such that an aerosol formed by volatile compounds released from the aerosol-forming substrate during use passes through and is cooled by the cooling element before being inhaled by a user. Cooling elements have a large surface area but produce a low pressure drop. Filters and other mouthpieces that produce a high pressure drop (e.g., filters formed of fiber bundles) are not considered aerosol cooling elements. Chambers and cavities within an aerosol-generating article are not considered aerosol cooling elements.

The spacing element may be a support element configured to resist downstream movement of the aerosol-forming substrate during insertion of the heating element into the aerosol-forming substrate. The spacing element may comprise a hollow tube. The spacing element may comprise a hollow tube of cellulose acetate.

In some embodiments, the downstream segment includes a flavor element. The flavor element may include one or more flavorants. As used herein, the term "flavorant" means an agent that, in use, imparts one or both of a taste or aroma to the aerosol generated by heating the aerosol-forming substrate. One example of a suitable flavorant is menthol. The flavor element may be disposed in any suitable location in the downstream segment.

The upstream segment comprises an aerosol-forming substrate. The upstream segment may also comprise one or more additional components, such as a layer of thermally conductive material, a cooling element, and a spacing element. The upstream segment preferably comprises an aerosol-forming substrate and, optionally, a layer of thermally conductive material.

The upstream segment may have an outer diameter of about 3 millimeters to about 12 millimeters. The upstream segment may have an outer diameter that is substantially constant along the length of the segment.

The upstream segment may have a length of about 8 millimeters to about 25 millimeters.

The aerosol-forming substrate has an aerosol-forming substrate outer surface having an outer substrate diameter. The aerosol-forming substrate may have an outer diameter of about 3 millimeters to about 12 millimeters. The outer substrate diameter is preferably substantially constant along the length of the aerosol-forming substrate.

The substrate outer diameter may be about 50% to about 98% of the downstream segment outer diameter, or about 60% to about 95% of the downstream segment outer diameter, or about 70% to about 90% of the downstream segment outer diameter.

The aerosol-forming substrate may have a length of about 8 millimeters to about 12 millimeters.

The aerosol-forming substrate may have any suitable cross-sectional shape. As used herein, a "cross-sectional shape" is a cross-section perpendicular to the longitudinal axis. For example, the substrate may have a circular, elliptical, stadium-shaped, rectangular, or triangular cross-sectional shape. Preferably, the substrate has a circular cross-sectional shape.

The aerosol-forming substrate is preferably a solid aerosol-forming substrate. The aerosol-forming substrate preferably comprises tobacco. The aerosol-forming substrate is preferably a solid aerosol-forming substrate comprising tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds which are released from the substrate on heating.

The solid aerosol-forming substrate may include a tobacco plug. The tobacco plug may include, for example, one or more of powder, granules, pellets, pieces, strands, strips, or sheets, including one or more of herb leaves, tobacco leaves, tobacco stems, expanded tobacco, and homogenized tobacco. The term "homogenized tobacco material" as used herein means a material formed by agglomerating particulate tobacco. Providing homogenized tobacco material may improve aerosol generation and the nicotine content and flavor profile of the aerosol generated during heating of the aerosol-generating article. Specifically, the process of making homogenized tobacco involves grinding tobacco leaves, which allows for more efficient release of nicotine and flavor upon heating. When the tobacco plug includes homogenized tobacco material, the homogenized tobacco material may be in the form of a sheet. As used herein, the term "sheet" means a layered element having a width and length substantially greater than its thickness.

The solid aerosol-forming substrate may comprise homogenized tobacco material. The solid aerosol-forming material may comprise pieces, strands, or strips of homogenized tobacco material. The solid aerosol-forming substrate may comprise a sheet of homogenized tobacco material.

The aerosol-forming substrate may have a substantially homogeneous composition. In one embodiment, the aerosol-forming substrate may have a substantially homogeneous composition at least along the longitudinal axis.

The homogenized tobacco material sheet may be formed by agglomerating particulate tobacco obtained by grinding or otherwise comminuted one or both of the tobacco lamina and the tobacco stems. The homogenized tobacco material sheet may also include one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed, for example, during tobacco processing, handling, and transport. The homogenized tobacco material sheet is preferably formed by a casting process of the type that generally involves casting a slurry including particulate tobacco and one or more binders onto a conveyor belt or other support surface, drying the cast slurry to form a homogenized tobacco material sheet, and removing the homogenized tobacco material sheet from the support surface.

The solid aerosol-forming substrate may comprise an assembly of sheets of homogenized tobacco material. As used herein, the term "assembly" is used to describe a sheet that is rolled, folded, or otherwise compressed or contracted substantially transversely to the longitudinal axis of the aerosol-generating article.

In some preferred embodiments, the aerosol-forming substrate comprises an assembly of textured sheets of homogenized tobacco material. As used herein, the term "textured sheet" means a sheet that has been crimped, embossed, debossed, perforated, or otherwise modified. The use of textured sheets of homogenized tobacco material may advantageously facilitate assembling the homogenized tobacco material sheets to form the aerosol-forming substrate. The aerosol-forming substrate may comprise an assembly of textured sheets of homogenized tobacco material that include a plurality of spaced indentations, protrusions, perforations, or combinations thereof.

In a particularly preferred embodiment, the aerosol-forming substrate comprises an assembly of a crimped sheet of homogenized tobacco material. As used herein, the term "crimped sheet" refers to a sheet having a plurality of substantially parallel ridges or corrugations. The substantially parallel ridges or corrugations preferably extend along or parallel to the longitudinal axis of the aerosol-generating article. This conveniently facilitates assembly of the crimped sheet of homogenized tobacco material to form the aerosol-generating article. However, it will be appreciated that a crimped sheet of homogenized tobacco material for inclusion in an aerosol-generating article may alternatively or additionally have a plurality of substantially parallel ridges or corrugations that are disposed at an acute or obtuse angle to the longitudinal axis of the aerosol-generating article.

The aerosol-forming substrate may include tobacco-containing and non-tobacco-containing materials.

The aerosol-forming substrate may include an aerosol former. The aerosol-forming substrate may include a single aerosol former or a combination of two or more aerosol formers. As used herein, the term "aerosol former" is used to describe any suitable known compound or mixture of compounds that facilitates the formation of an aerosol when used and is substantially resistant to thermal decomposition at the operating temperature of the aerosol-generating article. Suitable aerosol formers include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). Preferred aerosol formers are polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin) or mixtures thereof. The aerosol former content of the aerosol-forming substrate may be greater than 5 percent on a dry weight basis. The aerosol-forming substrate may have an aerosol former content of about 5 percent to about 30 percent on a dry weight basis. The aerosol-forming substrate may have an aerosol former content of about 20 percent on a dry weight basis.

The aerosol-forming substrate preferably comprises homogenized tobacco material, an aerosol former, and water.

The homogenized tobacco material may be provided in a sheet that is folded, crimped, or cut into strips. In a particularly preferred embodiment, the sheet is cut into strips having a width of about 0.2 millimeters to about 2 millimeters, more preferably about 0.4 millimeters to about 1.2 millimeters. In one embodiment, the width of the strips is about 0.9 millimeters.

In some embodiments, the aerosol-forming substrate may include an internal cavity. In other words, the aerosol-forming substrate may be a hollow tubular substrate. The aerosol-forming substrate may include an internal substrate surface having an internal substrate diameter, the internal substrate surface defining an internal cavity extending longitudinally within the aerosol-forming substrate. Providing an internal cavity within the aerosol-forming substrate may allow a heating element to be inserted within the aerosol-forming substrate within the cavity without penetrating the substrate and without modifying the substrate structure. Providing an internal cavity may also be beneficial to further reduce the thickness of the aerosol-forming substrate and enhance the heat transfer advantages discussed above.

The inner diameter of the substrate may be about 60% to about 90% of the outer diameter of the substrate, or about 70% to about 90%, or about 80% to about 90%. Such ranges may provide the necessary mechanical properties for the substrate while at the same time providing the necessary heat transfer within the aerosol-forming substrate.

When the aerosol-forming substrate includes an inner substrate surface that bounds an internal cavity, the inner substrate surface may have the same transverse cross-sectional shape as the outer substrate surface. In particular, the inner substrate surface may have a substantially circular, elliptical, or stadium-shaped transverse cross-section.

In some embodiments, the aerosol-generating article comprises a layer of thermally conductive material. In some embodiments, the layer of thermally conductive material may cover at least a portion of the aerosol-forming substrate that is otherwise exposed. In some embodiments, the layer of thermally conductive material may be disposed on at least the substrate outer surface. In some embodiments, the layer of thermally conductive material may be disposed on at least the substrate inner surface. In some embodiments, the layer of thermally conductive material may be disposed on at least the substrate inner surface and the substrate outer surface. By providing a layer of thermally conductive material on an otherwise exposed substrate surface, heat from a heating element received by or engaged with the substrate may be distributed over a larger area of the aerosol-forming substrate, improving the efficiency of heat transfer between the heating element and the aerosol-forming substrate. The layer of thermally conductive material may also create a physical separation between the heating element received within the inner cavity and the aerosol-forming substrate, which may reduce the risk of overheating the aerosol-forming substrate in an area of the substrate near the heating element. The layer of thermally conductive material may also increase the robustness of the tubular aerosol-forming substrate, which may be reduced by reducing the thickness of the substrate by providing an internal cavity.

As used herein, the term "thermally conductive" refers to a material having a thermal conductivity of at least 10 W/m.K, preferably at least 40 W/m.K, and more preferably at least 100 W/m.K at 23 degrees Celsius and 50% relative humidity. In a preferred embodiment, the layer of thermally conductive material comprises a material having a thermal conductivity of at least 40 W/m.K, preferably at least 100 W/m.K, more preferably at least 150 W/m.K, and most preferably at least 200 W/m.K at 23 degrees Celsius and 50% relative humidity.

Examples of suitable conductive materials include, but are not limited to, aluminum, copper, zinc, nickel, silver, and combinations thereof.

The aerosol-forming substrate may be provided in a plurality of separate segments. In some embodiments, each segment may comprise the same aerosol-forming substrate composition. In some embodiments, one or more segments may comprise an aerosol-forming substrate having a different composition. The aerosol-forming substrate may comprise a first aerosol-forming substrate segment having a first composition, and a second aerosol-forming substrate segment having a second composition.

The different compositions of the first and second aerosol-forming substrate segments may allow aerosols having different compositions to be generated from a single aerosol-generating article. This may also allow a user to select a particular aerosol-forming substrate to be heated to generate a particular aerosol during an experience.

The first and second aerosol-forming substrate segments may be configured to be heated sequentially. This may be beneficial in establishing a predetermined user experience in which at least two types of aerosol are generated sequentially for a pre-set period of time.

In some preferred embodiments, the individual segments may be arranged end-to-end along the longitudinal axis of the article.

In some embodiments, the aerosol-generating article may comprise a wrapper surrounding the upstream segment. Advantageously, such a wrapper may prevent a user from touching the aerosol-forming substrate, which may help maintain a high level of hygiene. The wrapper may be made of any suitable material. In particular, the wrapper may be formed of a porous material. The wrapper may be made of a material that allows volatile compounds to be released from the aerosol-forming substrate when the wrapper is placed around the downstream segment.

In some embodiments, the aerosol-generating article may include a wrapper surrounding the downstream segment. Advantageously, when the downstream segment includes multiple components, the wrapper may hold the multiple components together.

In some embodiments, the aerosol-generating article may include a wrapper surrounding the upstream and downstream segments. Advantageously, the wrapper may hold the upstream and downstream segments together.

Advantageously, the provision of one or more wrappers can improve the structural integrity of the aerosol-generating article.

The upstream and downstream segments may be secured together. The upstream and downstream segments may be secured together by any suitable means. For example, the aerosol generating article may include a connection mechanism. The connection mechanism may contribute to holding the upstream and downstream segments together. In one embodiment, the connection mechanism may include a cavity provided at the upstream end of the downstream segment into which the downstream end of the upstream segment is inserted. The downstream end of the upstream segment may include a protrusion that is inserted into the cavity.

If a wrapper is provided that surrounds the downstream segment and the aerosol-generating article includes a connection mechanism, the wrapper may be configured to apply pressure to the connection mechanism. In one embodiment, the wrapper may apply pressure around a cavity that receives the downstream end of the downstream segment. This may also contribute to holding the upstream and downstream segments together.

The outer diameter of the downstream segment of the aerosol-generating article may be substantially the same as or larger than the inner diameter of the device cavity. This may be beneficial to ensure that aerosol exiting the airflow passage through the downstream edge of the airflow passage can be drawn through the downstream segment instead of being emitted directly towards the outside of the aerosol-generating system.

At least one heating element is positioned within the device cavity. 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 multiple heating elements. For example, in some embodiments, the device comprises two or more heating elements. In some embodiments, the at least one heating element is arranged to heat an outer surface of the aerosol-forming substrate. In some preferred embodiments, the at least one heating element is arranged to be at least partially inserted into the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity. If the aerosol-forming substrate comprises an inner cavity, in some embodiments, the at least one heating element may be arranged to be inserted into the inner cavity of the substrate when the aerosol-forming substrate is received within the device cavity. The at least one heating element may be an elongated heating element. The at least one elongated heating element may be blade-shaped. The at least one elongated heating element may be pin-shaped. The at least one elongated heating element may have a tapered shape, or at least a tapered end. The at least one elongated heating element may have a pointed end. The at least one elongated heating element may be cone-shaped. The at least one elongated heating element may be any suitable shape arranged to facilitate insertion of the heating element into the aerosol-forming substrate. Advantageously, the elongated heating element may provide easier engagement or easier disengagement, or both easier engagement and easier disengagement, of the heating element of the device with the aerosol-forming substrate.

The at least one heating element may include at least one resistive heating element. Preferably, the at least one heating element includes a plurality of resistive heating elements. Preferably, the resistive heating elements are electrically connected in a parallel arrangement. Advantageously, providing a plurality of resistive heating elements electrically connected in a parallel arrangement may facilitate delivery of a desired power to the at least one heating element while reducing or minimizing the voltage required to provide the desired power. Advantageously, reducing or minimizing the voltage required to operate the at least one heating element may facilitate reducing or minimizing the physical size of the power supply.

In some embodiments, at least one heating element may include an electrically insulating substrate and one or more conductive tracks on the electrically insulating substrate.

The electrically insulating substrate is preferably stable at the operating temperature of the at least one heating element. The electrically insulating substrate is preferably stable at a temperature of up to about 400 degrees Celsius, more preferably about 500 degrees Celsius, more preferably about 600 degrees Celsius, more preferably about 700 degrees Celsius, and more preferably about 800 degrees Celsius. The operating temperature of the at least one heating element in use may be at least about 200 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 700 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 600 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 500 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 400 degrees Celsius.

The electrically insulating substrate may comprise any suitable material. For example, the electrically insulating substrate may comprise one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may comprise mica, _alumina ( _Al2O3 ), or zirconia (ZrO2 ₎ . The electrically insulating substrate preferably has a thermal conductivity of about 40 watts/meter Kelvin or less, preferably about 20 watts/meter Kelvin or less, and ideally about 2 watts/meter Kelvin or less.

Suitable materials for forming the at least one resistive heating element, and in particular the one or more conductive tracks, include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, metal alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum-based alloys.

In some embodiments, at least one resistive heating element comprises one or more stamped sections of an electrically resistive material (such as stainless steel). Alternatively, at least one resistive heating element may comprise a heating wire or filament (e.g., Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire).

In some embodiments, the at least one heating element may include an induction heating element. The induction heating element may include an inductor coil and a power source configured to provide a high frequency oscillating current to the inductor coil. High frequency oscillating current as used herein means an oscillating current having a frequency between 500 kHz and 30 MHz. The at least one heating element may advantageously include a DC/AC inverter for converting a DC current provided by a DC power source to an alternating current. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field upon receiving a high frequency oscillating current from the power source. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field within the device cavity. In some preferred embodiments, the inductor coil may substantially surround the device cavity. The inductor coil may extend at least partially along the length of the device cavity.

The induction heating element may include a susceptor element. As used herein, the term "susceptor element" refers to an element that includes a material capable of converting electromagnetic energy into heat. Thus, when the susceptor element is located in an alternating electromagnetic field, the susceptor is heated. The heating of the susceptor element may be the result of hysteresis losses and/or eddy currents induced in the susceptor, depending on the electrical properties and magnetic properties of the susceptor material. Hysteresis losses occur in ferromagnetic or ferrimagnetic susceptor materials due to magnetic domains in the material that are switched under the influence of the alternating electromagnetic field. Eddy currents may be induced if the susceptor material is conductive. In the case of a conductive ferromagnetic or ferrimagnetic susceptor material, heat can be generated by both eddy currents and hysteresis losses. Thus, the susceptor element may be heatable by at least one of hysteresis losses or eddy currents, depending on the electrical properties and magnetic properties of the susceptor material.

The susceptor element is arranged such that when an aerosol-generating article is received within the device cavity, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element, heating it. The aerosol generating device is preferably capable of generating a varying electromagnetic field having a magnetic field strength (H-field strength) of 1-5 kiloamperes per meter (kA/m), preferably 2-3 kA/m, e.g., about 2.5 kA/m. The electrically operated aerosol generating device is preferably capable of generating a varying electromagnetic field having a frequency of 1-30 MHz, e.g., 1-10 MHz, e.g., 5-7 MHz.

In some embodiments, the susceptor element is located within the aerosol-generating article. In these embodiments, the susceptor element is preferably located in contact with the aerosol-forming substrate. The susceptor element may be located within the aerosol-forming substrate. The susceptor element is preferably an elongated susceptor extending along the length of the substrate along the longitudinal axis of the article. If the aerosol-forming substrate includes an internal cavity, the susceptor element may be disposed within the internal cavity. If the aerosol-forming substrate includes an internal cavity, the susceptor element may be disposed on an inner surface of the substrate. The aerosol-generating article may comprise one or more susceptor elements. The aerosol-generating article may comprise multiple susceptor elements.

In some embodiments, the susceptor element is located within the aerosol generating device. In these embodiments, the susceptor element may be located within the device cavity. The susceptor element may be configured to be at least partially inserted into the aerosol-forming substrate of the aerosol-generating article when the aerosol-generating article is received within the device cavity. If the aerosol-forming substrate includes an internal cavity, the susceptor element may be configured to be at least partially inserted into the internal cavity of the aerosol-forming substrate when the aerosol-generating article is received within the device cavity. The susceptor element may extend into the device cavity along a longitudinal axis of the device cavity. The susceptor element may be elongated. The elongated susceptor element may be blade-shaped. The elongated susceptor element may be pin-shaped. The elongated susceptor element may have a tapered shape or at least a tapered end. The elongated susceptor element may have a pointed end. The elongated susceptor element may be cone-shaped. The aerosol generating device may include one or more susceptor elements. The aerosol generating device may include multiple susceptor elements.

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 elongated susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptor elements include metal or carbon. Advantageously, the susceptor element may comprise or consist of a ferromagnetic material, such as ferromagnetic alloys, e.g., ferritic iron, ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrites. A suitable susceptor element may be or may include aluminum. The susceptor element preferably comprises more than 5 percent ferromagnetic or paramagnetic material, preferably more than 20 percent ferromagnetic or paramagnetic material, and more preferably more than 50 percent or more than 90 percent ferromagnetic or paramagnetic material. The preferred elongated susceptor elements can be heated to temperatures in excess of 250 degrees Celsius.

The susceptor element may include a non-metallic core having a metallic layer disposed thereon. For example, the susceptor element may include a ceramic core or a metallic track formed on the outer surface of the substrate.

In some embodiments, the aerosol generating system comprises at least one resistive heating element and at least one inductive heating element. In some embodiments, the aerosol generating system comprises a combination of a resistive heating element and an inductive heating element.

The aerosol generating device may include multiple heating elements. The aerosol generating device may include a first heating element and a second heating element. In some embodiments, the second heating element may be spaced apart from the first heating element. The second heating element may be spaced apart from the first heating element along the longitudinal axis of the device cavity. Providing heating elements spaced apart from one another may enable the aerosol generating device to individually heat different sections of the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity.

The aerosol-forming substrate may include a first aerosol-forming substrate segment and a second aerosol-forming substrate segment. The first aerosol-forming substrate segment may be longitudinally adjacent to the second aerosol-forming substrate segment. The first heating element may be arranged to heat the first longitudinal substrate segment and the second heating element may be arranged to heat the second longitudinal substrate segment when the aerosol-forming substrate is received within the device cavity.

The second aerosol-forming substrate segment may have a different composition than the first aerosol-forming substrate segment. The different compositions of the first and second aerosol-forming substrate segments may allow aerosols having different compositions to be generated from a single aerosol-generating article. This may allow a user to select a particular aerosol-forming substrate to be heated to generate a particular aerosol during an experience.

The first and second heating elements may be configured to heat the first and second aerosol-forming substrate segments sequentially during a user experience. This may be useful for establishing a predetermined user experience in which at least two types of aerosol are generated sequentially for a pre-set period of time.

The first heating element may be arranged to heat the first aerosol-forming substrate segment to a temperature at which the volatile compound is released from the first aerosol-forming substrate segment without heating the second aerosol-forming substrate segment to a temperature at which the volatile compound is released from the second aerosol-forming substrate segment. The second heating element may be arranged to heat the second aerosol-forming substrate segment to a temperature at which the volatile compound is released from the second aerosol-forming substrate segment without heating the first aerosol-forming substrate segment to a temperature at which the volatile compound is released from the first aerosol-forming substrate segment. In other words, each heating element may be arranged to heat an individual aerosol-forming substrate segment. This may facilitate continuous heating of such aerosol-forming substrate segments.

The aerosol generating device preferably includes a power source. The power source may be a DC voltage source. In a preferred embodiment, the power source is a battery. For example, the power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery (e.g., a lithium cobalt battery, a lithium iron phosphate battery, or a lithium polymer battery). Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows for the storage of sufficient energy for use of the aerosol generating device with one or more aerosol-forming substrates.

The power source may be electrically connected to the at least one heating element to provide power to the at least one heating element. When the heating element receives power from the power source, the heating element may generate heat. The power source may be configured to provide sufficient power to the at least one heating element to heat the aerosol-forming substrate to a temperature at which the volatile compound is released from the substrate.

The aerosol generating device preferably comprises a housing. The housing preferably at least partially defines a cavity for receiving the aerosol-forming substrate.

The aerosol generating device preferably comprises at least one air inlet in fluid communication with the cavity. In embodiments in which the aerosol generating device comprises a housing, the housing preferably at least partially defines the at least one air inlet. The at least one air inlet is preferably in fluid communication with an upstream end of the cavity. In embodiments in which the at least one heating element is at least one elongated heating element positioned within the cavity, the at least one elongated heating element preferably extends from the upstream end of the cavity into the cavity.

The aerosol generating device may include a controller. The controller may be configured to control the supply of power from the power source to the at least one heating element. The controller may be any suitable controller. The controller may include any suitable electrical circuitry and electrical components. The controller preferably includes a processor and a memory. The controller may include a microprocessor, which may be a programmable microprocessor.

The aerosol generating device may include a sensor for detecting airflow indicative of a user taking a puff. The airflow sensor may be an electromechanical device. The airflow sensor may be any of a mechanical device, an optical device, an opto-mechanical device, and a microelectromechanical system (MEMS) based sensor. The aerosol generating device may include a manual switch for a user to initiate a puff.

The aerosol generating device preferably includes an indicator for indicating when the at least one heating element is activated. The indicator may include a light that is activated when the at least one heating element is activated.

The aerosol generating device may include at least one external plug or socket and at least one external electrical contact that allows the aerosol generating device to be connected to another electrical device. For example, the aerosol generating device may include a USB plug or socket that allows the aerosol generating device to be connected to another USB-enabled device. For example, the USB plug or socket may allow the aerosol generating device to be connected to a USB charging device to charge a rechargeable power source within the aerosol generating device. Additionally or alternatively, the USB plug or socket may accommodate data transfer to or from the aerosol generating device, or both to and from the aerosol generating device. Additionally or alternatively, the aerosol generating device may be connected to a computer to transfer data to the device, such as a new heating profile for a new aerosol-generating article.

In embodiments in which the aerosol generating device comprises a USB plug or socket, the aerosol generating device may further comprise a removable cover that covers the USB plug or socket when not in use. In embodiments in which the USB plug or socket is a USB plug, the USB plug may additionally or alternatively be selectively retractable within the device.

According to a further aspect of the present invention there is provided an aerosol-generating device for receiving an aerosol-forming substrate, the aerosol-generating device comprising:
At least one heating element;
a housing including a first housing portion and a second housing portion, the first housing portion having a first cavity;
the second housing portion is movable relative to the first housing portion between an open position and a closed position;
In the closed position, the first cavity and the second housing portion define a device cavity having an upstream end and a downstream end and defining a longitudinal axis between the upstream end and the downstream end;
at least one heating element is arranged to heat the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity;
In the open position, an opening is formed between the first and second housing portions to allow the aerosol-forming substrate to be inserted into or removed from the first cavity in an orientation other than the longitudinal direction.

Advantageously, the aerosol generating device of this aspect allows the aerosol-forming substrate to be inserted into and removed from the device cavity in a direction other than along the longitudinal axis of the cavity. This may allow the substrate to be inserted into and removed from the device cavity particularly easily, and may reduce the risk of damaging the substrate or the device when inserting and removing the aerosol-forming substrate.

In particular, the opening between the first and second housing parts allows the aerosol-forming substrate to be inserted into or removed from the first cavity in a direction other than the longitudinal direction. The direction other than the longitudinal direction may be any suitable direction other than the longitudinal direction. Preferably, the direction is substantially perpendicular to the longitudinal direction.

The device cavity may be an elongated cavity. In other words, the device cavity may have a length that is greater than other dimensions of the cavity, such as the diameter. The length of an elongated device cavity may extend in a longitudinal direction. Typically, the device cavity is a circular cylindrical cavity. However, the device cavity may have any suitable shape and size. For example, the device cavity may have any suitable transverse cross-section. In particular, the device cavity may have a circular, elliptical, stadium-shaped, square, or triangular transverse cross-section.

The device cavity may be configured to surround the aerosol-forming substrate about its longitudinal axis. In other words, the device cavity may be configured to form a tube that laterally surrounds or encloses the aerosol-forming substrate. The device cavity may have an open end. The device cavity may be open at both ends. The device cavity may have one open end and one substantially closed end. The open end may be at a downstream end of the device cavity and the substantially closed end may be at an upstream end of the device cavity. The substantially closed end may include one or more air inlets configured to draw ambient air into the device cavity.

The device cavity may have one or more air inlets configured to draw ambient air into the device cavity. The first housing portion may include one or more air inlets configured to draw ambient air into the device cavity. The second housing portion may include one or more air inlets configured to draw ambient air into the device cavity.

The aerosol generating device of this aspect includes at least one heating element. Preferably, the device of this aspect includes multiple heating elements. In some embodiments, the at least one heating element is disposed in the first housing portion. In some embodiments, the at least one heating element is disposed in the second housing portion.

The at least one heating element may be any suitable type of heating element. In some embodiments, the at least one heating element is arranged to heat the outer surface of the aerosol-forming substrate. In some preferred embodiments, the at least one heating element is arranged to be at least partially inserted into the aerosol-forming substrate when the aerosol-forming substrate is received in the device cavity. If the aerosol-forming substrate includes an inner cavity, in some embodiments, the at least one heating element may be arranged to be inserted into the inner cavity of the substrate when the aerosol-forming substrate is received in the device cavity. The at least one heating element may be an elongated heating element. The at least one elongated heating element may be blade-shaped. The at least one elongated heating element may be pin-shaped. The at least one elongated heating element may have a tapered shape or at least a tapered end. The at least one elongated heating element may have a pointed end. The at least one elongated heating element may be cone-shaped. The at least one elongated heating element may be any suitable shape arranged to facilitate insertion of the heating element into the aerosol-forming substrate. Advantageously, an elongated heating element may provide easier engagement or easier disengagement, or both easier engagement and easier disengagement, of the heating element of the device with the aerosol-forming substrate.

The resistive heating elements are preferably electrically connected in a parallel arrangement. Advantageously, providing multiple resistive heating elements electrically connected in a parallel arrangement may facilitate delivery of a desired power to at least one heating element while reducing or minimizing the voltage required to provide the desired power. Advantageously, reducing or minimizing the voltage required to operate at least one heating element may facilitate reducing or minimizing the physical size of the power supply.

In some embodiments, at least one heating element may include an electrically insulating substrate and one or more conductive tracks on the electrically insulating substrate.

The electrically insulating substrate is preferably stable at the operating temperature of the at least one heating element. The electrically insulating substrate is preferably stable at a temperature of up to about 400 degrees Celsius, more preferably about 500 degrees Celsius, more preferably about 600 degrees Celsius, more preferably about 700 degrees Celsius, and more preferably about 800 degrees Celsius. The operating temperature of the at least one heating element in use may be at least about 200 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 700 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 600 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 500 degrees Celsius. The operating temperature of the at least one heating element in use may be less than about 400 degrees Celsius.

The electrically insulating substrate may comprise any suitable material. For example, the electrically insulating substrate may comprise one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may comprise mica, _alumina ( _Al2O3 ), or zirconia (ZrO2 ₎ . The electrically insulating substrate preferably has a thermal conductivity of about 40 watts/meter Kelvin or less, preferably about 20 watts/meter Kelvin or less, and ideally about 2 watts/meter Kelvin or less.

Suitable materials for forming the at least one resistive heating element, and in particular the one or more conductive tracks, include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, metal alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum-based alloys.

In some embodiments, at least one resistive heating element comprises one or more stamped sections of an electrically resistive material (such as stainless steel). Alternatively, at least one resistive heating element may comprise a heating wire or filament (e.g., Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire).

In some embodiments, the at least one heating element may include an induction heating element. The induction heating element may include an inductor coil and a power source configured to provide a high frequency oscillating current to the inductor coil. High frequency oscillating current as used herein means an oscillating current having a frequency between 500 kHz and 30 MHz. The at least one heating element may advantageously include a DC/AC inverter for converting a DC current provided by a DC power source to an alternating current. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field upon receiving a high frequency oscillating current from the power source. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field within the device cavity. In some preferred embodiments, the inductor coil may substantially surround the device cavity. The inductor coil may extend at least partially along the length of the device cavity.

The induction heating element may include a susceptor element. As used herein, the term "susceptor element" refers to an element that includes a material capable of converting electromagnetic energy into heat. Thus, when the susceptor element is located in an alternating electromagnetic field, the susceptor is heated. The heating of the susceptor element may be the result of hysteresis losses and/or eddy currents induced in the susceptor, depending on the electrical properties and magnetic properties of the susceptor material. Hysteresis losses occur in ferromagnetic or ferrimagnetic susceptor materials due to magnetic domains in the material that are switched under the influence of the alternating electromagnetic field. Eddy currents may be induced if the susceptor material is conductive. In the case of a conductive ferromagnetic or ferrimagnetic susceptor material, heat can be generated by both eddy currents and hysteresis losses. Thus, the susceptor element may be heatable by at least one of hysteresis losses or eddy currents, depending on the electrical properties and magnetic properties of the susceptor material.

The susceptor element is arranged such that when an aerosol-generating article is received within the device cavity, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element, heating it. The aerosol generating device is preferably capable of generating a varying electromagnetic field having a magnetic field strength (H-field strength) of 1-5 kiloamperes per meter (kA/m), preferably 2-3 kA/m, e.g., about 2.5 kA/m. The electrically operated aerosol generating device is preferably capable of generating a varying electromagnetic field having a frequency of 1-30 MHz, e.g., 1-10 MHz, e.g., 5-7 MHz.

In some embodiments, the susceptor element is located within the aerosol-generating article. In these embodiments, the susceptor element is preferably located in contact with the aerosol-forming substrate. The susceptor element may be located within the aerosol-forming substrate. The susceptor element is preferably an elongated susceptor extending along the length of the substrate along the longitudinal axis of the article. If the aerosol-forming substrate includes an internal cavity, the susceptor element may be disposed within the internal cavity. If the aerosol-forming substrate includes an internal cavity, the susceptor element may be disposed on an inner surface of the substrate. The aerosol-generating article may comprise one or more susceptor elements. The aerosol-generating article may comprise multiple susceptor elements.

In some embodiments, the susceptor element is located within the aerosol generating device. In these embodiments, the susceptor element may be located within the device cavity. The susceptor element may be configured to be at least partially inserted into the aerosol-forming substrate of the aerosol-generating article when the aerosol-generating article is received within the device cavity. If the aerosol-forming substrate includes an internal cavity, the susceptor element may be configured to be at least partially inserted into the internal cavity of the aerosol-forming substrate when the aerosol-generating article is received within the device cavity. The susceptor element may extend into the device cavity along a longitudinal axis of the device cavity. The susceptor element may be elongated. The elongated susceptor element may be blade-shaped. The elongated susceptor element may be pin-shaped. The elongated susceptor element may have a tapered shape or at least a tapered end. The elongated susceptor element may have a pointed end. The elongated susceptor element may be cone-shaped. The aerosol generating device may include one or more susceptor elements. The aerosol generating device may include multiple susceptor elements.

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 elongated susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptor elements include metal or carbon. Advantageously, the susceptor element may comprise or consist of a ferromagnetic material, such as ferromagnetic alloys, e.g., ferritic iron, ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrites. A suitable susceptor element may be or may include aluminum. The susceptor element preferably comprises more than 5 percent ferromagnetic or paramagnetic material, preferably more than 20 percent ferromagnetic or paramagnetic material, and more preferably more than 50 percent or more than 90 percent ferromagnetic or paramagnetic material. The preferred elongated susceptor elements can be heated to temperatures in excess of 250 degrees Celsius.

The susceptor element may include a non-metallic core having a metallic layer disposed thereon. For example, the susceptor element may include a ceramic core or a metallic track formed on the outer surface of the substrate.

In some embodiments, the aerosol generating system comprises at least one resistive heating element and at least one inductive heating element. In some embodiments, the aerosol generating system comprises a combination of a resistive heating element and an inductive heating element.

The at least one heating element of this embodiment is preferably configured to be inserted into the aerosol-forming substrate when the first and second housing portions are in the closed position and the aerosol-forming substrate is received within the device cavity. Thus, the at least one heating element may protrude from the first housing portion into the device cavity when the first and second housing portions are in the closed position. Thus, the at least one heating element may extend or protrude from the second housing portion into the device cavity when the first and second housing portions are in the closed position.

Where a heating element extends from one of the first and second housing portions into the device cavity, the heating element may extend into the device cavity in any suitable direction. In some embodiments, it is preferred that the heating element extends into the device cavity in a direction substantially perpendicular to the longitudinal axis. Where the device comprises multiple heating elements extending into the device cavity, it may be preferred that all of the heating elements are substantially parallel to one another.

The device of this aspect may include any suitable number of heating elements. For example, the device may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 heating elements. When the device includes multiple heating elements, the heating elements may be spaced apart. The heating elements may be spaced apart along the longitudinal axis of the device cavity between the upstream and downstream ends of the device cavity. The heating elements may be spaced apart across the device cavity parallel to the longitudinal axis.

In some embodiments, the device of this aspect comprises at least two heating elements, a first heating element and a second heating element, the second heating element being spaced apart from the first heating element along the longitudinal axis of the device cavity. In these embodiments, the device may be suitable for use with an aerosol-generating article comprising two or more segments of aerosol-forming substrate spaced apart along the longitudinal axis, as described above in connection with the previous aspect. In these embodiments, the first heating element may be arranged to heat a first segment of the aerosol-forming substrate received within the device cavity, and the second heating element may be arranged to heat a second segment of the aerosol-forming substrate received within the device cavity. The device may be configured to heat the first and second heating elements at different times or to different temperatures to vary the aerosol generated by the system and the user's experience.

In some embodiments of devices of this aspect, the device comprises at least one heating element extending from the first housing portion and at least one heating element extending from the second housing portion. Advantageously, by providing heating elements in both the first and second housing portions, the heating elements may be inserted into the aerosol-forming substrate from different sides, which may reduce variations in the temperature of the aerosol-forming substrate. Furthermore, movement of the first and second housing portions between the open and closed positions allows the aerosol-forming substrate to be easily inserted into and removed from such devices.

The second housing portion is movable relative to the first housing portion. The first housing portion and the second housing portion may be movably connectable. The first and second housing portions may be movably connected together by any suitable connecting means.

In some embodiments, the first and second housing parts may be slidably coupled together. In these embodiments, the first and second housing parts may be provided with complementary rails that allow the second housing part to slide relative to the first housing part between the open and closed positions.

In some embodiments, the second housing portion can be removably connectable to the first housing portion. In these embodiments, the first and second housing portions can be in an open position when the second housing portion is removed from the first housing portion. In these embodiments, the first and second housing portions can be in a closed position when the second housing portion is removably connected to the first housing portion.

In some preferred embodiments, the first and second housing portions are rotatably coupled together. The second housing portion is rotatably coupled to the first housing portion and is rotatable between an open position and a closed position. The first and second housing portions may be rotatably coupled by any suitable means. For example, the first and second housing portions may be rotatably coupled by a pivot or a hinge.

The second housing part may be rotatable relative to the first housing part in any suitable direction. Preferably, the second housing part is rotatable relative to the first housing part in a direction perpendicular to the longitudinal direction. This may facilitate the insertion of the aerosol-forming substrate into and removal of the aerosol-forming substrate from the cavity of the device when the first and second housing parts are in an open position in a direction other than the longitudinal direction.

In some preferred embodiments, the second housing portion includes a second cavity. The second cavity may be arranged such that in the closed position, the first cavity and the second cavity define a device cavity. In other words, the first cavity and the second cavity may be aligned to form a larger cavity, the device cavity, when the first housing portion and the second housing portion are in the closed position.

In some embodiments, the second cavity is different from the first cavity. This may allow the first and second cavities to form a device cavity having an asymmetric shape.

The second cavity is preferably substantially identical to the first cavity and has the same shape and size. For example, the first cavity may be substantially semi-cylindrical and the second cavity may be substantially semi-cylindrical, the first and second cavities forming a substantially cylindrical device cavity when the first and second housing portions are in the closed position. The first and second cavities may have any suitable size and shape to accommodate any suitable amount of aerosol-forming substrate.

In all other embodiments, the aerosol generating device of this embodiment may be the same as the aerosol generating device described above in connection with the previous embodiments.

For example, the device preferably includes one or more air inlets configured to allow ambient air to be drawn into the device cavity, a power source for providing power to the at least one heating element, and a controller for controlling the supply of power from the power source to the at least one heating element.

According to a further aspect of the present invention,
An aerosol generating device according to the above-mentioned embodiment;
An aerosol-generating system is provided that comprises an aerosol-generating article that comprises an aerosol-forming substrate.

The aerosol generating articles used in combination with the aerosol generating device of this embodiment may include the same features as the aerosol generating articles described above in relation to the previous embodiment of the invention. However, it will be appreciated that other aerosol generating articles may be suitable for use in a system comprising the device of the previous embodiment. For example, aerosol generating articles having a substantially constant outer diameter along their length may be suitable for use with the device of the previous embodiment.

These and other features and advantages of the present invention will become more apparent in the light of the following detailed description of preferred embodiments, given by way of illustrative and non-limiting example only, with reference to the accompanying drawings.

FIG. 1 shows a schematic diagram of an aerosol-generating article according to a first embodiment of the present invention. FIG. 2 shows a schematic diagram of an aerosol-generating article according to a second embodiment of the present invention. FIG. 3 shows a schematic diagram of an aerosol generating system comprising the aerosol generating article of FIG. 1 according to a third embodiment of the present invention. FIG. 4 shows a schematic diagram of an aerosol generation system according to a fourth embodiment of the present invention. FIG. 5 shows a schematic diagram of an aerosol generation system according to a fifth embodiment of the present invention. FIG. 6 shows a schematic diagram of an aerosol generation system according to a sixth embodiment of the present invention. FIG. 7 shows a schematic diagram of an aerosol generating device according to a seventh embodiment of the present invention. FIG. 8 shows a schematic diagram of an aerosol generation system according to an eighth embodiment of the present invention, comprising the aerosol generation device of FIG.

1 shows an aerosol-generating article 10 with an upstream end 11 and a downstream end 12. The article 10 comprises an upstream segment including an aerosol-forming substrate 13 and a downstream segment 14, which in this embodiment is comprised of a filter 15. The filter 15 generally forms a cylindrical part having an outer cylindrical surface with a downstream segment outer diameter D1. In this embodiment, the aerosol-forming substrate 13 generally forms a hollow cylindrical tube of homogenized cast leaf tobacco. The tubular aerosol-forming substrate 13 has a substrate outer surface 17 with a substrate outer diameter D2 and a substrate inner surface 18 with a substrate inner diameter D3. The substrate inner surface 18 defines an inner cavity 16 extending longitudinally within the aerosol-forming substrate 13.

The outer diameter D1 of the filter is greater than the outer diameter D2 of the base.

The thickness of the aerosol-forming substrate 13 is significantly reduced compared to the thickness of the aerosol-forming substrate in an article in which the aerosol-forming substrate is not tubular and has a consistent outer diameter along its length and the article. The reduced thickness of the aerosol-forming substrate 13 may allow heat applied to the substrate 13 to propagate more rapidly through the thickness of the substrate. This may reduce the time required to increase the temperature of the substrate 13. For example, this may reduce the time required to increase the temperature of the substrate 13 in the region of the substrate 13 that is furthest from the heating element 31. The reduced thickness of the aerosol-forming substrate 13 of the aerosol-generating article 10 may improve the efficiency of aerosol generation from the aerosol-generating article.

The aerosol-generating article 10 of FIG. 2 is similar to the embodiment of the article of FIG. 1, except that the downstream segment 14 includes a spacing element 19 and a filter 15. In this embodiment, the spacing element 19 is disposed between the filter 15 and the aerosol-forming substrate 13.

In this embodiment, the spacing element 19 is a support element. However, it will be appreciated that in other embodiments, the article may be provided with a cooling element disposed between the filter 15 and the substrate 13 in addition to or instead of the support element.

Figure 3 shows an aerosol generating system 40 comprising the aerosol-generating article 10 of Figure 1 and an aerosol-generating device 30. The aerosol-generating device 30 comprises a heating element 31 configured to be inserted into the aerosol-forming substrate 13 when the aerosol-generating article is received within the device 30. In the embodiment of Figure 3, the heating element 31 is received within the interior cavity 16 of the article 10 defined by the substrate inner surface 18.

The aerosol generating device 30 comprises a device cavity 32 having a device cavity inner surface 33. The device cavity inner surface 33 has a device cavity inner diameter D4. In FIG. 3, the device cavity 32 receives the aerosol-forming substrate 13 of the article 10. When the aerosol-forming substrate 13 is received within the device cavity 32, an annular gap is formed between the substrate outer surface 17 and the device cavity inner surface 33, which provides an airflow passage 35 that surrounds the substrate 13 in a longitudinal direction along the length of the substrate 13. The width of the airflow passage 35 is the difference between the chamber inner diameter D4 and the substrate outer diameter D2. The airflow passage 35 is external to the aerosol-forming substrate 13.

When the aerosol generating system 40 is in use, as shown in FIG. 3, power is supplied to the heating element 31 to heat the aerosol-forming substrate 13 to a temperature at which volatile compounds are released from the substrate 13. When a user draws on a downstream segment 14, such as the filter 15 of the article 10, air is drawn through the air inlet 36 at the distal end of the device cavity 32, along the longitudinal axis of the article 10 into the airflow passage 35, and out of the device cavity 32 through the downstream segment 14, such as through the filter 15. Volatile compounds released from the heated aerosol-forming substrate 13 are released into the airflow passage 35, as represented diagrammatically by the curved arrows in FIG. 3, and are cooled to form an aerosol that can be inhaled by the user. The aerosol is entrained in the air drawn through the airflow passage 35 and flows out of the device cavity 32 through the filter 15 of the article 10 toward the downstream end 12, as shown by arrow A1.

In the embodiment of FIG. 3, the downstream segment outer diameter D1 is the same as the device cavity inner diameter D4. Thus, the airflow passage is bounded at its downstream edge by the downstream segment 14, which in this embodiment corresponds to the filter 15. Thus, aerosol exiting the airflow passage 35 must flow through the filter 15.

In the aerosol-generating system 40 of FIG. 4, the aerosol-generating article 10 differs from that of FIGS. 1 and 3 in that the aerosol-forming substrate 13 does not include an inner cavity, but instead is a solid cylindrical plug of homogenized cast tobacco leaf. The aerosol-generating device 30 is identical to that of FIG. 3, except that it includes a heating element 31 that penetrates the aerosol-forming substrate 13 when the substrate 13 is received within the device cavity 32. In some embodiments, the heating element is either a blade, a pin, a spike, or any other shape configured to facilitate insertion of the heating element into the aerosol-forming substrate. For example, the heating element may have a tapered or pointed end. In the embodiment of FIG. 4, the heating element is a blade-shaped heating element.

In the aerosol generating system 40 of FIG. 5, the aerosol generating article 10 differs from that of FIGS. 1 and 3 in that the aerosol generating article 10 comprises a downstream segment 14, which in this embodiment is a filter 15, having a downstream segment outer diameter D1 larger than the device cavity inner diameter D4. Such a downstream segment configuration may further ensure that the upstream edge of the filter 15 delimits the downstream edge of the airflow passage 35. Furthermore, a layer of thermally conductive material 23 is disposed on the substrate inner surface 18. The layer of thermally conductive material 23 substantially covers the substrate inner surface 18, surrounds the inner cavity 16, and extends the entire length of the inner cavity 16. This may improve the distribution of heat from the heating element 31 to the substrate 13. The layer of thermally conductive material 23 may also create a physical separation between the heating element 31 and the aerosol-forming substrate 13 received in the inner cavity 16, which may reduce the risk of overheating the aerosol-forming substrate 13 in the region of the substrate 13 near the heating element 31. The layer 23 of thermally conductive material may also increase the robustness of the tubular aerosol-forming substrate 13, which may be compromised by the reduction in thickness of the substrate 13 due to the provision of the inner cavity 16.

Other features of system 40 in FIG. 5 correspond to the features of system 40 in FIG. 3.

In the aerosol generating system 40 of FIG. 6, the aerosol generating device 30 comprises a first heating element 34 and a second heating element 38 spaced apart from each other longitudinally of the device cavity 32. The aerosol generating article 10 comprises an aerosol-forming substrate 13 having two aerosol-forming substrate segments, a first aerosol-forming substrate segment 21 and a second aerosol-forming substrate segment 22, disposed end-to-end along the longitudinal axis of the article. The first aerosol-forming substrate segment 21 comprises a first aerosol-forming substrate composition, and the second aerosol-forming substrate segment 22 comprises a second aerosol-forming substrate composition that is different from the composition of the first longitudinal substrate segment 21.

When the aerosol-forming substrate 13 is received in the device cavity 32, the first heating element 34 is arranged to heat the first aerosol-forming substrate segment 21 and the second heating element 38 is arranged to heat the second aerosol-forming substrate segment 22. Thus, the aerosol generating device 30 may be configured to heat each segment of the aerosol-forming substrate 13 individually. Since heat can be selectively applied to the first substrate segment 21 and the second substrate segment 22, the segments 21, 22 may be heated sequentially by the aerosol generating device 40. Each segment may also be heated according to the type of aerosol that the user wishes to consume.

6 further includes sensors 37 disposed within the device cavity 32, on the device cavity inner surface 33, and within the airflow passage 35 when the aerosol-forming substrate 13 is received within the device cavity 32. The sensors 37 may provide the device and/or the user with relevant data such as the onset of a puff in the airflow passage 35, the duration of the puff, the temperature of the aerosol, or the concentration of a particular component of the aerosol.

Figure 7 shows an aerosol generating device 300 according to a further embodiment of the invention. The device 300 comprises a housing capable of forming a device cavity 305 for receiving an aerosol-forming substrate. The housing comprises a first housing part 301 and a second housing part 302 that are movable relative to each other. In this embodiment, the first and second housing parts 301, 302 are rotatable relative to each other, the relative movement being represented by the arrow R1 in Figure 7. A hinge 307 rotatably attaches the first housing part 301 to the second housing part 302.

The first and second housing parts 301, 302 are rotatable between an open position and a closed position. In the closed position, the first and second housing parts 301, 302 are arranged to form a device cavity for receiving the aerosol-forming substrate 130. In the closed position, the formed device cavity can surround the aerosol-forming substrate. In the open position, the first and second housing parts 301, 302 are arranged such that the aerosol-forming substrate 130 can be received on and removed from the body 301, 302.

The first housing part 301 comprises a first cavity 303 and the second housing part 302 comprises a second cavity 304. In this embodiment, the first cavity 303 is a substantially semi-cylindrical cavity and the second cavity 304 is a substantially semi-cylindrical cavity. In the closed position, the first cavity 303 and the second cavity 304 are aligned to form a device cavity 305 for receiving the aerosol-forming substrate 130. In this embodiment, the device cavity 305 surrounds the aerosol-forming substrate 130 about the longitudinal axis direction X when the aerosol-forming substrate 130 is received in the device cavity 305. In other words, the device cavity 305 forms a tubular cavity that surrounds or encloses the aerosol-forming substrate 130, the tubular cavity having a length extending in the longitudinal axis direction X. The tubular cavity may be closed at the ends. In the open position, the first cavity 303 and the second cavity 304 rotate to form an opening 306 through which the aerosol-forming substrate 130 can be inserted into each of the first cavity 303 and the second cavity 304 in a direction different from the longitudinal axis direction X, as shown in FIG. 7. In this embodiment, the aerosol-forming substrate 130 can be inserted into either the first cavity 303 or the second cavity 304 in a direction P1 that is substantially perpendicular to the longitudinal axis direction X.

The aerosol generating device 300 comprises a plurality of internal heating elements 310. The internal heating elements 310 are configured to at least partially penetrate the aerosol-forming substrate. In this embodiment, the internal heating elements 310 are pin-shaped heating elements 310. The first housing part 301 comprises a plurality of pin-shaped heating elements 310 extending into the first cavity 303, and the second housing part 302 comprises a plurality of pin-shaped heating elements 310 extending into the second cavity 304. Specifically, in the illustrated embodiment, the device 300 comprises twelve heating elements 310: six heating elements 310 extending from the first housing part 301 into the first cavity 303 and six heating elements 310 extending from the second housing part 302 into the second cavity 304. The pin-shaped heating elements 310 extend substantially transversely into the chamber 305. The pin-shaped heating elements 310 are arranged to extend substantially parallel to each other and perpendicular to the longitudinal axis X of the cavity when the first housing part 301 and the second housing part 302 are in the closed position. Although pin-shaped heating elements are described and illustrated herein, it will be appreciated that any of a variety of shapes may be used. For example, the heating elements may have any one or combination of blades, pins, spikes, or any other shapes configured to facilitate the insertion of the heating elements into the aerosol-forming substrate. For example, the heating elements may have tapered or pointed ends. The heating elements of the first cavity 303 may be the same as each other or may vary. The heating elements of the second cavity 304 may be the same as each other or may vary. The heating elements in the first cavity 303 may have the same shape or a different shape compared to the heating elements in the second cavity 304. With reference to the illustrated embodiment, twelve heating elements are described, but it will be appreciated that other numbers of heating elements may be used. The illustrated invention describes heating elements in both cavities 303 and 304, but it will be appreciated that in some embodiments there may only be heating elements extending from one cavity.

Each of the first housing portion 301 and the second housing portion 302 may further include an air inlet 360. The air inlet 360 is disposed at one end of the device cavity 305 and is disposed such that ambient air is drawn into the device cavity 305.

8 shows a longitudinal cross-section of the aerosol generating device 300 of FIG. 7 in the closed position for use with the aerosol generating article 100. The aerosol generating article 100 shown in FIG. 8 is similar to that of FIG. 1. The article 100 comprises an aerosol-forming substrate 130 in the upstream segment. The article 100 comprises a downstream segment 140, which in this embodiment comprises a filter 150 immediately downstream of the aerosol-forming substrate 130. In the embodiment shown in FIG. 8, the aerosol-forming substrate 130 has a cylindrical tubular shape with an inner cavity 160. However, it will be appreciated that other aerosol generating articles, particularly non-tubular aerosol generating articles, may be equally suitable for use with the aerosol generating device of FIG. 7.

The device cavity 30 of the aerosol generating device 300 extends in a longitudinal direction X from an upstream end 308 of the device cavity to a downstream end 309 of the device cavity. In the closed position, the first cavity 303 and the second cavity 304 are aligned to form a substantially cylindrical device cavity 305.

When the aerosol-forming substrate 130 is placed in the first cavity 303 and the first and second housing parts 301, 302 are in the open position, the pin-shaped heating elements 310 of the first housing part 301 penetrate the aerosol-forming substrate. When the first and second housing parts 301, 302 are moved to the closed position, the aerosol-forming substrate is held in the cylindrical device cavity 305 and the pin-shaped heating elements 310 of the second housing part 302 also penetrate the aerosol-forming substrate 130. As shown in FIG. 8, the pin-shaped heating elements 310 are spaced apart from each other in both the longitudinal direction X and the transverse direction. In this way, the pin-shaped heating elements 310 are arranged to heat different parts of the aerosol-forming substrate 130. Advantageously, this ensures that all of the aerosol-forming substrate 130 is heated to the desired temperature during use of the system 400.

During use, when a user draws on the filter 150 of the aerosol-generating article 100, air is drawn into the device cavity through the air inlet 360 at the upstream end 308 of the device cavity. In this embodiment, the air inlet 360 is oriented toward the central longitudinal axis of the device chamber. Air drawn into the device cavity through the air inlet 360 and into the inner cavity 160 of the aerosol-forming substrate 130 is drawn along the inner cavity 160 toward the filter 150, as shown by arrow A10, and is released from the filter 150 at the downstream end 120 of the aerosol-generating article 100 for delivery to the user.

When power is provided to the multiple heating elements 310, the multiple heating elements 310 heat the aerosol-forming substrate 130 to a temperature at which volatile compounds are released from the substrate 130 into the substrate 130's inner cavity 160, where they cool and form an aerosol that can be inhaled by a user. The aerosol is mixed with air drawn through the inner cavity 160, drawn from the inner cavity 160 through the filter 150, and delivered to the user at the downstream end 120.

Claims (15)

1. An aerosol generation system comprising:
1. An aerosol-generating article having an upstream end and a downstream end, the aerosol-generating article defining a longitudinal direction between the upstream end and the downstream end, the aerosol-generating article comprising:
an upstream segment disposed at the upstream end of the aerosol-generating article, the upstream segment comprising an aerosol-forming substrate, the aerosol-forming substrate comprising a substrate outer surface having a substrate outer diameter; and
an aerosol-generating article comprising: a downstream segment disposed at the downstream end of the aerosol-generating article, the downstream segment having a downstream segment outer diameter that is greater than the substrate outer diameter;
An aerosol generating device, comprising:
an apparatus cavity including an apparatus cavity inner surface having an apparatus cavity inner diameter, the apparatus cavity configured to receive at least the aerosol-forming substrate of the aerosol-generating article; and
and an aerosol generating device comprising at least one heating element configured to heat the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity;
an aerosol generating system, wherein when the aerosol-forming substrate of the aerosol-generating article is received within the device cavity, an airflow passage is defined between the substrate outer surface and the device cavity inner surface, the airflow passage extending in the longitudinal direction along the length of the aerosol-forming substrate. The aerosol generating system of claim 1, wherein the aerosol-forming substrate includes an inner substrate surface having an inner substrate diameter, the inner substrate surface defining an inner cavity extending longitudinally within the aerosol-forming substrate. The aerosol generating system of claim 2, wherein the inner diameter of the substrate is about 60% to about 90% of the outer diameter of the substrate. The aerosol generating system of claim 2 or 3, wherein a layer of thermally conductive material is disposed on the inner surface of the substrate. 5. The aerosol generating system of claim 1, wherein the upstream segment and the downstream segment are arranged coaxially aligned with a longitudinal axis of the aerosol generating article. The aerosol generating system of any one of claims 1 to 5, wherein the downstream segment includes a filter. The aerosol generating system of claim 6, wherein the downstream segment further includes at least one of a cooling element and a spacing element disposed between the aerosol-forming substrate and the filter. The aerosol generating system of any one of claims 1 to 7, wherein the outer diameter of the substrate is about 50% to about 98% of the outer diameter of the downstream segment. The aerosol generating system according to any one of claims 1 to 8, wherein the outer surface of the substrate has a circular or elliptical cross section. The aerosol generating system according to any one of claims 1 to 9, wherein the aerosol-forming substrate comprises a tobacco cast leaf. The aerosol generating system according to any one of claims 1 to 10, wherein the aerosol-forming substrate has a substantially homogeneous composition along the longitudinal axis. The aerosol generating system according to any one of claims 1 to 10, wherein the aerosol-forming substrate includes a first aerosol-forming substrate segment extending in the longitudinal direction, and a second aerosol-forming substrate segment adjacent to the first aerosol-forming substrate segment in the longitudinal direction. The aerosol generating system of any one of claims 1 to 12, wherein the aerosol generating device cavity defines a longitudinal direction between an upstream end of the device cavity and a downstream end of the device cavity, and the at least one heating element includes a first heating element and a second heating element spaced apart from each other in the longitudinal direction of the device cavity. The aerosol generating system of any one of claims 1 to 13, wherein the downstream segment outer diameter of the aerosol generating article is substantially the same as or larger than the device cavity inner diameter. 15. An aerosol generating system according to any one of claims 1 to 14, wherein the airflow passage is external to the aerosol-forming substrate and provides a space into which volatile compounds from the aerosol-forming substrate can migrate.

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