EP3945887A1

EP3945887A1 - Aerosol generating system

Info

Publication number: EP3945887A1
Application number: EP20715160.6A
Authority: EP
Inventors: Patrick MOLONEY
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2019-04-05
Filing date: 2020-03-18
Publication date: 2022-02-09
Also published as: US20220202094A1; JP7601940B2; CA3134471A1; JP7277013B2; BR112021020050A2; WO2020201702A1; AU2020250957A1; CN113660876A; JP2022528394A; AU2023204016A1; JP2025041672A; IL286133A; US20250151803A1; KR102700561B1; KR20210132183A; CN118303677A; JP2023099153A; CN113660876B; GB201904845D0

Abstract

There is provided an aerosol generating system (100) comprising: a consumable unit (110) having a plurality of air flow paths (112) therethrough, each of the plurality of air flow paths being associated with at least a respective one of a corresponding plurality of sources of aerosol generating medium (114); and, a housing (120) for housing the consumable unit, the housing having an air inlet (122) and an air outlet (124), wherein the system is configured so that any of the air flow paths can be selectively brought into contact with the inlet and the outlet to form an air flow path.

Description

AEROSOL GENERATING SYSTEM

Technical Field

The present invention relates to an aerosol generating system, an aerosol generating device, a consumable part for use in an aerosol generating device, a housing for an aerosol generating device and a method of generating an aerosol in an aerosol generating device.

Background

Aerosol generating devices are known. Common devices use heaters to create an aerosol from a suitable medium which is then inhaled by a user. Current devices offer users a large variety in the media from which inhalable aerosol can be generated. Aerosol generated can be deposited on components within the device.

Various approaches are described herein which seek to help address or mitigate at least some of the issues discussed above.

Summary

Aspects of the invention are defined in the accompanying claims.

In accordance with some embodiments described herein, there is provided an aerosol generating system comprising: a consumable unit having a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with at least a respective one of a corresponding plurality of sources of aerosol generating medium; and, a housing for housing the consumable unit, the housing having an air inlet and an air outlet, wherein the system is configured so that any of the air flow paths can be selectively brought into contact with the inlet and the outlet to form an air flow path.

In accordance with some embodiments described herein, there is provided an aerosol generating device configured to receive a consumable unit having a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with a respective one of a corresponding plurality of sources of aerosol generating medium, comprising: a housing for housing the consumable unit, the housing having an air inlet and an air outlet, wherein the device is configured so that any of the air flow paths can be selectively brought into contact with the inlet and the outlet to form an air flow path.

In accordance with some embodiments described herein, there is provided a consumable part for use in an aerosol generating device.

In accordance with some embodiments described herein, there is provided a housing part for an aerosol generating device.

In accordance with some embodiments described herein, there is provided a method of generating an aerosol in an aerosol generating device, the method comprising: providing a consumable unit having a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with a respective one of a corresponding plurality of sources of aerosol generating medium; providing a housing for housing the consumable unit, the housing having an air inlet and an air outlet, selectively bringing an air flow path into contact with the air inlet and the air outlet to form an air flow path.

In accordance with some embodiments described herein, there is provided a consumable unit for use with an aerosol generating device configured to receive the consumable unit, the device having a housing for housing the consumable unit, the housing having an air inlet and an air outlet, wherein the consumable unit has a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with at least a respective one of a corresponding plurality of sources of aerosol generating medium; wherein the consumable unit is arranged such that any of the air flow paths can be selectively brought into contact with the air inlet and the air outlet to form an air flow path.

In accordance with some embodiments described herein, there is provided aerosol provision means comprising: a consumable unit having a plurality of air flow means therethrough, each of the plurality of air flow means being associated with a respective one of a corresponding plurality of sources of aerosol generating means; and a housing for housing the consumable unit, the housing having air inlet means and air outlet means, wherein the system is configured so that any of the air flow paths can be selectively brought into contact with the inlet and the outlet to form an air flow path.

The present teachings will now be described by way of example only with reference to the following figures in which like parts are depicted by like reference numerals:

Figure 1 is a schematic sectional view of a portion of an aerosol generating system according to an example;

Figure 2 is a schematic sectional view of a portion of an aerosol generating system according to an example;

Figure 3 is a schematic sectional view of a portion of an aerosol generating system according to an example;

Figure 4 is a schematic sectional view of a consumable unit for an aerosol generating system according to an example;

Figure 5 is a schematic sectional view of a consumable unit for an aerosol generating system according to an example;

Figure 6 is a schematic sectional view of a consumable unit for an aerosol generating system according to an example; and,

Figure 7 is a perspective view of two consumable units for an aerosol generating system according to an example. While the invention is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description of the specific embodiments are not intended to limit the invention to the particular forms disclosed. On the contrary, the invention covers all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.

Aspects and features of certain examples and embodiments are discussed / described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed / described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

The present disclosure relates to aerosol generating systems, which may also be referred to as aerosol generating systems, such as e-cigarettes. Throughout the following description the term“e-cigarette” or“electronic cigarette” may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol generating system / device and electronic aerosol generating system / device. Furthermore, and as is common in the technical field, the terms "aerosol" and "vapour", and related terms such as "vaporise", "volatilise" and "aerosolise", may generally be used interchangeably.

As used herein, the term“plurality of sources of aerosol generating medium” may be used interchangeably with“portions of aerosol generating medium”, and the term“device” may be used interchangeably with“system” with the understanding that the device is a standalone tool while a system is the tool with a consumable.

Figure 1 illustrates a schematic view of a portion of an aerosol generating system 100. The system 100 has a consumable unit 110 within the device 100. The consumable unit 100 has a plurality of air flow paths 112 therethrough, each of the plurality of air flow paths 112 being associated with a respective one of a corresponding plurality of sources of aerosol generating medium 114. The consumable unit 110 in this example comprises an upper wall and an opposite lower wall separate by a gap, wherein the air flow paths 112 through the consumable unit 110 are arranged to pass through, or be substantially formed by, the gap. The device 100 has a housing 120 for housing the consumable unit 110. The housing 120 has an air inlet 122 and an air outlet 124. The system 100 is configured such that any of the air flow paths 112 can be selectively brought into contact with the inlet 122 and the outlet 124 to form an air flow path from the inlet 112 to the outlet 124.

In an example, the consumable unit 110 is selectively moveable relative to the housing 120 so as to form an air flow path from the air inlet 122 of the housing 120 to the air outlet 124 of the housing 120, through a selected one 112A, 112B, 112C, 112D, 112E of the plurality of air flow paths 112 through the consumable unit 110.

In another example, the housing 120 is selectively moveable so that an air flow path in the consumable unit 110 can be selectively brought into contact with at least one of the inlet 122 and the outlet 124 to form an air flow path through the system 100.

In another example, the inlet 122 is selectively moveable so that an air flow path in the consumable unit 110 can be selectively brought into contact with at least one of the inlet 122 and the outlet 124 to form an air flow path through the system 100.

In another example, the outlet 124 is selectively moveable so that an air flow path in the consumable unit 110 can be selectively brought into contact with at least one of the inlet 122 and the outlet 124 to form an air flow path through the system 100.

As shown in the example of Figure 1, the consumable unit 110 (or housing 120) may move along a direction shown by arrow D so as to form an air flow path through the housing 120 and the consumable unit 110. This relative movement aligns the air inlet 122 with one of the air flow paths 112A, 112B, 112C, 112D, 112E so that air may enter the device 100 from the external environment. The device 100 may have a heater (not shown) or the like arranged within it so as to heat either the aerosol generating medium or the airflow prior to passing over or through the aerosol generating medium.

The heater may be an electrically resistive heater. The heater may be a chemically activated heater which may or may not operate via exothermic reactions or the like. The heater provides thermal energy, heat, to the surrounding environment of the heater. At least some portion of the consumable unit 110 is within the area of effect of the heater. The area of effect of the heater is the area within which the heater may provide heat to the consumable unit 110. The heater may be a source of energy for heating which may be part of an inductive heating system, wherein the source of energy for heating is the source of energy for inductive heating and the consumable unit 110 may be or may contain a susceptor or the like. The susceptor may for example be a sheet of aluminium foil or the like.

The system 100 may have in an example substantially the same distance between the consumable unit 110 to the heater for providing a more consistent user experience. In an example the aerosol generating medium 114 is disposed in the consumable unit 110 at a distance from the source of energy for heating within the range of 0.010mm, 0.015mm, 0.017mm, 0.020mm. 0.023mm, 0.025mm, 0.05mm, 0.075mm, 0.1mm, to about 4mm, 3.5mm, 3mm, 2.5mm, 2.0mm, 1.5mm, 1.0mm, 0.5mm or 0.3mm. In some cases, there may be a minimum spacing between the source of energy for heating and aerosol generating medium in the consumable unit 110 of at least about 10pm, 15pm, 17pm, 20pm, 23pm, 25pm, 50pm, 75pm or 0.1mm.

Figure 2 shows an example of an aerosol generating device 100 during use. The consumable unit 110 has been moved relative to the housing 120 to form an air path through the device 100. A user then inhales on the device 100. The arrows in Figure 2 show a general direction of air flow through the device 100. Air enters through the air inlet 122 in the housing 120 and passes along air flow path 112D. The air flow then passes over aerosol generating medium 114D associated with air flow path 112D. Elements from aerosol generating medium 114D are entrained in the air flow in air flow path 112D and carried to the air outlet 124 of the housing 120, as illustrated by the series of arrows in Figure 2. The consumable unit 110 shown in Figure 2 has a plurality of dividing walls 116. The plurality of air flow paths 112 through the consumable unit 110 are separated from one another by the plurality of dividing walls 116. As relative movement of the consumable unit 110 and the housing 120 occurs, the specific air flow paths 112A, 112B, 112C, 112D, 112E will be moved into and out of fluid communication with the air inlet 122 of the housing 120. When an air flow path 112 is not in fluid communication with the air inlet 122, the air flow path from the air inlet 122 to the air outlet 124 through the device 100 will be blocked. This blocking may occur by virtue of the dividing walls 116 of the consumable unit 110.

Figure 3 shows an example of a portion of an aerosol generating device 100. The consumable unit 110 has a plurality of air inlet apertures 117 and a plurality of air outlet apertures 118. The sources of aerosol generating medium 114 are arranged between one air inlet aperture 117 and one air outlet aperture 118.

The consumable unit 110 is in a position relative to the housing 120 so as to form an air flow path through the device 100 from the air inlet 122 to the air outlet 124. Incoming air enters through the air inlet 122 and is shown by arrow A. The air flows over or through a source of aerosol generating medium 114 to form an aerosol or an aerosol. The subsequent air flow of the aerosol or aerosol is shown by arrow B as it exits the air flow path 112 through the consumable unit 110 towards the air outlet 124 of the housing 120. The aerosol generating medium 114 arranged within the consumable unit 110 may be arranged to fill a portion of the path through the consumable unit 110 such that air flow must pass through the aerosol generating medium 114 to exit the consumable unit 110 (in the direction of air flow). See, for example, aerosol generating medium 114E arranged between air inlet aperture 117E and air outlet aperture 118E. “Between” here is taken to mean along the route of the air flow path, as shown in Figure 3. Alternatively, the aerosol generating medium 114 may be arranged so that air flow simply passes over the aerosol generating medium 114 as it passes through the consumable unit 110 (in the direction of air flow). See, for example, aerosol generating medium 114A arranged between air inlet aperture 117A and air outlet aperture 118A.

The consumable unit 110 as shown in Figure 3 has a plurality of apertures 117, 118. These apertures 117, 118 enable air flow to enter the consumable unit 110. As such, the apertures 117, 118 may be replaced by a portion of air permeable material through which air can enter the consumable unit 110. The air permeable material should be of a suitable resistance to air flow such that excessive inhalation pressure is not required to draw air flow through the air permeable material.

In an example of a consumable unit 110, any (or all) of the apertures 117, 118 or equivalent may have a filter material arranged therein or thereon. The filter material should be of a suitable resistance to air flow such that excessive inhalation pressure is not required to draw air flow through the filter material. This can assist in removing particulates and the like from incoming air or outgoing aerosol.

The consumable unit 110 is arranged within the device 100 so that air flow entering the device 100 through the air inlet 122 may enter an air flow path 112 of the consumable unit 110. If the consumable unit 110 is arranged in the device 100 with too great a distance between the air inlet 122 and the air inlet aperture 117 of the consumable unit 110, incoming air flow may not pass through the consumable unit 110, but rather pass around it to the air outlet 124. In this arrangement, the device 100 may not generate an aerosol for inhalation.

In an example, it is desirable to ensure airflow passes only through one specific air flow path 112A, 112B, 112C, 112D, 112E so that the depletion of the source of aerosol generating medium 114 contained respectively in each specific air flow path 112A, 112B, 112C, 112D, 112E can be controlled.

The above identified issues may be overcome by having a specific air inlet aperture 117A, 117B, 117C, 117D, 117E of the consumable unit 110 abut the air inlet 122 of the housing 120. This ensures that incoming air flow passes over the aerosol generating medium 114 contained within the specific air flow path 112A, 112B, 112C, 112D, 112E of the specific air inlet aperture 117A, 117B, 117C, 117D, 117E that is abutting the air inlet 122 of the housing 120 at the point of inhalation of the user.

The consumable unit 110 may be arranged substantially close to the air outlet 124 of the housing 120. The closer the consumable unit 110 to the air outlet 124 of the housing 120, the shorter the distance is in which the aerosol flows while inside the device 100 but outside the consumable unit 110. Reducing this distance reduces the area inside the device 100 on which aerosol can condense. Aerosol condensing with the device 100 can be undesirable as the aerosol can damage components within the device 100 and so reduce more generally the lifetime of the device 100. As such, an arrangement as described above may increase the lifetime of the device 100.

In the examples of Figure 3, a specific air inlet aperture 117A and corresponding air outlet aperture 118A of the consumable unit 110 are arranged at an angle to one another. In the example shown, a specific air inlet aperture 117A is arranged perpendicularly to the corresponding air outlet aperture 118A. In other examples, some air inlet apertures 117 may be arranged at different angles to some air outlet apertures 118. The arrangement of air inlet apertures 117 and air outlet apertures 118 may be altered to conform to a desirable shape of the housing 120. Alternatively, the arrangement may be manipulated to reduce the size of the consumable unit 110, enabling a compact and efficient design.

The air inlet apertures 117 or any of the air inlet apertures 117 may be arranged at an angle to any of the air outlet apertures 118. In some examples, the angle may be at least 15°, at least 20°, at least 25°, at least 30°, at least 35°, at least 40°, at least 45°, at least 50°, at least 55°, at least 60°, at least 65°, at least 70°, at least 75°, at least 80°, at least 85° or at least 90°.

Figure 4 shows a schematic example of a consumable unit 110 according to an example. The consumable unit 110 of Figure 4 has a number (3) of airflow paths 112 through the consumable unit 110. The consumable unit 110 is shown as in use. Incoming air flow, illustrated by arrow A, is entering the consumable unit 110, passing over aerosol generating medium 114 and exiting as outgoing aerosol, illustrated by arrow B. The consumable unit 110 in the example has biased caps to respectively cover the air inlet apertures 117 and air outlet apertures 118 of the consumable unit 110 after use of the device 100 has ceased, i.e. once the airflow decreases to the point that use of the device 100 is deemed to have ceased. The level of biasing of the caps 119 may be set so that air flow during the usual stages of a use session (which might be known as a smoking session or a vaping session) can move a cap 119 from a closed position, whereby at rest the cap 119 is blocking an airflow path 112, to an open position, whereby the cap 119 moves to unblock the airflow path. This biasing should be of a suitable resistance to air flow pressure such that excessive inhalation pressure is not required to move the cap 119 to the open position, and therefore enable drawing of air through the device 100.

After use of the device 100 has ceased, the caps 119 on the relevant air inlet aperture(s) 117 and air outlet aperture(s) 118 move, under biasing of the caps 119, to the closed position. This prevents aerosol generated at the end, or after the end, of the use session which might not exit the device 100 exiting the consumable 110 and then condensing on the inside of the device 100. As mentioned above, this can increase the lifetime of the device 100. The consumable unit 110 may be replaced once the sources of aerosol generating medium 114 are fully depleted. As such, removal of the consumable unit 110 then removes the condensed aerosol contained within the consumable unit 110.

The biased caps 119 need not be arranged at the air inlet apertures 117 and the air outlet apertures 118, but may be arranged within the consumable unit 110. Similarly, a number of biased caps 119 may be used per route from air inlet apertures 117 to air outlet apertures 118. Figure 5 shows schematic example of a consumable unit 110 according to an example. The consumable unit 110 has seven biased caps 119. The consumable unit 110 also has three air inlet apertures 117 and one air outlet aperture 118. The use of biased caps 119 ensures that aerosol generated by one source of aerosol generating medium 114 in one route within the consumable unit 110 passes in the desired route to the air outlet aperture 118 without entering another route. This is desirable to ensure that the sources of aerosol generating medium 114 are only in use when desired by the user. The use of multiple biased caps 119 as in the example of Figure 5 is useful when there are multiple routes in the consumable unit 110 that are in fluid communication with one another within the consumable unit 110.

The example shown in Figure 5 may also be useful wherein the sources of aerosol generating medium 114 are of different flavours or constitutions. The multiple biased caps 119 prevent hot aerosol from one source of aerosol generating medium 114 entering a different route and passing over a second source of aerosol generating medium 114 to cause vaporisation of that second source of aerosol generating medium 114. This prevents the result of producing inter- mixed flavours from two different sources of aerosol generating medium 114 which may not provide an optimal user experience of the device 100.

In the example shown in Figure 5, the middle air inlet aperture 117 is aligned with the air inlet 122 of the housing 120 (not shown). Incoming air is shown by arrow A and this incoming air has moved one biased cap 119 into the open position. The incoming air has then passed over the source of aerosol generating medium 114 to entrain elements from the source of aerosol generating medium 114. This subsequent aerosol, shown by arrow B, then moves a second biased cap 119 into the open position. The aerosol then travels towards the air outlet aperture 118 and moves the biased cap 119 over the air outlet aperture 118 into the open position to exit the consumable unit 110.

Figure 6 shows a schematic sectional view of a consumable unit 110 according to an example. The consumable unit 110 has no biased caps 119 displayed but these may or may not be used in this or any other example. The consumable unit 110 shown in Figure 6 is surrounded by a rotatable outer element 130. This may be part of the consumable unit 110 or part of the housing 120. The outer element 130 may be moved in a rotational movement shown by the arrow R. By rotating this outer element 130, the openings 132, 134 may selectively enable air to flow through one route in the consumable unit 110 to the air outlet aperture 118. The distances between the openings 134 reflect the distance opening 132 must travel to align with a subsequent air inlet aperture 117 of the consumable unit 110. In this way, air is prevented from entering via more than one air inlet aperture 117, and therefore only one source of aerosol generating medium 114 is used at once. As above, biased caps 119 may be used to prevent airflow passing two sources of aerosol generating medium 114 if this is desired.

Figure 7 shows a perspective view of two examples of a consumable unit 110. The consumable unit 110 has the shape of a thin cylinder and has, in Fig. 7(i), five air inlet apertures 117 and one air outlet aperture 118. The five air inlet apertures 117 are arranged on the outer curved surface of the cylindrical consumable unit 110 and the one air outlet aperture 118 is arranged centrally in a flat end surface of the cylindrical consumable unit 110. In this example, the consumable unit 110 is rotatable to present one of the air inlet apertures 117 to the air inlet 122 of the housing 120 (not shown in Figure 7). The device 100 may then be used. Airflow will enter through the selected air inlet aperture 117 and airflow exiting the consumable unit 110 will pass through the air outlet aperture 118. This can be arranged to be near to the air outlet aperture 124 of the housing 120 as mentioned above. Rotation may occur around the central longitudinal axis of the consumable unit 110. In this manner, the centrally-located air outlet aperture 118 does not during movement of the air inlet apertures

117 arranged on the side of the consumable unit 110. This may enable greater control on the location of exit of aerosol from the consumable unit 110.

In Fig. 7(ii) the consumable unit 110 has the same shape as the consumable unit 110 shown in Fig. 7(i). The consumable unit 110 also has five air inlet apertures 117. The consumable unit 110 has three air outlet apertures 118 arranged in the same surface as the air outlet aperture

118 of Fig. 7(i).

The consumable unit 110 could have a rotating inner housed inside a non-rotating outer. The sources of aerosol generating medium 114, the dividing walls 116 and the air flow paths 112 may be part of the rotating inner. The non-rotating outer may have an inlet and an outlet. The rotating inner may be rotated to align specific air flow paths with the inlet and outlet, arranged in the non-rotating outer, which remain stationary. In such an arrangement there would only need to be one inlet and one outlet. This would further prevent contamination between sources of aerosol generating medium 114.

The consumable unit 110 may have a number of layers arranged within the consumable unit 110. The plurality of layers provide a series of condensing surfaces on which aerosol may condense preferentially over the inside of the device 100. Each of the plurality of sources of aerosol generating medium 114 is arranged on a layer of the plurality of layers. An airflow path 112 may pass over various layers of the consumable unit 110. There may be multiple sources of aerosol generating medium 114 arranged on one layer in the consumable unit 110. The dividing walls 116 may divide parts of one layer within the consumable unit 110. There may be multiple sources of aerosol generating medium 114 arranged on multiple layers in the consumable unit 110. In any of the examples discussed, the consumable unit 110 or the housing 120 may be moved by rotation or translation or the like to affect relative movement between the consumable unit 110 and the housing 120. The device 100 may have gearing or a displaceable/rotatable shaft connected to the consumable unit 110 or housing 120 to enable movement. The device may have a displaceable/rotatable housing 120 which can be moved in the hands of a user. The movement enables an air inlet aperture 117 to abut the air inlet 122 of the housing 120.

The relative movement of the consumable unit 110 to the housing 120 may be affected by a user of the aerosol generating device 100. In an example this may be by the user pressing a button to operate a system within the aerosol generating device 100, or by manually moving or rotating the housing or a turn crank or the like.

In another example, the relative movement of the consumable unit 110 to the housing 120 is automatically initiated. The movement may be affected automatically, for example, by a controller which detects when heating of the selected one of the plurality of sources of aerosol generating medium 114 begins or ceases. Alternatively or additionally, the movement may be affected by a controller on depletion of a source of aerosol generating medium 114 or on cessation of a use session. This would ensure that the device 100 is ready to be activated again as soon as a use session has finished.

In any of the above examples, the consumable unit 110 may be removable from the device 100. This would enable re-using the device 100 after the sources of aerosol generating medium 114 of a particular consumable unit 110 are depleted. The device 100 may have a door or cover which is openable to access the consumable unit 110.

Minor alterations can be made to the above examples, if it is desired to activate more than one source of aerosol generating medium 114 at one time.

The device 100 may have a plurality of chambers or regions that may or may not be separate from one another. The device 100 of any of the above examples may have a power chamber (not shown) comprising energy stores for supplying power to a heater (not shown) and/or the movement mechanisms where these are present (e.g. not manually driven by the user). The heater may be an electrically resistive heater. The heater may be a chemically activated heater which may or may not operate via exothermic reactions or the like.

The sources of aerosol generating medium 114 contained within the device 100 may comprise at least one of tobacco and glycol and may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, oil, liquid, or powder.

The aerosol-forming layer described herein comprises an“amorphous solid”, which may alternatively be referred to as a“monolithic solid” (i.e. non-fibrous), or as a“dried gel”. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some cases, the aerosol-forming layer comprises from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid. In some cases, the aerosol-forming layer consists of amorphous solid.

In some cases, the amorphous solid may comprise l-50wt% of a gelling agent wherein these weights are calculated on a dry weight basis.

Suitably, the amorphous solid may comprise from about lwt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 27wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 5-40wt%, 10-30wt% or 15-27wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium- crosslinked alginate and/or a calcium-crosslinked pectin.

Suitably, the amorphous solid may comprise from about 5wt%, 10wt%, 15wt%, or 20wt% to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt%, 45wt% 40wt%, or 35wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the amorphous solid may comprise 10-60wt%, 15-50wt% or 20- 40wt% of an aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of or consists of glycerol. The inventors have established that if the content of the plasticiser is too high, the amorphous solid may absorb water resulting in a material that does not create an appropriate consumption experience in use. The inventors have established that if the plasticiser content is too low, the amorphous solid may be brittle and easily broken. The plasticiser content specified herein provides an amorphous solid flexibility which allows the amorphous solid sheet to be wound onto a bobbin, which is useful in manufacture of aerosol generating articles.

In some cases, the amorphous solid may comprise a flavour. Suitably, the amorphous solid may comprise up to about 60wt%, 50wt%, 40wt%, 30wt%, 20wt%, 10wt% or 5wt% of a flavour. In some cases, the amorphous solid may comprise at least about 0.5wt%, lwt%, 2wt%, 5wt% 10wt%, 20wt% or 30wt% of a flavour (all calculated on a dry weight basis). For example, the amorphous solid may comprise 10-60wt%, 20-50wt% or 30-40wt% of a flavour. In some cases, the flavour (if present) comprises, consists essentially of or consists of menthol. In some cases, the amorphous solid does not comprise a flavour.

In some cases, the amorphous solid additionally comprises a tobacco material and/or nicotine. For example, the amorphous solid may additionally comprise powdered tobacco and/or nicotine and/or a tobacco extract. In some cases, the amorphous solid may comprise from about lwt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine.

In some cases, the amorphous solid comprises a tobacco extract. In some cases, the amorphous solid may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 55wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) tobacco extract. For example, the amorphous solid may comprise 5-60wt%, 10-55wt% or 25-55wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises lwt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that which results from the tobacco extract.

In some embodiments the amorphous solid comprises no tobacco material but does comprise nicotine. In some such cases, the amorphous solid may comprise from about lwt%, 2wt%, 3wt% or 4wt% to about 20wt%, 15wt%, 10wt% or 5wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise l-20wt% or 2-5wt% of nicotine.

In some cases, the total content of tobacco material, nicotine and flavour may be at least about lwt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of tobacco material, nicotine and flavour may be less than about 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis). In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15wt%, 12wt% or 10 wt% of water calculated on a wet weight basis (WWB). In some cases, the hydrogel may comprise at least about 2wt% or at least about 5wt% of water (WWB).

The amorphous solid may be made from a gel, and this gel may additionally comprise a solvent, included at 0.1-50wt%. However, the inventors have established that the inclusion of a solvent in which the flavour is soluble may reduce the gel stability and the flavour may crystallise out of the gel. As such, in some cases, the gel does not include a solvent in which the flavour is soluble.

The amorphous solid comprises less than 20wt%, suitably less than 10wt% or less than 5wt% of a filler. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In some cases, the amorphous solid comprises less than lwt% of a filler, and in some cases, comprises no filler. In particular, in some cases, the amorphous solid comprises no calcium carbonate such as chalk.

In some cases, the amorphous solid may consist essentially of, or consist of a gelling agent, an aerosol generating agent, a tobacco material and/or a nicotine source, water, and optionally a flavour.

Thus there has been described an aerosol generating device comprising: a consumable unit having a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with a respective one of a corresponding plurality of sources of aerosol generating medium; and, a housing for housing the consumable unit, the housing having an air inlet and an air outlet, wherein the consumable unit is selectively moveable relative to the housing so as to form an air flow path from the air inlet of the housing to the air outlet of the housing, through a selected one of the plurality of air flow paths through the consumable unit. The aerosol generating device may be used in a tobacco industry product, for example a non combustible aerosol provision system.

In one embodiment, the tobacco industry product comprises one or more components of a non-combustible aerosol provision system, such as a heater and an aerosolizable substrate.

In one embodiment, the aerosol provision system is an electronic cigarette also known as a vaping device.

In one embodiment the electronic cigarette comprises a heater, a power supply capable of supplying power to the heater, an aerosolizable substrate such as a liquid or gel, a housing and optionally a mouthpiece.

In one embodiment the aerosolizable substrate is contained in or on a substrate container. In one embodiment the substrate container is combined with or comprises the heater.

In one embodiment, the tobacco industry product is a heating product which releases one or more compounds by heating, but not burning, a substrate material. The substrate material is an aerosolizable material which may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment, the heating device product is a tobacco heating product.

In one embodiment, the heating product is an electronic device.

In one embodiment, the tobacco heating product comprises a heater, a power supply capable of supplying power to the heater, an aerosolizable substrate such as a solid or gel material.

In one embodiment the heating product is a non-electronic article.

In one embodiment the heating product comprises an aerosolizable substrate such as a solid or gel material, and a heat source which is capable of supplying heat energy to the aerosolizable substrate without any electronic means, such as by burning a combustion material, such as charcoal. In one embodiment the heating product also comprises a filter capable of filtering the aerosol generated by heating the aerosolizable substrate.

In some embodiments the aerosolizable substrate material may comprise an aerosol or aerosol generating agent or a humectant, such as glycerol, propylene glycol, triacetin or diethylene glycol.

In one embodiment, the tobacco industry product is a hybrid system to generate aerosol by heating, but not burning, a combination of substrate materials. The substrate materials may comprise for example solid, liquid or gel which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and a solid substrate. The solid substrate may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and tobacco.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for a superior electronic aerosol provision system. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims

1. An aerosol generating system comprising:

a consumable unit having a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with at least a respective one of a corresponding plurality of sources of aerosol generating medium; and,

a housing for housing the consumable unit, the housing having an air inlet and an air outlet,

wherein the system is configured so that any of the air flow paths can be selectively brought into contact with the inlet and the outlet to form an air flow path.

2. An aerosol generating system according to claim 1, wherein the consumable unit is selectively moveable so that an air flow path in the consumable unit can be selectively brought into contact with the inlet and the outlet to form an air flow path through the system.

3. An aerosol generating system according to claims 1 or 2, wherein the housing is selectively moveable so that an air flow path in the consumable unit can be selectively brought into contact with the inlet and the outlet to form an air flow path through the system.

4. An aerosol generating system according to claim 3, wherein the inlet is selectively moveable so that an air flow path in the consumable unit can be selectively brought into contact with the inlet and the outlet to form an air flow path through the system.

5. An aerosol generating system according to claims 3 or 4, wherein the outlet is selectively moveable so that an air flow path in the consumable unit can be selectively brought into contact with the inlet and the outlet to form an air flow path through the system.

6. An aerosol generating system according to any of claims 1 to 5, the consumable unit further comprising a corresponding plurality of dividing walls,

wherein the plurality of air flow paths through the consumable unit are separated from one another by the corresponding plurality of dividing walls in the consumable unit.

7. An aerosol generating system according to any of claims 1 to 6, wherein the consumable unit further comprises a cover,

the cover covering a portion of the consumable unit, the cover providing a condensing surface for aerosol generated in the device.

8. An aerosol generating system according to any of claims 1 to 7, wherein the consumable unit further comprises a plurality of apertures through which air can flow, wherein one aperture is an air inlet aperture and one aperture is an air outlet aperture,

wherein aerosol generating medium is arranged between the air inlet aperture and the air outlet aperture.

9. An aerosol generating system according to claim 8, further comprising filter material arranged in one of the plurality of apertures through which air can flow.

10. An aerosol generating system according to claim 8 or claim 9, wherein the air inlet aperture is arranged at an angle to the air outlet aperture.

11. An aerosol generating system according to any of claims 8 to 10, wherein the air inlet aperture of the consumable unit abuts the air inlet of the housing so as to form the air flow path from the air inlet of the housing to the air outlet of the housing.

12. An aerosol generating system according to any of claims 8 to 11, the consumable unit comprising biased caps to cover respectively the air inlet aperture and the air outlet aperture of the consumable unit after use of the device has ceased.

13. An aerosol generating system according to any of claims 1 to 12, wherein the consumable unit is rotatable relative to the housing.

14. An aerosol generating system according to any of claims 1 to 13, wherein relative movement of the consumable unit to the housing is affected by a user of the aerosol generating system.

15. An aerosol generating system according to any of claims 1 to 14, wherein relative movement of the consumable unit to the housing is automatically initiated.

16. An aerosol generating system according to any of claims 1 to 15, the consumable unit further comprising a plurality of layers providing condensing surfaces,

wherein each of the plurality of sources of aerosol generating medium is arranged on a layer of the plurality of layers.

17. An aerosol generating system according to any of claims 1 to 16, wherein the consumable unit is removable from the system.

18. An aerosol generating system according to any of claims 1 to 17, the consumable unit further comprising:

a base on which aerosol generating medium is arranged;

a side wall projecting from the base;

a corresponding plurality of dividing walls projecting from the base and the side wall, wherein the plurality of air flow paths through the consumable unit are separated from one another by the corresponding plurality of dividing walls; and,

a cover covering a portion of the consumable unit, the cover providing a condensing surface for aerosol generated in the device,

an aperture in the side wall through which air can flow, wherein the aperture in the side wall abuts the air inlet of the housing.

an opening in the cover through which air can flow, wherein the opening in the cover is in fluid communication with the air outlet of the housing.

19. An aerosol generating device configured to receive a consumable unit having a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with a respective one of a corresponding plurality of sources of aerosol generating medium, comprising:

a housing for housing the consumable unit, the housing having an air inlet and an air outlet, wherein the device is configured so that any of the air flow paths can be selectively brought into contact with the inlet and the outlet to form an air flow path.

20. A consumable part for the aerosol generating device of claim 19.

21. A housing part for the aerosol generating device of claim 19.

22. A method of generating an aerosol in an aerosol generating device, the method comprising:

providing a consumable unit having a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with a respective one of a corresponding plurality of sources of aerosol generating medium;

providing a housing for housing the consumable unit, the housing having an air inlet and an air outlet,

selectively bringing an air flow path into contact with the air inlet and the air outlet to form an air flow path.

23. A method according to claim 22, wherein selectively bringing an air flow path into contact with the air inlet and the air outlet to form an air flow path comprises selectively moving at least one of:

the consumable unit;

the housing;

the air inlet; and,

the air outlet.

24. A consumable unit for use with an aerosol generating device configured to receive the consumable unit, the device having a housing for housing the consumable unit, the housing having an air inlet and an air outlet,

wherein the consumable unit has a plurality of air flow paths therethrough, each of the plurality of air flow paths being associated with at least a respective one of a corresponding plurality of sources of aerosol generating medium; wherein the consumable unit is arranged such that any of the air flow paths can be selectively brought into contact with the air inlet and the air outlet to form an air flow path.

25. Aerosol provision means comprising:

a consumable unit having a plurality of air flow means therethrough, each of the plurality of air flow means being associated with a respective one of a corresponding plurality of sources of aerosol generating means; and

a housing for housing the consumable unit, the housing having air inlet means and air outlet means,