JP2023509702A - Flavor cartridge for aerosol generator - Google Patents

Abstract

The present invention relates to replaceable flavor cartridges for aerosol generators. The cartridge includes a housing and a flavored substrate. A flavored substrate is disposed within the housing. The housing includes a proximal opening in the proximal end face of the housing. The housing includes a distal opening in the distal end face of the housing. The flavored substrate includes substrate apertures. The proximal opening, distal opening, and base opening are aligned with each other to form a cartridge airflow channel through the cartridge. The invention further relates to an aerosol generator.
[Selection drawing] Fig. 1

Description

The present invention relates to an aerosol generator.

Aerosol generation is known. One type of aerosol generating system is an electronic cigarette. Electronic cigarettes typically use a liquid aerosol-forming substrate that is vaporized to form an aerosol. A "heated non-combustion" (HNB) device can heat one or more solid aerosol-forming substrates to a temperature at which one or more components of the aerosol-forming substrate volatilize without burning the solid aerosol-forming substrate. . Furthermore, hybrid aerosol generators are known that have both a liquid aerosol forming function and an HNB function. All three of these devices, liquid aerosol forming devices or e-cigarettes, HNB devices and hybrid devices are aerosol generating devices.

Typically, an aerosol generating device comprises an upper portion and a main body. Typically, the main body contains the power supply. Typically, the upper portion, which may be replaceable, includes a heater and means for introducing the aerosol-forming substrate into the heater.

The aerosol-generating substrate may be provided or inserted within a cavity, such as a heating chamber, in the upper portion of the aerosol-generating device. A heating element may be disposed in or around the heating chamber to heat the aerosol-forming substrate after the aerosol-generating article is provided in the heating chamber of the aerosol-generating device.

It is desirable to have an aerosol generating device that can modify the flavor of the generated aerosol. It is desirable to have an aerosol generator that allows the user to control and modify the flavor modification of the generated aerosol. It is desirable to have an aerosol generating device in which user-based flavor modification of the generated aerosol is simple. It would be desirable to have an aerosol generating device with flavor modifying capabilities. It would be desirable to have an aerosol generating device that can modify flavor by providing a flavor cartridge separate from the solid or liquid aerosol generating material.

According to one embodiment of the present invention, a replaceable flavor cartridge for an aerosol generator is provided. The cartridge is insertable into the aerosol generator such that the airflow passes through the flavor cartridge either before or after the airflow passes through the aerosol-generating portion of the aerosol generator. The flavor cartridge can provide flavor upstream or downstream of the aerosol generator.

In embodiments, the cartridge includes a housing and a flavored substrate. A flavored substrate is disposed within the housing. Flavored substrates may be tobacco-free. Flavored substrates may be nicotine-free. Preferably, the flavored substrate comprises a flavoring agent.

The housing includes a proximal opening in a proximal portion of the housing. A proximal opening is preferably provided in the proximal end face of the housing. A proximal end face is provided on the proximal portion. The housing includes a distal opening in a distal portion of the housing. A distal opening is preferably provided in the distal end face of the housing. A distal end surface is provided on the distal portion. The flavored substrate includes substrate apertures. The proximal opening, distal opening, and base opening are aligned with each other to form a cartridge airflow channel through the flavor cartridge.

By providing replaceable flavor cartridges, the flavor of the generated aerosol can be modified. The interchangeability of the cartridge allows the user to modify the flavor of the generated aerosol as desired.

The cartridge may be a non-heated cartridge. Flavorants from the flavor substrate may be entrained in the air flowing through the cartridge airflow channels. Preferably, the flavored substrate is in direct contact with air flowing through the cartridge airflow channels. Direct contact between the flavor substrate and the cartridge airflow channel can facilitate entrainment of the flavorant into the air flowing through the cartridge airflow channel.

The cartridge airflow channel may be straight. The airflow channel may extend directly from the distal opening through the substrate opening to the proximal opening. The distal opening of the housing may directly abut the base opening of the base portion. The base opening of the base portion may directly abut the proximal opening of the housing. The distal end face of the housing may directly abut the flavor substrate. The flavored substrate may directly abut the proximal end face of the housing. The flavored substrate may be sandwiched between the proximal end face of the housing and the distal end face of the housing. A cartridge airflow channel may be formed from a distal opening, a substrate opening, and a proximal opening. The cartridge airflow channel preferably extends parallel to the central axis through the cartridge airflow channel.

The cartridge may contain only flavored substrates. The flavored substrate may be enclosed by the housing of the cartridge. The proximal end face of the flavor substrate may be covered by the proximal end face of the housing. The distal end face of the flavored substrate may be covered by the distal end face of the housing. The sides of the flavor substrate may be covered by the side walls of the housing.

The cartridge may be disc-shaped. The proximal end face of the cartridge may be flat. The distal end face of the cartridge may be flat. The sidewall of the cartridge may be tubular. The cartridge is preferably cylindrical. The cross-section of the flavor cartridge may be, for example, substantially circular, oval, square or rectangular.

The cartridge may include a removable fluid impermeable proximal foil covering the proximal opening. The removable fluid impermeable proximal foil may be peeled off by the user prior to using the cartridge. The foil may be peeled off by the user prior to inserting the cartridge into the aerosol generating device.

The cartridge may include a removable, fluid-impermeable distal foil covering the distal opening. The removable fluid impermeable distal foil may be peeled off by the user prior to using the cartridge. The foil may be peeled off by the user prior to inserting the cartridge into the aerosol generating device.

The housing may be porous. By providing a porous housing, the flavorant from the flavored substrate can soak into the housing. Flavorants from the flavored substrate can be wicked by the porous housing. The contact surface between the flavorant and air flowing through the cartridge airflow channels may be increased by the porous housing. In particular, flavorant from the flavored substrate may be drawn by the cartridge toward one or both of the proximal and distal openings of the housing in fluid contact with the cartridge airflow channels. The entire housing may be porous. Alternatively, a portion of the housing may be porous. Advantageously, the portion of the housing forming one or both of the proximal and distal openings may be porous.

The flavor cartridge housing may be a single unitary element. However, it is preferred that the housing of the flavor cartridge consists of at least two elements. A proximal portion of the flavor cartridge may include a proximal opening and a proximal end face of the housing. A distal portion of the flavor cartridge may include a distal opening and a distal end face. The sidewall of the flavor cartridge may be one or more of a portion of the proximal portion of the flavor cartridge, a portion of the distal portion of the flavor cartridge, and a separate element. The proximal portion may be attachable to the distal portion. A flavored substrate may be sandwiched between the proximal portion and the distal portion. The proximal portion may be removably attachable to the distal portion. The flavored substrate may be recycled by removing the proximal and distal portions after use.

The proximal portion of the flavor cartridge may be configured to be removably attachable to one of the side wall and distal portion of the flavor cartridge. The distal portion of the flavor cartridge may be configured to be removably attachable to one of the side wall and proximal portion of the flavor cartridge. For example, the proximal portion of the flavor cartridge may include male connecting elements and the distal portion of the flavor cartridge may include female connecting elements, or vice versa. The sidewalls may include corresponding male and female connecting elements attached between the proximal and distal portions. Alternatively, the proximal portion of the flavor cartridge may be removably attached directly to the distal portion of the flavor cartridge. Removable attachment may be facilitated by threaded connections. Removable attachment may be facilitated by a snap-fit connection. Removable attachment may be facilitated by a friction fit connection.

The proximal portion of the housing and the distal portion of the housing may be connected with a luer connector. One or more of the proximal opening, distal opening, and substrate opening may be configured as luer connectors. One or both of the proximal portion of the flavor cartridge housing and the distal portion of the flavor cartridge housing may include a luer connector. Secure attachment between one or more of the proximal opening, the distal opening, and the substrate opening can be achieved by providing one or more of these components as luer connectors.

In additional embodiments, one or more of the proximal opening, distal opening, and substrate opening can include a connector. A connector may be configured to connect one or more of the proximal opening, the distal opening, and the substrate opening. The connector is preferably configured to securely hold the components of the flavor cartridge together by allowing removable attachment between the components of the flavor cartridge. The connector preferably allows removable attachment between the proximal portion of the flavor cartridge and the distal portion of the flavor cartridge. The connector can be any connector known in the art that creates a removable hermetic and/or liquid tight seal. For example, the connector can be a threaded connection or a snap-fit connection.

The flavored substrate may comprise one or more of flavored liquids, high retention materials impregnated with flavored liquids, flavored gels, particles impregnated with flavored liquids, and gel capsules containing flavored liquids or flavored gels. If the flavor substrate comprises a flavor gel, the flavor gel may be configured as a viscous flavor gel. When the flavored substrate comprises particles or gel capsules, the particles or gel capsules may be embedded in the carrier. The flavor substrate is preferably configured dimensionally stable so that a substrate opening can be provided in the flavor substrate.

In particular, by providing the flavored substrate as a high retention material impregnated with a flavored liquid, the flavored liquid can be wicked away by the high retention material. During use of the cartridge, the flavored liquid may be entrained in the air flowing through the cartridge airflow channels. As a result, a portion of the flavor substrate adjacent to the cartridge airflow channel may be depleted. Flavor liquid from other non-depleted portions of the flavor substrate adjoins the cartridge airflow channels such that flavor liquid from other portions of the flavor substrate is gradually entrained in the air flowing through the cartridge airflow channels. It may be drawn toward a portion of the flavored substrate.

Flavor substrates may include ambient temperature atomizable flavor substrates. Ambient temperature atomizable flavor substrates can be airborne at standard pressure and temperature conditions. As a result, ambient temperature atomizable flavored substrates may aerosolize at the interface between the flavored substrate and air flowing through the cartridge airflow channels. The aerosolized ambient temperature atomizable flavored substrate may be entrained in the air flowing through the cartridge airflow channels. As a result of the ambient temperature atomizable flavor substrate, there is no need to heat the cartridge to aerosolize the flavor substrate. Therefore, the cartridge is preferably configured as a non-heated cartridge.

The flavored substrate may comprise at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol in use and is substantially resistant to thermal decomposition at the operating temperature of the system. be. Suitable aerosol formers are well known in the art and include polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (glycerol monoacetate, diacetate or triacetate). etc.), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). Aerosol formers can also be polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1,3-butanediol and glycerin. The aerosol former may be propylene glycol. Aerosol formers may contain both glycerin and propylene glycol.

In embodiments, the flavor substrate is a high retention material that can be shaped to provide substrate openings. For example, the flavored substrate may be a material wetted or soaked or impregnated with a flavoring liquid or gel. Flavoring agents may include water, solvents, ethanol, plant extracts, and natural or artificial flavors. The liquid may contain nicotine. The liquid may have a nicotine concentration of about 0.5% to about 10% (eg, about 2%).

The flavor cartridge housing may be a rigid housing. As used herein, the term "rigid housing" is used to mean a self-supporting housing. A rigid housing of the flavor cartridge may provide mechanical support to the flavor cartridge. The flavor cartridge housing may comprise any suitable material. The flavor cartridge housing may comprise a substantially fluid impermeable material. The flavor cartridge housing may include a transparent or translucent portion such that the substrate portion stored within the flavor cartridge may be visible to a user through the housing. The flavor cartridge may be configured such that the aerosol-forming substrate stored within the flavor cartridge is protected from light. This may reduce the risk of substrate degradation and may maintain a high level of hygiene.

A flavor cartridge may include one or more inlets, which may be one-way inlets. This may allow ambient air to enter the flavor cartridge. The one or more one-way inlets are permeable to allow ambient air to enter the flavor cartridge and substantially prevent air and liquids inside the flavor cartridge from exiting the flavor cartridge. It may be a semi-permeable membrane or a one-way valve that is impermeable to do so. One or more semi-open inlets may allow air to pass into the flavor cartridge under certain conditions. The flavor cartridge may be refillable. Alternatively, the flavor cartridge may be configured as a replaceable flavor cartridge. The flavor cartridge may be part of a replaceable cartridge or configured as a replaceable cartridge.

The term "ambient air" refers to air drawn into the aerosol-generating device from outside the aerosol-generating device. In other words, the term "ambient air" refers to the air surrounding the aerosol generator.

The invention further relates to an aerosol generating device comprising an upper portion, a replaceable flavor cartridge as described herein, and a main body. The cartridge may be configured to be removably attachable between the top portion and the main body.

A user can easily modify the flavor of the aerosol generated by the aerosol generator by inserting the desired flavor cartridge containing the desired flavor into the aerosol generator. The replaceable flavor cartridges allow the user to modify the flavor of the generated aerosol by modifying the flavor cartridge to a different desired flavor.

The flavor cartridge may be modular. A number of different flavor cartridges may be used in conjunction with a single aerosol generating device.

The upper portion of the aerosol generator may be configured as a mouth end portion. The upper portion may be configured as a mouthpiece. Alternatively, the top portion may have a cavity for inserting a solid aerosol-generating substrate. A conventional aerosol generating device provides an air inlet, an airflow channel, and an air outlet. In the present invention, the flavor cartridges are preferably provided within a common airflow channel so that the aerosol generator does not require additional air inlets or airflow channels. In other words, the flavor cartridge can be modularly sandwiched between the top portion and the main body and utilize the same comment airflow channels. In embodiments, the flavor cartridge may be refillable.

The airflow path may allow the user to draw air through the heated substrate. The upper portion may include upper portion airflow channels. The main body may include main body airflow channels. The main body airflow channel, cartridge airflow channel, and upper partial airflow channel may be fluidly connected to form a common airflow channel through the aerosol generating device.

Preferably, the aerosol generator can be used without a cartridge. In this case, the upper portion is attached to the main body such that the upper portion airflow channels are in fluid communication with the main portion airflow channels. These two airflow channels form a common airflow channel. If the user wishes to modify the flavor of the generated aerosol, the user can insert the flavor cartridge described herein between the top portion and the main body to modify the desired flavor. . This insertion of the flavor cartridge utilizes the same upper and main airflow channels by aligning the cartridge airflow channel with these two airflow channels. The resulting common airflow channel is therefore a combination of the aforementioned airflow channel (aerosol generator without flavor cartridge) and the cartridge airflow channel of the flavor cartridge.

The top portion can include a cavity configured to receive an aerosol-generating article that includes an aerosol-forming substrate. The upper portion may include a heating element disposed within or around the cavity. The heating element can be configured to heat the aerosol-forming substrate of the aerosol-generating article.

The heating element may be positioned away from the replaceable flavor cartridge such that the flavor substrate may be substantially insulated from the heating element. The heating element can be configured to heat the aerosol-forming substrate of the aerosol-generating article. At the same time, the heating element may be configured not to heat the flavor cartridge. As described herein, the flavor cartridge may be an unheated flavor cartridge. As a result, the aerosol generator does not require additional heating elements to modify the flavor of the aerosol. In alternative embodiments, the heating element is also configured to heat the flavor cartridge, or the aerosol generator includes a further heating element for heating the flavor cartridge when the flavor cartridge is received by the aerosol generator. may be provided.

A replaceable flavor cartridge may be configured to be attachable between the top portion and the main body. The attachment is preferably configured as a removable attachment. The upper portion of the aerosol generator may be configured to be removably attachable to the proximal portion of the flavor cartridge. The main portion of the aerosol generator may be configured to be removably attachable to the distal portion of the flavor cartridge. Removable attachment between the flavor cartridge and the aerosol generating device may be facilitated by known attachment means. For example, the upper portion of the aerosol generator may include male connection elements and the proximal portion of the flavor cartridge may include female connection elements, or vice versa. The main portion of the aerosol generator may include the male connecting element and the distal portion of the flavor cartridge may include the female connecting element, or vice versa. The removable attachment between one or both of the upper portion and main body of the aerosol generator and one or both of the proximal and distal portions of the flavor cartridge may be a threaded connection, a snap-fit connection, or It can be configured as a friction fit connection.

The replaceable flavor cartridge may be configured to be attachable between the top portion and the main body by placing the cartridge between the top portion and the main body and rotating the cartridge. Attachment of the replaceable flavor cartridge between the top portion and the main body may be facilitated by a swivel connection, bayonet mount, or luer connection, or any other quick reversible connection known in the art.

Removable attachment of the flavor cartridge to the aerosol generator can depend on the connections chosen. If the connection is facilitated by a threaded connection, the user may screw the proximal portion of the flavor cartridge to the upper portion of the aerosol generator. Alternatively, the user may screw the top portion of the aerosol generator to the proximal portion of the flavor cartridge. The user may then screw the distal portion of the flavor cartridge onto the main body of the aerosol generating device. Alternatively, the user may then screw on the main body of the aerosol generator to move the distal portion of the flavor cartridge. As a further alternative, the user may first screw the distal portion of the flavor cartridge onto the main body of the aerosol generator and then screw the flavor cartridge onto the top portion of the aerosol generator.

If the connection is facilitated as a snap-fit connection or a friction-fit connection, the user first presses the proximal portion of the flavor cartridge against the upper portion of the aerosol generator and snaps between the proximal and upper portions. A fit or friction fit connection may be established. The user may then press the distal portion of the flavor cartridge against the main body of the aerosol generating device to establish a snap or friction fit connection between the distal portion and the main body. . Alternatively, the user may first press the distal portion of the flavor cartridge against the main body and then press the proximal portion against the upper portion.

If the connection is facilitated as a swivel connection or bayonet mount, the user can place the flavor cartridge between the top portion of the aerosol generator and the main body of the aerosol generator. Optionally, the projection of the flavor cartridge is placed in a recess in the aerosol generator or in a recess in the flavor cartridge penetration of the aerosol generator to facilitate correct alignment of the flavor cartridge between the top portion and the main body. good too. The user may then rotate the flavor cartridge relative to the aerosol generator to facilitate engagement of the swivel connection or bayonet mount of the flavor cartridge with corresponding elements of the aerosol generator.

The flavor cartridge may be securely held between the upper portion and the main body of the aerosol generating device by any of the connection means described above. Additionally, any of the connection means described above may allow the flavor cartridge to be removed from the aerosol generator when the flavor cartridge is depleted. An unused flavor cartridge may then be removably attached to the aerosol generator. Alternatively or additionally, the flavor substrate of a depleted flavor cartridge may be refilled to replace the depleted flavor cartridge with an unused flavor cartridge.

To refill a depleted flavor cartridge, the flavor cartridge may include a refill opening. The refill opening may be configured as a membrane or one-way valve. In one embodiment, the refill opening may be disposed within the housing of the flavor cartridge so as to be accessible when the flavor cartridge is rotated relative to further components of the aerosol generating device. This embodiment is particularly beneficial when the connection between the flavor cartridge and the aerosol generator is facilitated by a swivel connection or bayonet mount. When the flavor cartridge of this embodiment is rotated into the operating position, the refill opening is preferably inaccessible to prevent spillage of the flavor substrate.

As used herein, "aerosol-generating device" relates to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate may be part of an aerosol-generating article, such as a smoking article. The aerosol-generating device may be a smoking device that interacts with the aerosol-forming substrate of the aerosol-generating article to generate an inhalable aerosol through the user's mouth and directly into the user's lungs. The aerosol generator may be a holder. The device may be an electrically heated smoking device. The aerosol generating device may comprise a housing, an electrical circuit, a power source, a heating chamber and a heating element.

The aerosol-generating device may comprise a cavity for receiving an aerosol-generating article comprising an aerosol-forming substrate. The cavity of the aerosol-generating device may have an open end and the aerosol-generating article is inserted therein. The open end may be the proximal end. The cavity may have a closed end opposite the open end. The closed end may be the base of the cavity. The closed end may be closed except to provide an air opening disposed within the base. The base of the cavity may be flat. The base of the cavity may be circular. The base of the cavity may be arranged upstream of the cavity. The open end may be arranged downstream of the cavity. The cavity may have an elongated extension. The cavity may have a central longitudinal axis. The longitudinal direction may be the direction extending between the open end and the closed end along the longitudinal central axis. The central longitudinal axis of the cavity may be parallel to the longitudinal axis of the aerosol generating device.

The cavity may be configured as a heating chamber. The cavity may have a cylindrical shape. The cavity may have a hollow cylindrical shape. The cavity may have a shape corresponding to the shape of the aerosol-generating article received in the cavity. The cavity may have a circular cross-section. The cavity may have an elliptical or rectangular cross-section. The cavity may have an inner diameter corresponding to the outer diameter of the aerosol-generating article.

An upper partial airflow channel may extend through the cavity. Ambient air may be drawn into the aerosol generating device, into the cavity, through the upper partial airflow channel and towards the user. Downstream of the cavity, a mouthpiece may be disposed, or the user may directly inhale the aerosol-generating article. An airflow channel may extend through the mouthpiece. A flavor cartridge may be disposed upstream of the cavity.

The terms "upstream," "downstream," "proximal," and "distal" as used herein refer to the components of the aerosol generating device or Used to describe the relative positions of component parts.

The aerosol generator may comprise a heating element. The heating element may comprise an electrically resistive material. Suitable electrically resistive materials include semiconductors such as doped ceramics, "conductive" ceramics (such as molybdenum disilicide), carbon, graphite, metals, alloys, and ceramic and metallic materials. Composite materials include, but are not limited to: Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum platinum, gold and silver. 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-, gold-, and iron-containing alloys, as well as superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, and iron-manganese-aluminum based alloys. In composites, the electrically resistive material is optionally embedded in, enclosed in, or covered with an insulating material depending on the required energy transfer kinetics and external physico-chemical properties. and vice versa.

The aerosol-generating device may comprise an internal heating element, or an external heating element, or both internal and external heating elements, where "internal" and "external" refer to the aerosol-forming substrate. The internal heating element may take any suitable form. For example, the internal heating element may take the form of a heating blade. Alternatively, the internal heater may take the form of a casing or substrate having different conductive portions or electrically resistive metal tubes. Alternatively, the internal heating element may be one or more heated needles or rods passing through the center of the aerosol-forming substrate. Other alternatives include heating wires or filaments such as Ni—Cr (nickel chromium), platinum, tungsten, or alloy wires or heating plates. Optionally, the internal heating element may be arranged in or on a rigid carrier material. In one such embodiment, an electrically resistive heating element may be formed using a metal that has a well-defined relationship between temperature and resistivity. In such exemplary devices, the metal may be formed as tracks on a suitable insulating material such as a ceramic material and then sandwiched in another insulating material such as glass. A heater formed in this manner may be used both to heat a heating element and to monitor its temperature during operation.

The external heating element can take any suitable form. For example, the external heating element may take the form of one or more flexible heating foils on a dielectric substrate such as polyimide. A flexible heating foil can be shaped to fit around the cavity. Alternatively, the external heating elements may take the form of metal grids, flexible printed circuit boards, molded circuit components (MIDs), ceramic heaters, flexible carbon fiber heaters, or substrates of appropriate shape. It may also be formed thereon using a coating technique such as plasma deposition. External heating elements may also be formed using metals that have a well-defined relationship between temperature and resistivity. In such exemplary devices, the metal may be formed as tracks between two layers of suitable insulating material. An external heating element formed in this manner may be used to both heat the external heating element and monitor the temperature of the external heating element during operation.

The internal or external heating element may comprise a heat sink or heat reservoir comprising a material capable of absorbing and storing heat and then releasing the heat over time to the aerosol-forming substrate. A heat sink may be formed of any suitable material, such as a suitable metal or ceramic material. In one embodiment, the material is a material that has a high heat capacity (sensible heat storage material) or has the ability to absorb heat and then release heat by a reversible process (such as a high temperature phase change). Suitable sensible heat storage materials include silica gel, alumina, carbon, glass mat, glass fibers, minerals, metals or alloys (such as aluminum, silver, or lead), and cellulosic materials (such as paper). Other suitable materials that release heat by reversible phase change include paraffins, sodium acetate, naphthalene, waxes, polyethylene oxide, metals, metal salts, mixtures of eutectic salts, or alloys. A heat sink or heat reservoir may be arranged in direct contact with the aerosol-forming substrate and capable of transferring the stored heat directly to the substrate. Alternatively, heat stored in a heat sink or reservoir may be transferred to the aerosol-forming substrate by a thermal conductor such as a metal tube.

The heating element advantageously heats the aerosol-forming substrate by conduction. The heating element may be in at least partial contact with the substrate or carrier on which the substrate is disposed. Alternatively, heat from either internal or external heating elements may be conducted to the substrate by thermally conductive elements.

During operation, the aerosol-forming substrate may be completely contained within the aerosol-generating device. In that case, the user may puff on the mouthpiece of the aerosol generator. Alternatively, during operation, the smoking article containing the aerosol-forming substrate may be partially contained within the aerosol-generating device. In that case, the user may smoke the smoking article directly.

As an alternative to an electrically resistive heating element, the heating element may be configured as an induction heating element. An induction heating element may include an induction coil and a susceptor. Generally, a susceptor is a material that has the ability to absorb electromagnetic energy and convert it to heat. When placed in an alternating electromagnetic field, eddy currents are typically induced in the susceptor and hysteresis losses occur, causing heating of the susceptor. A changing electromagnetic field generated by one or several induction coils heats the susceptor, which then transfers heat to the aerosol-generating article such that an aerosol is formed. Heat transfer may be primarily by conduction of heat. Such heat transfer is best when the susceptor is in intimate thermal contact with the aerosol-generating article.

The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. A preferred susceptor may comprise or consist of a ferromagnetic material such as a ferromagnetic alloy, ferritic iron, or ferromagnetic steel or ferromagnetic stainless steel. A suitable susceptor may be or include aluminum. Preferred susceptors may be heated to temperatures in excess of 250 degrees Celsius.

A preferred susceptor is a metal susceptor (eg stainless steel). However, susceptor materials also include graphite, molybdenum, silicon carbide, aluminum, niobium, inconel alloys (austenitic nickel-chromium based superalloys), metallized films, ceramics (such as zirconia), transition metals (such as iron, cobalt, nickel, etc.), or metalloid components (eg, boron, carbon, silicon, phosphorous, aluminum, etc.).

The susceptor material is preferably a metallic susceptor material. The susceptor may also be a multi-material susceptor and may include a first susceptor material and a second susceptor material. In some embodiments, the first susceptor material may be placed in physical contact with the second susceptor material. The second susceptor material preferably has a Curie temperature below the ignition point of the aerosol-forming substrate. Preferably, the first susceptor material is primarily used to heat the susceptor when the susceptor is placed in a varying electromagnetic field. Any suitable material may be used. For example, the first susceptor material may be aluminum, or it may be a ferrous material such as stainless steel. The second susceptor material is preferably primarily used to indicate when the susceptor has reached a particular temperature (which is the Curie temperature of the second susceptor material). The Curie temperature of the second susceptor material can be used to regulate the temperature of the entire susceptor during operation. Suitable materials for the second susceptor material may include nickel and certain nickel alloys.

By providing a susceptor with at least a first susceptor material and a second susceptor material, the heating of the aerosol-forming substrate and the temperature control of the heating may be separated. The second susceptor material is preferably a magnetic material having a second Curie temperature substantially the same as the desired maximum heating temperature. That is, the second Curie temperature is preferably about the same as the temperature to which the susceptor should be heated to generate an aerosol from the aerosol-forming substrate.

If an induction heating element is employed, the induction heating element may be configured as an internal heating element as described herein or as an external heater as described herein. When the induction heating element is configured as an internal heating element, the susceptor element is preferably configured as a pin or blade for penetrating the aerosol-generating article. If the induction heating element is configured as an external heating element, the susceptor element is preferably configured as a cylindrical susceptor that at least partially surrounds the cavity or forms the sidewalls of the cavity.

The aerosol generator may comprise an electrical circuit. The electrical circuit may comprise a microprocessor, which may be a programmable microprocessor. A microprocessor may be part of the controller. The electrical circuit may comprise further electronic components. The electrical circuit may be configured to regulate the power supply to the heating element. Power may be supplied to the heating element continuously following activation of the aerosol generator, or may be supplied intermittently (eg, with each puff). Power may be supplied to the heating element in the form of current pulses. The electrical circuit may be configured to monitor the electrical resistance of the heating element and may be configured to control the supply of electrical power to the heating element, preferably in response to the electrical resistance of the heating element.

The aerosol generator may include a power source (typically a battery) within the main body of the aerosol generator. In one embodiment, the power source is a lithium ion battery. Alternatively, the power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery (eg, a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery). Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power supply may require recharging and may have capacity to allow storage of sufficient energy for one or more usage experiences. For example, the power source may have sufficient capacity to continuously generate an aerosol for about 6 minutes, or a multiple of 6 minutes. In another embodiment, the power supply may have sufficient capacity to provide a predetermined number of puffs, or discontinuous activation of the heating element.

As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of releasing volatile compounds capable of forming an aerosol. For example, the aerosol-generating article may be a smoking article that generates an inhalable aerosol through the user's mouth and directly into the user's lungs. Aerosol-generating articles may be disposable. As described herein, aerosol-generating articles may be provided in addition to flavor cartridges. The aerosol-generating article is preferably received by a cavity in the upper portion of the aerosol-generating device and the flavor cartridge is preferably disposed upstream of the cavity between the upper portion of the aerosol-generating device and the main body.

The aerosol-generating article may be substantially cylindrical in shape. The aerosol-generating article may be substantially elongated. The aerosol-generating article may have a length and a circumference substantially perpendicular to the length. The aerosol-generating article may be substantially rod-shaped. The aerosol-forming substrate may be substantially cylindrical in shape. The aerosol-forming substrate may be substantially elongated. The aerosol-forming substrate may also have a length and a circumference substantially perpendicular to the length. The aerosol-forming substrate may be substantially rod-shaped.

The aerosol-generating substrate may comprise an aerosol former. The aerosol-generating substrate preferably comprises a homogenized tobacco material, an aerosol former, and water. Providing a 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 crushing tobacco leaves, which more effectively allows for the release of nicotine and flavor upon heating.

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

Alternatively, the homogenized tobacco material may be formed into spheres using spheronization. The average diameter of the spheres is preferably from about 0.5 millimeters to about 4 millimeters, more preferably from about 0.8 millimeters to about 3 millimeters.

The aerosol-generating substrate comprises from about 55 weight percent to about 75 weight percent homogenized tobacco material, from about 15 weight percent to about 25 weight percent aerosol former, and from about 10 weight percent to about 20 weight percent water. preferably included.

Samples of aerosol-generating substrates were equilibrated at 50 percent relative humidity and 22 degrees Celsius for 48 hours before being measured. The Karl Fischer technique was used to determine the moisture content of homogenized tobacco material.

Sheets of homogenized tobacco material for use in aerosol-generating articles, including capsules, were obtained by crushing or otherwise comminuting one or both of tobacco leaf blades and tobacco leaf stems. It may also be formed by agglomerating particulate tobacco.

Sheets of homogenized tobacco material for use in aerosol-generating articles, including capsules, include one or more endogenous binders that are tobacco-intrinsic binders, tobacco-exogenous binders, to aid in cohesion of the tobacco particulate. It may contain one or more exogenous binding agents, or combinations thereof, which are binding agents. Alternatively, or additionally, the sheet of homogenized tobacco material may contain tobacco and non-tobacco fibers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof, and others. may contain additives.

Exogenous binders suitable for inclusion within sheets of homogenized tobacco material for use in aerosol-generating articles, including capsules, are known in the art and include gums such as guar gum, xanthan gum, gum arabic, and locust bean gum), cellulosic binders (such as hydroxypropylcellulose, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, and ethylcellulose), polysaccharides (such as starch), organic acids (such as alginic acid), conjugates of organic acids. Examples include, but are not limited to, base salts (such as sodium alginate), agar, and 30 pectin, and combinations thereof.

Numerous reconstitution processes are known in the art for producing sheets of homogenized tobacco material. These include, for example, papermaking processes of the type described in US Pat. No. 3,860,012; "cast leaf" processes, such as dough reconstitution processes of the type described in US-A-3,894,544, and extrusion processes of the type described, for example, in GB-A-983,928. include, but are not limited to. Typically, the density of sheets of homogenized tobacco material produced by extrusion and dough reconstitution processes is greater than the density of sheets of homogenized tobacco material produced by casting processes.

Sheets of homogenized tobacco material for use in aerosol-generating articles, including capsules, are produced by casting a slurry comprising tobacco particulate and one or more binders onto a conveyor belt or other support surface. , drying a cast slurry to form a sheet of homogenized tobacco material, and removing the sheet of homogenized tobacco material from a support surface. preferable.

Homogenized tobacco sheet materials may be produced using different types of tobacco. For example, tobacco sheet materials may be formed using a number of different varieties of tobacco or tobacco from different parts of the tobacco plant (such as leaves and stems). After processing, the sheet has consistent properties and a homogenized flavor. A single sheet of homogenized tobacco material may be produced to have a particular flavor. Different tobacco sheet materials need to be produced to produce products with different flavors. Some flavors produced by blending many different shredded tobacco into a conventional cigarette can be difficult to replicate in a single homogenized tobacco sheet. For example, Virginia tobacco and Burley tobacco may need to be processed differently to optimize their individual flavors. It may not be possible to replicate certain blends of Virginia and Burley tobacco in a single sheet of homogenized tobacco material. As such, the aerosol-generating substrate may comprise a first homogenized tobacco material and a second homogenized tobacco material. Combining two different sheets of tobacco material within a single aerosol-generating substrate may create new blends that cannot be produced with a single sheet of homogenized tobacco.

The aerosol former preferably contains at least one polyhydric alcohol. In preferred embodiments, the aerosol former comprises at least one of triethylene glycol, 1,3-butanediol, propylene glycol, and glycerin.

The aerosol-forming substrate of the aerosol-generating article is preferably free of flavorants. If desired, the flavorant is preferably provided by a flavor cartridge disposed upstream of the cavity between the upper portion and the main body of the aerosol generating device.

Alternatively or additionally to providing an aerosol-generating article comprising a solid aerosol-forming substrate, the aerosol-generating device may operate with a liquid aerosol-forming substrate. A liquid aerosol-forming substrate may be held within a liquid storage portion. A liquid storage portion may be disposed in the upper portion of the aerosol generating device. A liquid storage portion may be disposed downstream of the flavor cartridge. A liquid aerosol-forming substrate may comprise a liquid aerosol former. The liquid aerosol-forming substrate may contain flavorants, illustratively tobacco flavor or menthol flavor. The liquid aerosol-forming substrate may contain nicotine. A liquid aerosol-forming substrate contained in a liquid reservoir is preferably provided in addition to the flavor cartridge. The liquid aerosol-forming substrate from the liquid storage portion is heated and vaporized by the heating element.

Below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more of the features of other examples, embodiments, or aspects described herein.

Example A:
A replaceable flavor cartridge for an aerosol generator, the cartridge comprising:
housing, and
a flavor substrate disposed within the housing;
The housing includes a proximal opening in a proximal portion of the housing, the housing includes a distal opening in a distal portion of the housing, the flavor substrate includes a substrate opening, the proximal opening, the distal opening, and the substrate opening. are replaceable flavor cartridges that align with each other to form a cartridge airflow channel through the cartridge.
Example B:
The cartridge of example B, wherein the cartridge airflow channel is straight.
Example C:
The cartridge of any of Examples A or B, wherein the cartridge includes a removable fluid-impermeable proximal foil covering the proximal opening.
Example D:
The cartridge of any of Examples AC, wherein the cartridge includes a removable, fluid-impermeable distal foil covering the distal opening.
Example E:
The cartridge of any of Examples AD, wherein the flavor substrate does not contain tobacco.
Example F:
The cartridge of any of Examples AE, wherein the flavored substrate does not contain nicotine.
Example G:
The cartridge of any of Examples AF, wherein the housing is porous.
Example H:
The cartridge of any of Examples AG, wherein the proximal portion of the housing and the distal portion of the housing are connected with a luer connector.
Example I:
The cartridge of any of Examples AH, wherein the flavor substrate comprises a high retention material impregnated with a flavor liquid or flavor gel.
Example J:
The cartridge of any of Examples AI, wherein the flavor substrate comprises an ambient temperature atomizable flavor substrate.
Example K:
An aerosol generator,
an upper part;
A replaceable flavor cartridge according to any of Examples A-J;
a main body;
An aerosol generating device, wherein the cartridge is configured to be removably attachable between the upper portion and the main body.
Example L:
The upper portion includes an upper portion airflow channel, the main body includes a main body airflow channel, the main body airflow channel, the cartridge airflow channel, and the upper portion airflow channel are fluidly connected to form the cartridge into the upper portion and the main body. The aerosol generating device of Example K which, when attached between and forms a common airflow channel through the aerosol generating device.
Example M:
The upper portion includes a cavity configured to receive an aerosol-generating article including an aerosol-forming substrate, the upper portion includes a heating element disposed within or around the cavity, the heating element comprising an aerosol The aerosol generating device of Example K or L, configured to heat an aerosol-forming substrate of the generating article.
Example N:
The aerosol generating device of Example M, wherein the heating element is positioned away from the replaceable flavor cartridge such that the flavor substrate is substantially thermally insulated from the heating element.
Example O:
The replaceable flavor cartridge is configured to be attachable between the top portion and the main body by placing the cartridge between the top portion and the main body and rotating the cartridge. An aerosol generating device according to any of Examples K-N.

Features described with respect to one embodiment may apply equally to other embodiments of the invention.

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

FIG. 1 shows an exploded view of the flavor cartridge. FIG. 2A shows a cross-sectional view of the flavor cartridge in disassembled condition. FIG. 2B shows a cross-sectional view of the assembled flavor cartridge. FIG. 3 shows an exemplary diagram of an aerosol generator. Figure 4 shows a diagram of the attachment of the flavor cartridge to the aerosol generator. Figure 5 shows a cross-sectional view of a further embodiment of the aerosol generating device.

FIG. 1 shows a flavor cartridge configured for use with an aerosol generator. The aerosol generator and the use of flavor cartridges in the aerosol generator are described below in conjunction with FIGS. The flavor cartridge includes a proximal portion 10 , a distal portion 12 and a flavor substrate 14 . Flavor substrate 14 is disposed between proximal portion 10 and distal portion 12 . Proximal portion 10 and distal portion 12 together form the housing of the flavor cartridge. Flavor substrate 14 is sandwiched between distal portion 12 and proximal portion 10 .

Proximal portion 10 includes proximal opening 16 . A proximal opening 16 is disposed in a proximal end face 18 of proximal portion 10 . Distal portion 12 includes distal opening 20 . Distal opening 20 is disposed in distal end face 22 of distal portion 12 . Flavor substrate 14 includes substrate openings 24 . Proximal opening 16, substrate opening 24 and distal opening 20 are aligned with each other. Cartridge airflow channel 26 extends through proximal opening 16 , substrate opening 24 and distal opening 20 .

Before using the flavor cartridge, the flavor cartridge is sealed to prevent flavor evaporation during storage. A removable fluid impermeable proximal foil 56 may be provided over the proximal opening 16 to seal the flavor cartridge. Additionally, a removable fluid impermeable distal foil 58 may be provided over the distal opening 20 . A user may remove the removable fluid-impermeable proximal foil 56 and the removable fluid-impermeable distal foil 58 prior to use of the flavor cartridge. After removal, a cartridge airflow channel 26 is established and air can flow through the flavor cartridge.

As the air flows through the flavor cartridge, it contacts the flavor substrate 14 . Flavorants contained in flavor substrate 14 may be entrained in the air. To increase the contact surface between the air flowing through the cartridge airflow channel 26 and the flavorant, one or both of the proximal portion 10 and the distal portion 12 are configured or porous. It may also contain sexual regions. The flavorant may then be wicked into one or both of proximal portion 10 and distal portion 12, or the porous regions of these elements.

FIG. 2A shows the state of the flavor cartridge prior to assembly of the flavor cartridge. It can be seen that the cartridge airflow channel 26 extends parallel to the central axis 28 of the flavor cartridge. In the region of the proximal opening 16 the flavor cartridge contains a female connecting element 30. As shown in FIG. Within the region of the distal opening 20 the flavor cartridge contains a male connecting element 32 . Of course, it is also an option for the female connecting element 30 to be arranged in the area of the proximal opening 16 and the male connecting element 32 to be arranged in the area of the distal opening 20 . Male connection element 32 and female connection element 30 are configured to allow attachment of the flavor cartridge to the aerosol generator.

FIG. 3 shows one embodiment of an aerosol generator. The aerosol generator comprises an upper portion 34 . The upper part 34 is configured as a mouthpiece. A user may inhale the aerosol generated within the aerosol generator through the upper portion 34 . Upper portion 34 is disposed at the proximal or distal end of the aerosol generating device. The aerosol-generating device may further comprise a main body 36. As shown in FIG. The main body 36 may include additional components such as a power source 46 in the form of a battery and a controller 48 . These components are shown in more detail in FIG. The aerosol generating device may further comprise a heating element 38 (heating element 38 is not shown in the embodiment shown in Figures 3 and 4, but is shown in the embodiment shown in Figure 5). A flavor cartridge is also illustrated in FIG. A flavor cartridge is sandwiched between the top portion 34 and the main body 36 . Ambient air is drawn into the aerosol generator through an air inlet 50 (shown in the embodiment of FIG. 5) when the user inhales on the upper portion 34 . Air is drawn through airflow channels (shown in the embodiment of FIG. 5), heated by heating element 38 along with the aerosol-forming substrate, and aerosol is generated by the aerosol generator. The aerosol can then be inhaled by the user. A flavor cartridge is disposed within the airflow channel. Flavor cartridges add flavors to the air so that the user can modify the generated aerosol.

Attachment of the flavor cartridge to the aerosol generator is shown in FIG. The male connecting element 32 of the flavor cartridge in the embodiment shown in Figure 4 is inserted into a corresponding female part 40 of the main body 36 of the aerosol generating device. After insertion of male connection element 32 , the flavor cartridge may be rotated to secure the flavor cartridge to main body 36 . The top portion 34 can then be attached to the flavor cartridge, illustratively by attaching the top portion 34 to the female connecting element 30 of the flavor cartridge.

Figure 5 shows a further embodiment of the aerosol generator. The main elements are similar to the aerosol generator shown in FIGS. The differences are shown below. The upper portion 34 of the aerosol-generating device shown in Figure 5 includes a cavity 42 for receiving an aerosol-generating article 44 that includes an aerosol-forming substrate. A heating element 38 is disposed downstream of the flavor cartridge within the upper portion 34 . The heating element 38 is configured as an induction heating element 38 . Heating element 38 at least partially surrounds cavity 42 . Heating element 38 is configured to heat the aerosol-forming substrate of aerosol-generating article 44 .

A flavor cartridge is sandwiched between the top portion 34 and the main body 36 .

Main body 36 includes power supply 46 and controller 48 . Controller 48 is configured to control the supply of electrical energy from power source 46 to heating element 38 . Power source 46 is preferably a battery. Main body 36 includes an air inlet 50 . Air inlet 50 is fluidly connected with main body airflow channel 52 . When the flavor cartridge is disposed between main body 36 and upper portion 34 , main body airflow channel 52 of main body 36 is fluidly connected with cartridge airflow channel 26 . Cartridge airflow channel 26 is fluidly connected with upper partial airflow channel 54 . An upper portion airflow channel 54 is disposed within the upper portion 34 . Upper partial airflow channel 54 is fluidly connected with cavity 42 . As shown in FIG. 5, the main partial airflow channel, cartridge airflow channel 26 and upper partial airflow channel 54 form a common airflow channel. In use, the user inhales the aerosol-generating article 44, thereby drawing ambient air into the air inlet 50, through the main body airflow channel 52, through the cartridge airflow channel 26, and through the upper partial airflow channel 54. , into cavity 42 . In cavity 42 air flows through the aerosol-forming substrate of aerosol-generating article 44 . The heating action of the heating element 38 heats the air and the aerosol-forming substrate to generate an aerosol. While drawing ambient air through the cartridge airflow channels 26, the air is enriched with flavorants from the flavor substrate 14 of the flavor cartridge. Accordingly, the flavor of the aerosol exiting the system comprising the aerosol-generating device and the aerosol-generating article 44 can be adjusted by means of suitable flavor cartridges.

Claims (14)

An aerosol generator,
an upper portion and a main body;
A replaceable flavor cartridge, said cartridge comprising:
housing, and
a flavor substrate, said flavor substrate disposed within said housing, and a replaceable flavor cartridge comprising a flavor substrate;
said housing includes a proximal opening in a proximal portion of said housing; said housing includes a distal opening in a distal portion of said housing; said flavor substrate includes a substrate opening; a distal opening and said base opening aligned with each other to form a cartridge airflow channel through said cartridge, said cartridge being removably attachable between said top portion and said main body. Generator. 2. The aerosol generating device of Claim 1, wherein the cartridge airflow channel is straight. 3. The aerosol generating device of any of claims 1 or 2, wherein the cartridge includes a removable fluid impermeable proximal foil covering the proximal opening. The aerosol generating device of any of claims 1-3, wherein the cartridge includes a removable, fluid-impermeable distal foil covering the distal opening. The aerosol generating device according to any one of claims 1 to 4, wherein the flavor base does not contain tobacco. The aerosol generating device according to any one of claims 1 to 5, wherein the flavor substrate does not contain nicotine. An aerosol generating device according to any preceding claim, wherein the housing is porous. An aerosol generating device according to any preceding claim, wherein the proximal portion of the housing and the distal portion of the housing are connected by a luer connector. An aerosol generating device according to any preceding claim, wherein the flavored substrate comprises a high retention material impregnated with a flavored liquid or flavored gel. The aerosol generating device of any of claims 1-9, wherein the flavored substrate comprises an ambient temperature atomizable flavored substrate. The upper portion includes an upper portion airflow channel, the main body includes a main body airflow channel, the main body airflow channel, the cartridge airflow channel, and the upper portion airflow channel are connected to each other by the cartridge and the upper portion. An aerosol generating device according to any preceding claim, wherein when mounted between said main body, it is fluidly connected to form a common airflow channel through said aerosol generating device. The top portion includes a cavity configured to receive an aerosol-generating article including an aerosol-forming substrate, the top portion includes a heating element disposed within or around the cavity, the heating element comprising: 12. The aerosol-generating device of any of claims 1-11, configured to heat the aerosol-forming substrate of the aerosol-generating article. 13. The aerosol generating device of Claim 12, wherein the heating element is disposed remotely from the replaceable flavor cartridge such that the flavor substrate is substantially thermally insulated from the heating element. The replaceable flavor cartridge is attachable between the top portion and the main body by placing the cartridge between the top portion and the main body and rotating the cartridge. The aerosol generator according to any one of claims 1 to 13, which is configured as follows.

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