JP7478242B2 - Flavor cartridge for aerosol generating devices - Google Patents

Description

The present invention relates to an aerosol generating device.

Aerosol generation is known. One type of aerosol generating system is the electronic cigarette. Electronic cigarettes typically use a liquid aerosol-forming substrate that is vaporized to form an aerosol. "Heated-not-burned" (HNB) devices may 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. In addition, hybrid aerosol generating devices are known that have both liquid aerosol-forming and HNB functions. All three of these devices, liquid aerosol-forming devices or electronic cigarettes, HNB devices and hybrid devices, are aerosol generating devices.

Typically, the aerosol generating device comprises an upper portion and a main body. Typically, the main body contains a power source. Typically, the upper portion, which may be replaceable, contains a heater and a means for introducing the aerosol-forming substrate to 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 allows the user to control and modify the flavor modification of the generated aerosol. It is desirable to have an aerosol generating device that allows simple user-based flavor modification of the generated aerosol. It is desirable to have an aerosol generating device that has flavor modification capabilities. It is desirable to have an aerosol generating device that allows the flavor to be modified by providing a flavor cartridge that is separate from the solid or liquid aerosol generating material.

According to one embodiment of the present invention, a replaceable flavor cartridge for an aerosol generating device is provided. The cartridge is insertable into the aerosol generating device 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 an embodiment, the cartridge includes a housing and a flavor substrate. The flavor substrate is disposed within the housing. The flavor substrate may be tobacco-free. The flavor substrate may be nicotine-free. The flavor substrate preferably includes a flavoring agent.

The housing includes a proximal opening at a proximal portion of the housing. The proximal opening is preferably provided at a proximal end face of the housing. The proximal end face is provided at the proximal portion. The housing includes a distal opening at a distal portion of the housing. The distal opening is preferably provided at a distal end face of the housing. The distal end face is provided at the distal portion. The flavor substrate includes a substrate opening. The proximal opening, the distal opening, and the substrate opening are aligned with one another to form a cartridge airflow channel through the flavor cartridge.

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

The cartridge may be a non-heated cartridge. Flavour from the flavour substrate may be entrained in the air flowing through the cartridge airflow channel. The flavour substrate is preferably in direct contact with the air flowing through the cartridge airflow channel. Direct contact between the flavour substrate and the cartridge airflow channel may facilitate entrainment of flavour 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 base opening to the proximal opening. The distal opening of the housing may abut directly against the base opening of the base portion. The base opening of the base portion may abut directly against the proximal opening of the housing. The distal end face of the housing may abut directly against the flavor substrate. The flavor substrate may abut directly against the proximal end face of the housing. The flavor substrate may be sandwiched between the proximal end face of the housing and the distal end face of the housing. The cartridge airflow channel may be formed from the distal opening, the base opening, and the proximal opening. The cartridge airflow channel preferably extends parallel to the central axis through the cartridge airflow channel.

The cartridge may contain only the flavour substrate. The flavour substrate may be enclosed by the housing of the cartridge. The proximal end face of the flavour substrate may be covered by the proximal end face of the housing. The distal end face of the flavour substrate may be covered by the distal end face of the housing. The sides of the flavour 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 side wall of the cartridge may be tubular. The cartridge is preferably cylindrical. The cross section of the flavour 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 a user prior to using the cartridge. The foil may be peeled off by a user prior to inserting the cartridge into an 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 a user prior to using the cartridge. The foil may be peeled off by a user prior to inserting the cartridge into an aerosol generating device.

The housing may be porous. By providing a porous housing, the flavorant from the flavor substrate may soak into the housing. The flavorant from the flavor substrate may be sucked out by the porous housing. The contact surface between the flavorant and the air flowing through the cartridge airflow channel may be increased by the porous housing. In particular, the flavorant from the flavor substrate may be sucked out by the cartridge towards one or both of the proximal and distal openings of the housing that are in fluid contact with the cartridge airflow channel. The entire housing may be porous. Alternatively, a portion of the housing may be porous. Advantageously, the portion of the housing that forms one or both of the proximal and distal openings may be porous.

The housing of the flavour cartridge may be a single integral element. However, it is preferred that the housing of the flavour cartridge is comprised of at least two elements. The proximal portion of the flavour cartridge may include a proximal opening and a proximal end face of the housing. The distal portion of the flavour cartridge may include a distal opening and a distal end face. The sidewall of the flavour cartridge may be one or more of a part of the proximal portion of the flavour cartridge, a part of the distal portion of the flavour cartridge, and a separate element. The proximal portion may be attachable to the distal portion. The flavour substrate may be sandwiched between the proximal portion and the distal portion. The proximal portion may be removably attachable to the distal portion. The flavour 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 attached to one of the sidewall and the distal portion of the flavor cartridge. The distal portion of the flavor cartridge may be configured to be removably attached to one of the sidewall and the proximal portion of the flavor cartridge. For example, the proximal portion of the flavor cartridge may include a male connection element and the distal portion of the flavor cartridge may include a female connection element, or vice versa. The sidewall may include corresponding male and female connection 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. The removably attached may be facilitated by a threaded connection. The removably attached may be facilitated by a snap-fit connection. The removably attached 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, the distal opening, and the base opening may be configured as a luer connector. One or both of the proximal portion of the housing of the flavor cartridge and the distal portion of the housing of the flavor cartridge may include a luer connector. Secure attachment between one or more of the proximal opening, the distal opening, and the base opening can be achieved by providing one or more of these components as a luer connector.

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

The flavor substrate may comprise one or more of a flavor liquid, a high retention material impregnated with a flavor liquid, a flavor gel, particles impregnated with a flavor liquid, and a gel capsule containing a flavor liquid or a flavor gel. When the flavor substrate comprises a flavor gel, the flavor gel may be configured as a viscous flavor gel. When the flavor substrate comprises particles or gel capsules, the particles or gel capsules may be embedded in a carrier. The flavor substrate is preferably configured to be dimensionally stable such that a substrate opening may be provided within the flavor substrate.

In particular, by providing the flavor substrate as a high retention material impregnated with flavor liquid, the flavor liquid can be drawn up by the high retention material. During use of the cartridge, the flavor liquid can be entrained in the air flowing through the cartridge airflow channel. As a result, a portion of the flavor substrate adjacent to the cartridge airflow channel can become depleted. Flavor liquid from other, undepleted portions of the flavor substrate can be drawn towards the portion of the flavor substrate adjacent to the cartridge airflow channel such that flavor liquid from other portions of the flavor substrate is gradually entrained in the air flowing through the cartridge airflow channel.

The flavor substrate may include an ambient atomizable flavor substrate. The ambient atomizable flavor substrate may be airborne at standard pressure and temperature conditions. As a result, the ambient atomizable flavor substrate may be aerosolized at the interface between the flavor substrate and air flowing through the cartridge airflow channel. The aerosolized ambient atomizable flavor substrate may be entrained in the air flowing through the cartridge airflow channel. As a result of the ambient atomizable flavor substrate, it is not necessary to heat the cartridge to aerosolize the flavor substrate. Thus, the cartridge is preferably configured as a non-heated cartridge.

The flavor substrate may include 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 during use and is substantially resistant to thermal decomposition at the operating temperature of the system. Suitable aerosol formers are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). The aerosol former may be a polyhydric alcohol or mixtures thereof (such as triethylene glycol, 1,3-butanediol, and glycerin). The aerosol former may be propylene glycol. The aerosol former may include both glycerin and propylene glycol.

In an embodiment, the flavor substrate is a high retention material that can be shaped to provide a substrate opening. For example, the flavor substrate may be a material that is wetted, soaked, or impregnated with a flavoring liquid or gel. The flavoring may include water, solvents, ethanol, botanical extracts, and natural or artificial flavors. The liquid may include nicotine. The liquid may have a nicotine concentration of about 0.5% to about 10% (e.g., about 2%).

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

The 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 may be semi-permeable membranes or one-way valves that are permeable to allow ambient air to enter the flavor cartridge and impermeable to substantially prevent air and liquids inside the flavor cartridge from exiting the flavor cartridge. The 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 may be configured as a replaceable cartridge.

The term "ambient air" refers to air that is drawn into the aerosol generating device from outside the aerosol generating device. In other words, the term "ambient air" refers to the air that surrounds the aerosol generating device.

The present 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 upper portion and the main body.

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

The flavor cartridges may be modular. Multiple different flavor cartridges may be used in conjunction with a single aerosol generating device.

The top portion of the aerosol generating device may be configured as a mouth end portion. The top portion may be configured as a mouthpiece. Alternatively, the top portion may have a cavity for inserting a solid aerosol generating substrate. In conventional aerosol generating devices, an air inlet, an airflow channel, and an air outlet are provided. In the present invention, the flavor cartridge is preferably provided in a common airflow channel, such that the aerosol generating device does not require an additional air inlet or airflow channel. In other words, the flavor cartridge can be modularly sandwiched between the top portion and the main body and utilize the same comment airflow channel. In an embodiment, the flavor cartridge can be refillable.

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

Preferably, the aerosol generating device can be used without a cartridge. In this case, the top portion is attached to the main body such that the top portion airflow channel is in fluid communication with the main portion airflow channel. 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 a flavor cartridge as described herein between the top portion and the main body to modify the desired flavor. This insertion of the flavor cartridge utilizes the same top portion airflow channel and the main portion airflow channel by aligning the cartridge airflow channel with these two airflow channels. The resulting common airflow channel is thus a combination of the aforementioned airflow channel (aerosol generating device without a flavor cartridge) and the cartridge airflow channel of the flavor cartridge.

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

The heating element may be disposed away from the replaceable flavor cartridge such that the flavor substrate may be substantially insulated from the heating element. The heating element may 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 a non-heating flavor cartridge. As a result, the aerosol generating device does not require an additional heating element to modify the flavor of the aerosol. In alternative embodiments, the heating element may also be configured to heat the flavor cartridge, or the aerosol generating device may include a further heating element for heating the flavor cartridge when the flavor cartridge is received by the aerosol generating device.

The 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 top portion of the aerosol generator may be configured to be removably attachable to a proximal portion of the flavor cartridge. The main portion of the aerosol generator may be configured to be removably attachable to a distal portion of the flavor cartridge. The removable attachment between the aerosol generator and the flavor cartridge may be facilitated by known attachment means. For example, the top portion of the aerosol generator may include a male connection element and the proximal portion of the flavor cartridge may include a female connection element, or vice versa. The main portion of the aerosol generator may include a male connection element and the distal portion of the flavor cartridge may include a female connection element, or vice versa. The removable attachment between one or both of the top portion and the main body of the aerosol generator and one or both of the proximal and distal portions of the flavor cartridge may be configured as a threaded connection, a snap-fit connection, or 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, a bayonet mount, or a luer connection, or any other quick reversible connection known in the art.

The removable attachment of the flavor cartridge to the aerosol generation device may depend on the connection selected. If the connection is facilitated by a threaded connection, the user may screw the proximal portion of the flavor cartridge onto the top portion of the aerosol generation device. Alternatively, the user may screw the top portion of the aerosol generation device onto 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 generation device. Alternatively, the user may then screw the main body of the aerosol generation device 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 generation device and then screw the flavor cartridge onto the top portion of the aerosol generation device.

If the connection is facilitated as a snap-fit or friction-fit connection, the user may first press the proximal portion of the flavor cartridge against the top portion of the aerosol generating device to establish a snap-fit or friction-fit connection between the proximal portion and the top portion. 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-fit 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 top portion.

If the connection is facilitated as a swivel connection or bayonet mount, the user may place the flavor cartridge between the top portion of the aerosol generation device and the main body of the aerosol generation device. Optionally, a protruding portion of the flavor cartridge may be placed in a recess in the aerosol generation device or in a recess in the flavor cartridge penetration of the aerosol generation device to facilitate correct alignment of the flavor cartridge between the top portion and the main body. The user may then rotate the flavor cartridge relative to the aerosol generation device to facilitate engagement of the swivel connection or bayonet mount of the flavor cartridge with the corresponding element of the aerosol generation device.

The flavour cartridge may be held securely between the upper portion and the main body of the aerosol generating device by any of the connection means described above. Furthermore, any of the connection means described above may allow the flavour cartridge to be removed from the aerosol generating device when the flavour cartridge is depleted. An unused flavour cartridge may then be removably attached to the aerosol generating device. Alternatively or additionally, the flavour base of the depleted flavour cartridge may be refilled to replace the depleted flavour cartridge with an unused flavour 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 a one-way valve. In one embodiment, the refill opening may be disposed within the housing of the flavor cartridge such that it is accessible when the flavor cartridge is rotated relative to a further component of the aerosol generation device. This embodiment is particularly beneficial when the connection between the flavor cartridge and the aerosol generation device is facilitated by a swivel connection or a 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 base.

As used herein, "aerosol-generating device" refers 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, e.g., part of 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 aerosol that is inhalable directly through the user's mouth into the user's lungs. The aerosol-generating device 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 including an aerosol-forming substrate. The cavity of the aerosol generating device may have an open end into which the aerosol generating article is inserted. The open end may be a proximal end. The cavity may have a closed end opposite the open end. The closed end may be a base of the cavity. The closed end may be closed except for providing 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 disposed upstream of the cavity. The open end may be disposed downstream of the cavity. The cavity may have an elongated extension. The cavity may have a longitudinal central axis. The longitudinal axis may be a direction extending between the open end and the closed end along the longitudinal central axis. The longitudinal central 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 to be received within 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.

The upper airflow channel may extend through the cavity. Ambient air may be drawn into the aerosol generating device, into the cavity, and through the upper airflow channel towards the user. Downstream of the cavity, a mouthpiece may be disposed, or the user may inhale the aerosol generating article directly. The airflow channel may extend through the mouthpiece. Upstream of the cavity, a flavour cartridge may be disposed.

As used herein, the terms "upstream," "downstream," "proximal," and "distal" are used to describe the relative location of components or portions of components of an aerosol generating device with respect to the direction in which a user draws on the aerosol generating device during use.

The aerosol generating device may include a heating element. The heating element may include an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum 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-containing, gold-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum-based alloys. In composite materials, the electrically resistive material may be optionally embedded in, encapsulated in, or coated with the insulating material, or vice versa, depending on the required energy transfer kinetics and external physicochemical properties.

The aerosol generating device may comprise an internal heating element, or an external heating element, or both an internal heating element and an external heating element, where "internal" and "external" are with respect 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 an electrically resistive metal tube. Alternatively, the internal heating element may be one or more heating 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 disposed in or on a rigid carrier material. In one such embodiment, the electrically resistive heating element may be formed using a metal that has a well-defined relationship between temperature and resistivity. In such an exemplary device, the metal may be formed as a track on a suitable insulating material, such as a ceramic material, and then sandwiched in another insulating material, such as glass. A heater constructed in this manner may be used to both heat the heating element and monitor its temperature during operation.

The external heating element may 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. The flexible heating foils may be shaped to fit around the cavity. Alternatively, the external heating element may take the form of a metal grid, a flexible printed circuit board, a molded integrated circuit device (MID), a ceramic heater, a flexible carbon fiber heater, or may be formed using a coating technique such as plasma deposition on a substrate of suitable shape. The external heating element may also be formed using a metal that has a well-defined relationship between temperature and resistivity. In such an exemplary device, the metal may be formed as a track 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 store, which comprises a material capable of absorbing and storing heat and then releasing the heat over time to the aerosol-forming substrate. The 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 it by a reversible process (such as a high temperature phase change). Suitable sensible heat storage materials include silica gel, alumina, carbon, glass mat, glass fiber, minerals, metals or alloys (such as aluminum, silver, or lead), and cellulosic materials (such as paper). Other suitable materials that release heat by a reversible phase change include paraffin, sodium acetate, naphthalene, wax, polyethylene oxide, metals, metal salts, mixtures of eutectic salts, or alloys. The heat sink or heat store may be disposed 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 heat store 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 with a carrier on which the substrate is disposed. Alternatively, heat from either an internal or external heating element may be conducted to the substrate by a thermally conductive element.

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

As an alternative to an electrically resistive heating element, the heating element may be configured as an induction heating element. The induction heating element may include an induction coil and a susceptor. Generally, the susceptor is a material that has the ability to absorb electromagnetic energy and convert it into heat. When located in an alternating electromagnetic field, eddy currents are typically induced in the susceptor and hysteresis losses occur, causing the susceptor to heat up. The changing electromagnetic field generated by one or several induction coils heats the susceptor, which then transfers heat to the aerosol-generating article so that the aerosol is formed. The heat transfer may be primarily by thermal conduction. 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 include or consist of a ferromagnetic material (e.g., a ferromagnetic alloy, ferritic iron, or ferromagnetic steel or stainless steel). A suitable susceptor may be or include aluminum. A preferred susceptor may be heated to a temperature in excess of 250 degrees Celsius.

The preferred susceptor is a metallic susceptor (e.g., stainless steel). However, the susceptor material may also include or be made of graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloys (austenitic nickel-chromium based superalloys), metal-deposited films, ceramics (e.g., zirconia, etc.), transition metals (e.g., iron, cobalt, nickel, etc.), or semi-metallic components (e.g., boron, carbon, silicon, phosphorus, 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 disposed in close physical contact with the second susceptor material. The second susceptor material preferably has a Curie temperature lower than the ignition point of the aerosol-forming substrate. The first susceptor material is preferably used primarily to heat the susceptor when it is placed in a fluctuating electromagnetic field. Any suitable material may be used. For example, the first susceptor material may be aluminum or an iron-based material such as stainless steel. The second susceptor material is preferably used primarily to indicate when the susceptor has reached a particular temperature (a temperature that is the Curie temperature of the second susceptor material). The Curie temperature of the second susceptor material may 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.

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

When 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. When 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 or forms a sidewall of the cavity.

The aerosol generating device may comprise an electrical circuit. The electrical circuit may comprise a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of the controller. The electrical circuit may comprise further electronic components. The electrical circuit may be configured to regulate the supply of power to the heating element. Power may be supplied to the heating element continuously following activation of the aerosol generating device or may be supplied intermittently (e.g. after 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 power to the heating element, preferably depending on the electrical resistance of the heating element.

The aerosol generating device may include a power source (typically a battery) within the main body of the aerosol generating device. 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 (e.g., 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 source may require recharging and may have a capacity that allows for storage of sufficient energy for one or more use experiences. For example, the power source may have a capacity sufficient to continuously generate aerosol for about six minutes, or a multiple of six minutes. In another example, the power source may have a capacity sufficient 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 that includes an aerosol-forming substrate capable of emitting a volatile compound capable of forming an aerosol. For example, the aerosol-generating article may be a smoking article that generates an aerosol that is inhalable directly through the user's mouth and into the user's lungs. The aerosol-generating article may be disposable. As described herein, the aerosol-generating article may be provided in addition to a flavor cartridge. 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 and the main body of the aerosol generating device.

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 include an aerosol former. Preferably, the aerosol-generating substrate includes homogenized tobacco material, an aerosol former, and water. Providing homogenized tobacco material may improve aerosol generation and the nicotine content and flavor profile of the aerosol generated during heating of the aerosol-generating article. Specifically, the process of making homogenized tobacco involves grinding tobacco leaves, which allows for more efficient release of nicotine and flavor upon heating.

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 a particularly preferred embodiment, the sheet is cut into strips having a width of about 0.2 millimeters to about 2 millimeters, more preferably about 0.4 millimeters to about 1.2 millimeters. In one embodiment, the width of the strips is about 0.9 millimeters.

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, and more preferably from about 0.8 millimeters to about 3 millimeters.

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

The aerosol-generating substrate samples 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 the homogenized tobacco material.

Sheets of homogenized tobacco material for use in aerosol-generating articles, including capsules, may be formed by agglomerating particulate tobacco obtained by grinding or otherwise comminuted one or both of the tobacco blades and the tobacco stems.

A sheet of homogenized tobacco material for use in an aerosol-generating article, including a capsule, may include one or more intrinsic binders that are tobacco intrinsic binders, one or more extrinsic binders that are tobacco extrinsic binders, or a combination thereof, to aid in the aggregation of particulate tobacco. Alternatively, or in addition, the sheet of homogenized tobacco material may include other additives, including, but not limited to, tobacco and non-tobacco fibers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof.

Suitable exogenous binders for inclusion within sheets of homogenized tobacco material for use in aerosol-generating articles, including capsules, are known in the art and include, but are not limited to, gums (e.g., guar gum, xanthan gum, gum arabic, and locust bean gum), cellulosic binders (e.g., hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose), polysaccharides (e.g., starch), organic acids (e.g., alginic acid), conjugate base salts of organic acids (e.g., sodium alginate), agar, and pectin, and combinations thereof.

Numerous reconstitution processes for producing sheets of homogenized tobacco material are known in the art. These include, but are not limited to, papermaking processes of the type described, for example, in U.S. Pat. No. A-3,860,012, casting or "cast leaf" processes of the type described, for example, in U.S. Pat. No. A-5,724,998, dough reconstitution processes of the type described, for example, in U.S. Pat. No. A-3,894,544, and extrusion processes of the type described, for example, in British Patent No. A-983,928. 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 preferably formed by a casting process of a type that generally involves casting a slurry containing particulate tobacco and one or more binders onto a conveyor belt or other support surface, drying the cast slurry to form a sheet of homogenized tobacco material, and removing the sheet of homogenized tobacco material from the support surface.

The homogenized tobacco sheet material may be produced using different types of tobacco. For example, the tobacco sheet material may be formed using many different varieties of tobacco or tobacco from different parts of the tobacco plant (such as leaves and stems). After processing, the sheet has consistent characteristics and homogenized flavor. A single sheet of homogenized tobacco material may be produced to have a specific flavor. To produce products with different flavors, different tobacco sheet materials need to be produced. Some flavors produced by blending many different shredded tobaccos into a traditional cigarette may be difficult to replicate in a single homogenized tobacco sheet. For example, Virginia and Burley tobacco may need to be processed in different ways to optimize their individual flavors. It may not be possible to replicate a particular blend of Virginia and Burley tobacco in a single sheet of homogenized tobacco material. Thus, the aerosol-generating substrate may comprise a first homogenized tobacco material and a second homogenized tobacco material. By combining sheets of two different tobacco materials in a single aerosol-generating substrate, new blends may be created that cannot be produced in a single sheet of homogenized tobacco.

The aerosol former preferably comprises at least one polyhydric alcohol. In a preferred embodiment, 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 flavourant. If desired, flavourant is preferably provided by a flavour cartridge disposed upstream of the cavity between the upper portion and the main body of the aerosol-generating device.

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

The following provides 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 features of another example, embodiment, or aspect described herein.

Example A:
1. A replaceable flavor cartridge for an aerosol generating device, the cartridge comprising:
Housing, and
a flavor substrate disposed within the housing;
A replaceable flavor cartridge, wherein the housing includes a proximal opening at a proximal portion of the housing, the housing includes a distal opening at a distal portion of the housing, and the flavor substrate includes a substrate opening, the proximal opening, the distal opening, and the substrate opening being aligned with one another 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 A-C, wherein the cartridge comprises a removable fluid impermeable distal foil covering the distal opening.
Example E:
The cartridge of any of Examples A-D, wherein the flavor substrate does not include tobacco.
Example F:
The cartridge of any of Examples A-E, wherein the flavor substrate does not contain nicotine.
Example G:
The cartridge of any of embodiments A-F, wherein the housing is porous.
Example H:
The cartridge of any of claims AG, wherein the proximal housing portion and the distal housing portion 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 generating device, comprising:
The upper part and
A replaceable flavor cartridge according to any one of Examples A to J;
a main body;
The cartridge is configured to be removably mountable between the top portion and the main body.
Example L:
An aerosol generating device as described in Example K, wherein the upper portion includes an upper portion airflow channel and the main body includes a main body airflow channel, and the main body airflow channel, the cartridge airflow channel, and the upper portion airflow channel are fluidly connected to form a common airflow channel through the aerosol generating device when the cartridge is attached between the upper portion and the main body.
Example M:
An aerosol generating device as described in Example K or L, wherein the upper portion includes a cavity configured to receive an aerosol-generating article including an aerosol-forming substrate, and the upper portion includes a heating element disposed within or around the cavity, the heating element being configured to heat the aerosol-forming substrate of the aerosol-generating article.
Example N:
The aerosol generating device of claim M, wherein the heating element is positioned away from the replaceable flavor cartridge such that the flavor substrate is substantially insulated from the heating element.
Example O:
An aerosol generating device as described in any of Examples K to N, wherein a replaceable flavor cartridge is configured to be attachable between the upper portion and the main body by placing the cartridge between the upper portion and the main body and rotating the cartridge.

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

The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 shows an exploded view of the flavor cartridge. FIG. 2A shows a cross-sectional view of the flavor cartridge in an exploded state. FIG. 2B shows a cross-sectional view of the flavor cartridge in an assembled state. FIG. 3 shows an exemplary diagram of an aerosol generating device. FIG. 4 shows a diagram of the installation of a flavor cartridge into an aerosol generating device. FIG. 5 shows a cross-sectional view of a further embodiment of an aerosol generating device.

Figure 1 shows a flavor cartridge configured for use with an aerosol generating device. The aerosol generating device and the use of the flavor cartridge in an aerosol generating device are described below in conjunction with Figures 3 and 4. The flavor cartridge includes a proximal portion 10, a distal portion 12, and a flavor substrate 14. The flavor substrate 14 is disposed between the proximal portion 10 and the distal portion 12. The proximal portion 10 and the distal portion 12 together form a housing for the flavor cartridge. The flavor substrate 14 is sandwiched between the proximal portion 10 and the distal portion 12.

The proximal portion 10 includes a proximal opening 16. The proximal opening 16 is disposed on a proximal end face 18 of the proximal portion 10. The distal portion 12 includes a distal opening 20. The distal opening 20 is disposed on a distal end face 22 of the distal portion 12. The flavor substrate 14 includes a substrate opening 24. The proximal opening 16, the substrate opening 24, and the distal opening 20 are aligned with one another. A cartridge airflow channel 26 extends through the proximal opening 16, the substrate opening 24, and the distal opening 20.

Prior to use of 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, the cartridge airflow channel 26 is established and air may flow through the flavor cartridge.

As air flows through the flavor cartridge, it contacts the flavor substrate 14. Flavorants contained in the 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 flavorants, one or both of the proximal portion 10 and the distal portion 12 may be configured to be porous or include porous regions. The flavorants may then be drawn into one or both of the proximal portion 10 and the distal portion 12, or into the porous regions of these elements.

2A shows the state of the flavor cartridge before assembly of the flavor cartridge. It can be seen that the cartridge airflow channel 26 runs parallel to the central axis 28 of the flavor cartridge. In the region of the proximal opening 16, the flavor cartridge includes a female connection element 30. In the region of the distal opening 20, the flavor cartridge includes a male connection element 32. Of course, it is also an option for the female connection element 30 to be arranged in the region of the proximal opening 16 and the male connection element 32 to be arranged in the region of the distal opening 20. The male connection element 32 and the female connection element 30 are configured to allow attachment of the flavor cartridge to an aerosol generating device.

3 shows one embodiment of the aerosol generating device. The aerosol generating device comprises an upper portion 34. The upper portion 34 is configured as a mouthpiece. A user may inhale the aerosol generated in the aerosol generating device through the upper portion 34. The 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. The main body 36 may include further 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. 5. The aerosol generating device may further comprise a heating element 38 (the heating element 38 is not shown in the embodiment shown in FIGS. 3 and 4, but is shown in the embodiment shown in FIG. 5). A flavor cartridge is also shown in FIG. 3. The flavor cartridge is sandwiched between the upper portion 34 and the main body 36. Ambient air is drawn into the aerosol generating device through an air inlet 50 (shown in the embodiment of FIG. 5) when a user inhales on the upper portion 34. Air is drawn through an airflow channel (shown in the embodiment of FIG. 5) and heated by a heating element 38 along with an aerosol-forming substrate, causing the aerosol to be generated by the aerosol generator. The aerosol can then be inhaled by a user. A flavor cartridge is disposed within the airflow channel. The flavor cartridge adds flavorants to the air so that the user can modify the aerosol that is generated.

Attachment of the flavor cartridge to the aerosol generating device is shown in FIG. 4. The male connecting element 32 of the flavor cartridge in the embodiment shown in FIG. 4 is inserted into a corresponding female part 40 of the main body 36 of the aerosol generating device. After insertion of the male connecting element 32, the flavor cartridge may be rotated to secure the flavor cartridge to the main body 36. The top portion 34 may 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 an aerosol generating device. The main elements are similar to the aerosol generating device shown in Figures 3 and 4. The differences are noted below. The upper part 34 of the aerosol generating device shown in Figure 5 includes a cavity 42 for receiving an aerosol-generating article 44 including an aerosol-forming substrate. A heating element 38 is disposed downstream of the flavor cartridge in the upper part 34. The heating element 38 is configured as an induction heating element 38. The heating element 38 at least partially surrounds the cavity 42. The heating element 38 is configured to heat the aerosol-forming substrate of the aerosol-generating article 44.

The flavor cartridge is sandwiched between the upper portion 34 and the main body 36.

The main body 36 includes a power source 46 and a controller 48. The controller 48 is configured to control the supply of electrical energy from the power source 46 to the heating element 38. The power source 46 is preferably a battery. The main body 36 includes an air inlet 50. The air inlet 50 is fluidly connected to a main body airflow channel 52. When a flavor cartridge is disposed between the main body 36 and the upper portion 34, the main body airflow channel 52 of the main body 36 is fluidly connected to the cartridge airflow channel 26. The cartridge airflow channel 26 is fluidly connected to the upper portion airflow channel 54. The upper portion airflow channel 54 is disposed in the upper portion 34. The upper portion airflow channel 54 is fluidly connected to the cavity 42. As shown in FIG. 5, the main portion airflow channel, the cartridge airflow channel 26 and the upper portion airflow channel 54 form a common airflow channel. During use, a user inhales on 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, through the upper portion airflow channel 54, and into the cavity 42. In the cavity 42, the air flows through the aerosol-forming substrate of the aerosol-generating article 44. The heating action of the heating element 38 heats the air and the aerosol-forming substrate, generating an aerosol. While drawing ambient air through the cartridge airflow channel 26, the air is enriched with flavorants from the flavor substrate 14 of the flavor cartridge. Thus, the flavor of the aerosol leaving the system including the aerosol generator and the aerosol-generating article 44 can be adjusted by the appropriate flavor cartridge.

Claims (14)

An aerosol generating device, comprising:
a main body having an upper portion and a main body, the main body including a power source;
a replaceable flavor cartridge, said replaceable flavor cartridge being sandwiched between said top portion and said main body, said replaceable flavor cartridge comprising:
Housing, and
a replaceable flavor cartridge including a flavor substrate, the flavor substrate being disposed within the housing;
1. An aerosol generating device, wherein the housing includes a proximal opening at a proximal portion of the housing, the housing includes a distal opening at a distal portion of the housing, the flavor substrate includes a substrate opening, the proximal opening, the distal opening, and the substrate opening are aligned with one another to form a cartridge airflow channel through the replaceable flavor cartridge, the proximal opening is provided at a proximal end face of the housing, the distal opening is provided at a distal end face of the housing, the flavor substrate is sandwiched between the proximal end face of the housing and the distal end face of the housing, the proximal portion is removably attached directly to the distal portion, the replaceable flavor cartridge is removably attachable between the top portion and the main body, the top portion is configured to be removably attachable to the proximal portion of the replaceable flavor cartridge, and the main body is configured to be removably attachable to the distal portion of the replaceable flavor cartridge. The aerosol generating device of claim 1, wherein the cartridge airflow channel is straight. The aerosol generating device of claim 1 or 2, wherein the replaceable flavor cartridge includes a removable fluid-impermeable proximal foil covering the proximal opening. The aerosol generating device according to any one of claims 1 to 3, wherein the replaceable flavour 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 substrate does not contain tobacco. The aerosol generating device according to any one of claims 1 to 5, wherein the flavor base does not contain nicotine. The aerosol generating device according to any one of claims 1 to 6, wherein the housing is porous. The aerosol generating device according to any one of claims 1 to 7, wherein the proximal portion of the housing and the distal portion of the housing are connected by a luer connector. The aerosol generating device according to any one of claims 1 to 8, wherein the flavour base comprises a high retention material impregnated with a flavour liquid or flavour gel. The aerosol generating device according to any one of claims 1 to 9, wherein the flavor substrate comprises a flavor substrate that can be atomized at ambient temperature. The aerosol generating device of any one of claims 1 to 10, wherein the top portion includes a top portion airflow channel, the main body includes a main body airflow channel, and the main body airflow channel, the cartridge airflow channel, and the top portion airflow channel are fluidly connected to form a common airflow channel through the aerosol generating device when the replaceable flavor cartridge is attached between the top portion and the main body. An aerosol generating device according to any one of claims 1 to 11, wherein the upper portion includes a cavity configured to receive an aerosol-generating article including an aerosol-forming substrate, and the upper portion includes a heating element disposed in or around the cavity, the heating element configured to heat the aerosol-forming substrate of the aerosol-generating article. The aerosol generating device of claim 12, wherein the heating element is disposed remotely from the replaceable flavor cartridge such that the flavor base is substantially insulated from the heating element. The aerosol generating device according to any one of claims 1 to 13, wherein the replaceable flavour cartridge is configured to be attachable between the upper part and the main body by placing the replaceable flavour cartridge between the upper part and the main body and by rotating the replaceable flavour cartridge.

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