KR20210132048A - An aerosol-generating article comprising an aerosol-generating system and an aerosol-forming substrate - Google Patents

Abstract

The aerosol-generating system 40 includes an aerosol-generating article 10 and an aerosol-generating device 30 . The article 10 has an upstream end 11 and a downstream end 12 , defines a longitudinal direction, and includes an upstream segment and a downstream segment 14 . The upstream segment comprises an aerosol-forming substrate 13 having a substrate outer surface 17 having a substrate outer diameter D2. The downstream segment 14 has a downstream segment outer diameter D1 that is greater than the substrate outer diameter D2. The device 30 includes a device cavity interior surface 33 having a device cavity inner diameter D4 , the device cavity 32 being configured to receive at least an aerosol-forming substrate 13 . The device 30 comprises at least one heating element 31 . When the aerosol-forming substrate 13 is received within the device cavity 32 , an airflow passage 35 is defined between the substrate exterior surface 17 and the device cavity interior surface 33 .

Description

An aerosol-generating article comprising an aerosol-generating system and an aerosol-forming substrate

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

Aerosol-generating articles, such as cigarettes, in which an aerosol-forming substrate is heated rather than combusted are known in the art. One goal of such heated aerosol-generating articles is to reduce harmful or potentially harmful by-products produced by the combustion and pyrolytic degradation of tobacco in conventional cigarettes.

In aerosol-generating articles, an inhalable aerosol is typically generated by the transfer of heat from a heating element to the aerosol-forming substrate. During heating, volatile compounds are released from the aerosol-forming substrate and are entrained in the air. For example, volatile compounds may be entrained in air drawn through the aerosol-generating article, onto the aerosol-generating article, around the aerosol-generating article, or otherwise within the vicinity of the aerosol-generating article. As the released volatile compound cools, the compound condenses to form an aerosol. The aerosol may be inhaled by the user. Aerosols may contain aromas, flavoring agents, nicotine and other desired elements.

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

In one aspect of the present invention, an aerosol-generating system is provided, the aerosol-generating system comprising:

an aerosol-generating article having an upstream end and a downstream end, the aerosol-generating article defining a longitudinal direction between the upstream end and the downstream end, the aerosol-generating article comprising:

an upstream segment disposed at the upstream end of the aerosol-generating article, the upstream segment comprising an aerosol-forming substrate, the aerosol-forming substrate comprising an upstream segment comprising an exterior surface of the substrate having an outer diameter of the substrate; and

a downstream segment disposed at the downstream end of the aerosol-generating article, the downstream segment having a downstream segment outer diameter, the downstream segment outer diameter being greater than the substrate outer diameter; and

an aerosol-generating device, the aerosol-generating device comprising:

A device cavity comprising a device cavity interior surface having a device cavity inner diameter, the device cavity configured to receive at least an aerosol-forming substrate of an aerosol-generating article; and

at least one heating element configured to heat the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity;

When the aerosol-forming substrate of the aerosol-generating article is received within the device cavity, an airflow passageway is defined between the substrate exterior surface and the device cavity interior surface, the airflow passageway extending longitudinally along the length of the aerosol-forming substrate.

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

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

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

Advantageously, providing an airflow passageway between the outer diameter of the substrate and the inner diameter of the device cavity provides space for volatile compounds deployed from the heated aerosol-forming substrate to migrate. As air drawn by the user through the article is drawn over the outer surface of the substrate, these airflow passages can promote the evolution of volatile compounds from the heated substrate.

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

According to another aspect of the present invention, there is provided an aerosol-generating article suitable for the aerosol-generating system, the aerosol-generating article comprising:

an upstream end and a downstream end, wherein the aerosol-generating article defines a longitudinal direction between the upstream end and the downstream end, the aerosol-generating article comprising:

an upstream segment disposed at the upstream end of the aerosol-generating article, the upstream segment comprising an aerosol-forming substrate, the substrate comprising an upstream segment comprising an exterior surface of the substrate having an outer diameter of the substrate; and

a downstream segment disposed at the downstream end of the aerosol-generating article and having a downstream segment outer diameter, wherein the downstream segment outer diameter is greater than the substrate outer diameter.

The downstream segment has an outer diameter greater than the outer diameter of the aerosol-forming substrate. As compared to an aerosol-generating article having a consistent outer diameter along the length of the article, providing an aerosol-generating article with segments having a different outer diameter means that the segment of the article comprising the aerosol-forming substrate is another component of the article, such as a filter or cooling element. It can be made thinner than the element. Advantageously, reducing the thickness of the aerosol-forming substrate allows heat applied to the substrate from the heating element to propagate rapidly through the thickness of the substrate, such that the heating element in the region of the substrate furthest from the heating element achieves the temperature of the substrate. It can reduce the time required to raise the This may reduce the change in temperature across the thickness of the aerosol-forming substrate and reduce the likelihood of an unheated and unused portion of the aerosol-forming substrate remaining in the region of the substrate furthest from the region heated by the heating element. Because the change in temperature across the thickness of the aerosol-forming substrate can be reduced, the composition and other properties of the aerosol generated from the substrate can be more uniform throughout the user experience and more difficult to control between user experiences for different substrates. It could be easier. Advantageously, this may create a more consistent experience for the user.

Since the aerosol-generating article of this aspect of the invention is suitable for the aerosol-generating system of the previous aspect of the invention, the advantages specified above for the system also apply to the article itself.

The term “aerosol-generating article” is used herein to refer to an article comprising an aerosol-forming substrate, wherein the aerosol-forming substrate can be heated to generate and deliver an aerosol to a user. As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing volatile compounds to generate an aerosol upon heating.

The aerosol-generating article may generally take the form of a rod. The article may include a central longitudinal axis extending centrally through the rod in a longitudinal direction from an upstream end to a downstream end. The upstream segment and the downstream segment of the aerosol-generating article may be arranged coaxially aligned with a central longitudinal axis of the aerosol-forming article. The upstream segment and the downstream segment of the aerosol-generating article may be arranged end-to-end to be coaxially aligned with a central longitudinal axis of the aerosol-forming article.

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

In a preferred embodiment, the aerosol-generating article has a total length of from about 40 mm to about 50 mm. Preferably, the aerosol-generating article has a total length of about 45 mm.

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

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

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

The downstream segment may have a downstream segment outer diameter of from about 5 mm to about 13 mm. Preferably, the downstream segment has an outer diameter that is substantially constant along the length of the segment.

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

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

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

The upstream segment may include a filter. The term “filter” is used to denote a section of an aerosol-generating article configured to at least partially remove a gaseous or particulate phase component or both a gaseous and particulate component from a mainstream aerosol drawn through the filter. Thus, filters can be advantageous in minimizing the presence of undesirable components in the formed aerosol. Preferably, the filter is a cellulose acetate filter plug. Preferably, the downstream segment comprises a mouthpiece in the form of a filter. Preferably, the downstream segment comprises a mouthpiece in the form of a filter having a length of about 7 mm, but may have a length of from about 5 mm to about 10 mm.

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

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

As used herein, a “cooling element” is positioned downstream of the aerosol-forming substrate such that, in use, the aerosol formed by the volatile compound released from the aerosol-forming substrate passes through and is cooled by the cooling element before being inhaled by the user. Refers to a component of an aerosol-generating article. The cooling element has a large surface area, but causes a low pressure drop. Filters and other mouthpieces that produce a high pressure drop, for example filters formed from fiber bundles, are not considered to be aerosol cooling elements. Chambers and cavities inside an aerosol-generating article are not considered to be aerosol cooling elements.

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

In some embodiments, the downstream segment comprises a flavor component. The flavor component may include one or more flavoring agents. As used herein, the term 'flavourant' refers to an agent that, in use, imparts one or both of a taste or aroma to an aerosol generated by heating the aerosol-forming substrate. One example of a suitable flavoring agent is menthol. The flavor elements may be arranged at any suitable location within the downstream segment.

The upstream segment includes an aerosol-forming substrate. The upstream segment may also include one or more additional components, such as a layer of thermally conductive material, a cooling element, and a spacing element. Preferably, the upstream segment consists of an aerosol-forming substrate and optionally a layer of thermally conductive material.

The upstream segment may have an outer diameter of about 3 mm to about 12 mm. The upstream segment may have a substantially constant outer diameter along the length of the segment.

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

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

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

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

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

Preferably, the aerosol-forming substrate is a solid aerosol-forming substrate. Preferably, the aerosol-forming substrate comprises tobacco. Preferably, the aerosol-forming substrate is a solid aerosol-forming substrate comprising tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing a volatile tobacco flavor compound that is released from the substrate upon heating.

The solid aerosol-forming substrate may comprise a tobacco plug. Plugs of tobacco may be, for example, powders, granules, pellets, shreds, strands, strips containing one or more of herbal leaves, tobacco leaves, tobacco ribs, expanded tobacco and homogenized tobacco. or one or more of the sheets. As used herein, the term 'homogenized tobacco material' refers to a material formed by agglomerating particulate tobacco. Providing a homogenized tobacco material can improve the aerosol generation, nicotine content and flavor profile of the aerosol generated during heating of the aerosol-generating article. Specifically, the process for producing homogenized tobacco involves grinding tobacco leaves, which allows for more effective release of nicotine and flavor upon heating. Where the tobacco plug comprises homogenized tobacco material, the homogenized tobacco material may be in the form of a sheet. As used herein, the term 'sheet' refers to a laminate element having a width and length substantially greater than its thickness.

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

The aerosol-forming substrate may have a substantially homogeneous composition. In one embodiment, the aerosol-forming substrate may have a composition that is substantially uniform at least in the longitudinal direction.

The homogenized sheet of tobacco material may be formed by agglomerating particulate tobacco obtained by grinding or otherwise subdividing one or both of a tobacco leaf lamina and a tobacco leaf stem. The sheet of homogenized tobacco material may include, for example, one or more of tobacco powder, tobacco fines, and other particulate tobacco by-products formed during the processing, handling and shipping of tobacco. A sheet of homogenized tobacco material is prepared by casting a slurry comprising 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 homogenizing from the support surface. It is preferably formed by a casting process of the type that generally includes the step of removing the sheet of tobacco material.

The solid aerosol-forming substrate may comprise a corrugated sheet of homogenized tobacco material. As used herein, the term 'gathered' is used to describe a sheet that is entangled, folded, or otherwise compressed or retracted substantially transverse to the longitudinal axis of the aerosol-generating article.

In some preferred embodiments, the aerosol-forming substrate comprises a corrugated texturized sheet of homogenized tobacco material. As used herein, the term 'textured sheet' refers to a sheet that has been crimped, embossed, engraved, perforated or otherwise deformed. Using a texturized sheet of homogenized tobacco material may advantageously facilitate gathering of the homogenized tobacco material sheet to form an aerosol-forming substrate. The aerosol-forming substrate may comprise a gathered texturized sheet of homogenized tobacco material comprising a plurality of spaced apart indentations, projections, perforations, or combinations thereof.

In a particularly preferred embodiment, the aerosol-forming substrate comprises a crimped crimped sheet of homogenized tobacco material. As used herein, the term 'crimped sheet' refers to a sheet having a plurality of substantially parallel ridges or corrugations. Preferably, the substantially parallel ridges or corrugations extend along or parallel to the longitudinal axis of the aerosol-generating article. This advantageously promotes pleating of the crimped sheet of homogenized tobacco material to form an aerosol-generating article. However, the crimped sheet of homogenized tobacco material for inclusion in an aerosol-generating article may alternatively or additionally include a plurality of substantially parallel ridges disposed at an acute or obtuse angle with respect to the longitudinal axis of the aerosol-generating article or It will be appreciated that you may have wavy lines.

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

The aerosol-forming substrate may comprise an aerosol former. The aerosol-forming substrate may comprise a single aerosol former or a combination of two or more aerosol formers. As used herein, the term 'aerosol former' refers to any suitable known compound or mixture of compounds that, in use, promotes the formation of an aerosol and is substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article. used to describe Suitable aerosol formers include polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Preferred aerosol formers are polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol or mixtures thereof, most preferably glycerin. The aerosol-forming substrate may have an aerosol former content of greater than 5% by dry weight. The aerosol aerosol-forming substrate may have an aerosol former content of from about 5% to about 30% by dry weight. The aerosol-forming substrate may have an aerosol former content of about 20% on a dry weight basis.

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

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

In some embodiments, the aerosol-forming substrate may comprise an interior cavity. That is, the aerosol-forming substrate may be a hollow tubular substrate. The aerosol-forming substrate may include a substrate interior surface having a substrate inner diameter, the substrate interior surface defining an interior cavity extending longitudinally within the aerosol-forming substrate. Providing an interior cavity into the aerosol-forming substrate allows the heating element to be inserted into the aerosol-forming substrate within the cavity without puncturing the substrate and altering the structure of the substrate. The provision of an interior cavity may also be beneficial to further reduce the thickness of the aerosol-forming substrate, enhancing the heat transfer advantages described above.

The inner diameter of the substrate may be from about 60% to about 90% of the outer diameter of the substrate, or from about 70% to about 90% or from about 80% to about 90% of the outer diameter of the substrate. This range can provide the required propagation of heat within the aerosol-forming substrate while imparting the necessary mechanical properties to the substrate.

Where the aerosol-forming substrate comprises a substrate interior surface defining an interior cavity, the substrate interior surface may have the same transverse cross-sectional shape as the substrate exterior surface. In particular, the inner surface of the substrate may have a substantially circular, oval or stadium-shaped transverse cross-section.

In some embodiments, the aerosol-generating article comprises a layer of thermally conductive material. In some embodiments, the layer of thermally conductive material can cover at least a portion of at least an otherwise exposed aerosol-forming substrate. In some embodiments, a layer of thermally conductive material may be disposed on at least the outer surface of the substrate. In some embodiments, a layer of thermally conductive material may be disposed on at least an interior surface of the substrate. In some embodiments, the layer of thermally conductive material can be disposed on at least the inner surface of the substrate and on the outer surface of the substrate. Providing a layer of thermally conductive material on the otherwise exposed substrate surface allows heat from the heating element received by or engaged with the substrate to be distributed over a larger area of the aerosol-forming substrate, thereby forming an aerosol with the heating element. Improves heat transfer efficiency between substrates. The layer of thermally conductive material may also create a physical separation between the aerosol-forming substrate and the heating element received within the interior cavity, which may reduce the risk of overheating the aerosol-forming substrate in areas of the substrate proximate to the heating element. The layer of thermally conductive material may also increase the rigidity of the tubular aerosol-forming substrate, which may be reduced by reducing the thickness of the substrate by providing an interior cavity.

As used herein, the term “thermal conductivity” means having a thermal conductivity of at least 10 W/mK, preferably at least 40 W/mK, more preferably at least 100 W/mK and a relative humidity of 50% at 23°C. refers to the material. In a preferred embodiment, the layer of thermally conductive material has at least 40 W/mK, preferably at least 100 W/mK, more preferably at least 150 W/mK, even more preferably at least 200 W/mK at 23°C. The material contains a thermal conductivity and a relative humidity of 50%.

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

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

The different compositions of the first and second aerosol-forming substrate segments allow aerosols with different compositions to be generated from a single aerosol-generating article. It also allows the user to select a specific aerosol-forming substrate to be heated to generate a specific aerosol during the experience.

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

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

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

In some embodiments, the aerosol-generating article may comprise a wrapper surrounding the downstream segment. Advantageously, if the downstream segment comprises a plurality of components, the wrapper may hold the plurality of components together.

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

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

The upstream segment and the downstream segment may be fixed together. The upstream segment and downstream segment may be secured together by any suitable means. For example, the aerosol-generating article may include a connection mechanism. The connecting mechanism may serve to hold the upstream segment and the downstream segment together. In one embodiment, the connection mechanism may include a cavity provided within the upstream end of the downstream segment into which the downstream end of the upstream segment is inserted. The downstream end of the upstream segment may include a projection inserted into the cavity.

When a wrapper surrounding the downstream segment is provided and the aerosol-generating article comprises a connection mechanism, the wrapper may be configured to apply pressure on the connection mechanism. In one embodiment, the wrapper can apply pressure around the cavity that receives the downstream end of the downstream segment. This may further contribute to holding the upstream segment and downstream segment together.

The downstream segment outer diameter of the aerosol-generating article may be substantially equal to or greater than the device cavity inner diameter. This may be beneficial to ensure that the aerosol exiting the airflow passageway through the downstream edge of the airflow passageway may be drawn in through the downstream segment instead of being emitted directly towards the exterior of the aerosol-generating system.

At least one heating element is positioned within the cavity. The at least one heating element may be any suitable type of heating element. In some embodiments, the device includes only one heating element. In some embodiments, the heating element comprises a plurality of heating elements. For example, in some embodiments, the device includes two or more heating elements. In some embodiments, the at least one heating element is arranged to heat the outer surface of the aerosol-forming substrate. In some preferred embodiments, the at least one heating element is arranged to be inserted at least partially into the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity. Where the aerosol-forming substrate comprises an interior cavity, in some embodiments, the at least one heating element may be arranged to insert into the interior cavity of the substrate when the aerosol-forming substrate is received within the device cavity. The at least one heating element may be an elongate heating element. The at least one elongate heating element may be blade-shaped. The at least one elongate heating element may be fin-shaped. The at least one elongate heating element may have a tapered shape, or at least a tapered end. The at least one elongate heating element may have a pointed end. The at least one elongate heating element may be conical in shape. The at least one elongate heating element may have any suitable shape arranged to facilitate insertion of the heating element into the aerosol-forming substrate. Advantageously, the elongate heating element may provide for easier engagement or easier disengagement or both easier engagement and easier disengagement of the aerosol-forming substrate with the heating element of the device.

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

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

Preferably, the electrically insulating substrate is stable at the operating temperature of the at least one heating element. Preferably, the electrically insulating substrate is stable at temperatures up to about 400° C., more preferably about 500° C., more preferably about 600° C., more preferably about 700° C., even more preferably about 800° C. The operating temperature of the at least one heating element during use may be at least about 200°C. The operating temperature of the at least one heating element during use may be less than about 700°C. The operating temperature of the at least one heating element during use may be less than about 600°C. The operating temperature of the at least one heating element during use may be less than about 500°C. The operating temperature of the at least one heating element during use may be less than about 400°C.

The electrically insulating substrate may comprise any suitable material. For example, the electrically insulating substrate may include one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may include mica, alumina (Al ₂ O ₃ ) or zircona (ZrO ₂ ). Preferably, the electrically insulating substrate has a thermal conductivity of about 40 W/mK or less, preferably about 20 W/mK or less, and ideally about 2 W/mK or less.

Suitable materials for forming the at least one resistive heating element, and in particular the one or more electrically conductive tracks, include semiconductors such as doped ceramics, electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metals. alloys and composite materials made of ceramic and metallic materials. 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 and metals of the platinum group. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese- , and iron-containing alloys, and nickel, iron, cobalt, stainless steel, Timetal® based superalloys and iron-manganese-aluminum based alloys.

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

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

The induction heating element may include a susceptor element. As used herein, the term “susceptor element” refers to an element comprising a material capable of converting electromagnetic energy into heat. Thus, when the susceptor element is placed in the alternating electromagnetic field, the susceptor heats up. Heating of the susceptor element may be the result of hysteresis losses and/or eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material. Hysteresis losses occur in ferromagnetic or ferrimagnetic susceptor materials due to the magnetic domains in the material being switched under the influence of alternating electromagnetic fields. Eddy currents can be induced when the susceptor material is electrically conductive. For electrically conductive ferromagnetic or ferrimagnetic susceptor materials, heat can be generated due to both eddy currents and hysteresis losses. Thus, the susceptor element may be heatable due to at least one of hysteresis losses or eddy currents, depending on the electrical and magnetic properties of the susceptor material.

The susceptor element is arranged such that, when the aerosol-generating article is received within the device cavity, an oscillating electromagnetic field generated by the inductor coil induces an electric current in the susceptor element such that the susceptor element is heated. The aerosol-generating device generates a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of 1 to 5 kA/m (kilo ampere per metre), preferably 2 to 3 kA/m, for example about 2.5 kA/m. It is desirable to be able to The electrically operated aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field with a frequency of 1 to 30 MHz, for example 1 to 10 MHz, for example 5 to 7 MHz.

In some embodiments, the susceptor element is positioned within the aerosol-generating article. In this embodiment, the susceptor element is preferably positioned in contact with the aerosol-forming substrate. The susceptor element may be positioned within the aerosol-forming substrate. Preferably, the susceptor element is an elongate susceptor extending along the length of the substrate, in the longitudinal direction of the article. Where the aerosol-forming substrate comprises an interior cavity, the susceptor element may be arranged within the interior cavity. Where the aerosol-forming substrate comprises an interior cavity, the susceptor element may be arranged on the interior surface of the substrate. The aerosol-generating article may include one or more susceptor elements. The aerosol-generating article may include a plurality of susceptor elements.

In some embodiments, the susceptor element is located within the aerosol-generating device. In this embodiment, the susceptor element may be positioned within the device cavity. The susceptor element may be configured to be at least partially inserted into the aerosol-forming substrate of the aerosol-generating article when the aerosol-generating article is received within the device cavity. Where the aerosol-forming substrate comprises an interior cavity, the susceptor element may be configured to be at least partially inserted into the interior cavity of the aerosol-forming substrate when the aerosol-generating article is received within the device cavity. The susceptor element may extend into the device cavity in a longitudinal direction of the device cavity. The susceptor element may be elongated. The elongate susceptor element may be blade-shaped. The elongate susceptor element may be pin-shaped. The elongate susceptor element may have a tapered shape, or at least a tapered end. The elongate susceptor element may have a pointed end. The elongate susceptor element may be conical in shape. The aerosol-generating device may comprise one or more susceptor elements. The aerosol-generating device may comprise a plurality of susceptor elements.

The susceptor element may comprise any suitable material. The susceptor element may be formed of any material capable of induction heating to a temperature sufficient to release the volatile compound from the aerosol-forming substrate. Suitable materials for the elongate susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptor elements include metal or carbon. Advantageously, the susceptor element may comprise or consist of a ferromagnetic material such as ferritic iron, a ferromagnetic alloy such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. A suitable susceptor element may be or include aluminum. The susceptor element preferably comprises more than 5%, preferably more than 20%, more preferably more than 50% or more than 90% of ferromagnetic or paramagnetic material. Preferred elongate susceptor elements can be heated to temperatures in excess of 250°C.

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

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

The aerosol-generating device may comprise a plurality of heating elements. The aerosol-generating device may comprise a first heating element and a second heating element. In some embodiments, the second heating element can be spaced apart from the first heating element. The second heating element may be spaced apart from the first heating element in a longitudinal direction of the device cavity. The provision of spaced apart heating elements from each other allows the aerosol-generating device to individually heat different sections of the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity.

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

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

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

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

Preferably, the aerosol-generating device comprises a power supply. The power supply may be a DC voltage source. In a preferred embodiment, the power supply is a battery. For example, the power supply may be a nickel-hydrogen alloy battery, a nickel cadmium battery, or a lithium-based battery, such as a lithium-cobalt, lithium-iron-phosphate or lithium-polymer battery. The power supply may alternatively be another type of electrical charge storage device such as a capacitor. The power supply may require recharging and may have a capacity to store sufficient energy for use of an aerosol-generating device having one or more aerosol-forming substrates.

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

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

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

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

The aerosol-generating device may include a sensor for detecting an airflow indicating that the user is performing a puff. The air flow sensor may be an electromechanical device. The air flow sensor may be any of a mechanical device, an optical device, an opto-mechanical device, and a microelectromechanical system (MEMS) based sensor. The aerosol-generating device may include a manually actuable switch for the user to initiate the puff.

Preferably, the aerosol-generating device comprises an indicator for indicating when the at least one heating element is activated. The indicator may include a light that is activated when the at least one heating element is activated.

The aerosol-generating device may comprise at least one of an external plug or socket and at least one external electrical contact to enable the aerosol-generating device to be connected to another electrical device. For example, the aerosol-generating device may include a USB plug or USB socket to connect the aerosol-generating device to other USB-enabled devices. For example, a USB plug or socket may connect the aerosol-generating device to a USB charging device to recharge the rechargeable power supply within the aerosol-generating device. Additionally, or alternatively, the USB plug or socket may support the transfer of data to or from an aerosol-generating device, or in both directions. Additionally or alternatively, the aerosol-generating device may be connected to a computer to transmit data to the device, such as a new heating profile for a new aerosol-generating article.

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

According to a further aspect of the present invention, there is provided an aerosol-generating device for receiving an aerosol-forming substrate, the aerosol-generating device comprising:

at least one heating element;

A housing comprising a first housing portion and a second housing portion, the first housing portion comprising a housing having a first cavity;

the second housing portion is movable relative to the first housing portion between an open position and a closed position;

in the closed position, the first cavity and the second housing portion define a device cavity, the device cavity having an upstream end and a downstream end and defining a longitudinal direction between the upstream end and the downstream end;

the at least one heating element is arranged to heat the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity;

In the open position, an opening is formed between the first and second housing portions to allow the aerosol-forming substrate to be inserted into or removed from the first cavity in a direction different from the longitudinal direction.

Advantageously, the aerosol-generating device of this embodiment allows the aerosol-forming substrate to be inserted into the cavity of the device and removed from the cavity of the device in a direction different from the length of the cavity. This may allow the substrate to be inserted into and particularly easily removed from the device cavity, thereby reducing the risk of damaging the substrate or device when inserting and removing the aerosol-forming substrate.

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

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

The device cavity may be configured to surround the aerosol-forming substrate about its longitudinal direction. That is, the device cavity may be configured to form a tube that surrounds or surrounds the side of the aerosol-forming substrate. The cavity may have an open end. The device cavity may be open at both ends. The device cavity may have one open end and one substantially closed end. The open end may be at a downstream end of the device cavity and the substantially closed end may be at an upstream end of the device cavity. The substantially closed end may include one or more air inlets configured to allow fresh air to be drawn into the device cavity.

The device cavity may have one or more air inlets configured to allow outside air to be drawn into the device cavity. The first housing portion may include one or more air inlets configured to allow fresh air to be drawn into the device cavity. The second housing portion may include one or more air inlets configured to allow outside air to be drawn into the device cavity.

The aerosol-generating device of this aspect comprises at least one heating element. Preferably, the device of this aspect comprises a plurality of heating elements. In some embodiments, the at least one heating element is arranged within the first housing portion. In some embodiments, the at least one heating element is arranged within the second housing portion.

The at least one heating element may be any suitable type of heating element. In some embodiments, the at least one heating element is arranged to heat the outer surface of the aerosol-forming substrate. In some preferred embodiments, the at least one heating element is arranged to be inserted at least partially into the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity. Where the aerosol-forming substrate comprises an interior cavity, in some embodiments, the at least one heating element may be arranged to insert into the interior cavity of the substrate when the aerosol-forming substrate is received within the device cavity. The at least one heating element may be an elongate heating element. The at least one elongate heating element may be blade-shaped. The at least one elongate heating element may be fin-shaped. The at least one elongate heating element may have a tapered shape, or at least a tapered end. The at least one elongate heating element may have a pointed end. The at least one elongate heating element may be conical in shape. The at least one elongate heating element may have any suitable shape arranged to facilitate insertion of the heating element into the aerosol-forming substrate. Advantageously, the elongate heating element may provide for easier engagement or easier disengagement or both easier engagement and easier disengagement of the aerosol-forming substrate with the heating element of the device.

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

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

Preferably, the electrically insulating substrate is stable at the operating temperature of the at least one heating element. Preferably, the electrically insulating substrate is stable at temperatures up to about 400° C., more preferably about 500° C., more preferably about 600° C., more preferably about 700° C., even more preferably about 800° C. The operating temperature of the at least one heating element during use may be at least about 200°C. The operating temperature of the at least one heating element during use may be less than about 700°C. The operating temperature of the at least one heating element during use may be less than about 600°C. The operating temperature of the at least one heating element during use may be less than about 500°C. The operating temperature of the at least one heating element during use may be less than about 400°C.

The electrically insulating substrate may comprise any suitable material. For example, the electrically insulating substrate may include one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may include mica, alumina (Al ₂ O ₃ ) or zircona (ZrO ₂ ). Preferably, the electrically insulating substrate has a thermal conductivity of about 40 W/mK or less, preferably about 20 W/mK or less, and ideally about 2 W/mK or less.

Suitable materials for forming the at least one resistive heating element, and in particular the one or more electrically conductive tracks, include semiconductors such as doped ceramics, electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metals. alloys and composite materials made of ceramic and metallic materials. 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 and metals of the platinum group. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese- , and iron-containing alloys, and nickel, iron, cobalt, stainless steel, Timetal® based superalloys and iron-manganese-aluminum based alloys.

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

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

The induction heating element may include a susceptor element. As used herein, the term “susceptor element” refers to an element comprising a material capable of converting electromagnetic energy into heat. Thus, when the susceptor element is placed in the alternating electromagnetic field, the susceptor heats up. Heating of the susceptor element may be the result of hysteresis losses and/or eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material. Hysteresis losses occur in ferromagnetic or ferrimagnetic susceptor materials due to the magnetic domains in the material being switched under the influence of alternating electromagnetic fields. Eddy currents can be induced when the susceptor material is electrically conductive. For electrically conductive ferromagnetic or ferrimagnetic susceptor materials, heat can be generated due to both eddy currents and hysteresis losses. Thus, the susceptor element may be heatable due to at least one of hysteresis losses or eddy currents, depending on the electrical and magnetic properties of the susceptor material.

The susceptor element is arranged such that, when the aerosol-generating article is received within the device cavity, an oscillating electromagnetic field generated by the inductor coil induces an electric current in the susceptor element such that the susceptor element is heated. The aerosol-generating device generates a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of 1 to 5 kA/m (kilo ampere per metre), preferably 2 to 3 kA/m, for example about 2.5 kA/m. It is desirable to be able to The electrically operated aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field with a frequency of 1 to 30 MHz, for example 1 to 10 MHz, for example 5 to 7 MHz.

In some embodiments, the susceptor element is positioned within the aerosol-generating article. In this embodiment, the susceptor element is preferably positioned in contact with the aerosol-forming substrate. The susceptor element may be positioned within the aerosol-forming substrate. Preferably, the susceptor element is an elongate susceptor extending along the length of the substrate, in the longitudinal direction of the article. Where the aerosol-forming substrate comprises an interior cavity, the susceptor element may be arranged within the interior cavity. Where the aerosol-forming substrate comprises an interior cavity, the susceptor element may be arranged on the interior surface of the substrate. The aerosol-generating article may include one or more susceptor elements. The aerosol-generating article may include a plurality of susceptor elements.

In some embodiments, the susceptor element is located within the aerosol-generating device. In this embodiment, the susceptor element may be positioned within the device cavity. The susceptor element may be configured to be at least partially inserted into the aerosol-forming substrate of the aerosol-generating article when the aerosol-generating article is received within the device cavity. Where the aerosol-forming substrate comprises an interior cavity, the susceptor element may be configured to be at least partially inserted into the interior cavity of the aerosol-forming substrate when the aerosol-generating article is received within the device cavity. The susceptor element may extend into the device cavity in a longitudinal direction of the device cavity. The susceptor element may be elongated. The elongate susceptor element may be blade-shaped. The elongate susceptor element may be pin-shaped. The elongate susceptor element may have a tapered shape, or at least a tapered end. The elongate susceptor element may have a pointed end. The elongate susceptor element may be conical in shape. The aerosol-generating device may comprise one or more susceptor elements. The aerosol-generating device may comprise a plurality of susceptor elements.

The susceptor element may comprise any suitable material. The susceptor element may be formed of any material capable of induction heating to a temperature sufficient to release the volatile compound from the aerosol-forming substrate. Suitable materials for the elongate susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptor elements include metal or carbon. Advantageously, the susceptor element may comprise or consist of a ferromagnetic material such as ferritic iron, a ferromagnetic alloy such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. A suitable susceptor element may be or include aluminum. The susceptor element preferably comprises more than 5%, preferably more than 20%, more preferably more than 50% or more than 90% of ferromagnetic or paramagnetic material. Preferred elongate susceptor elements can be heated to temperatures in excess of 250°C.

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

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

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

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

The apparatus of this aspect may include any suitable number of heating elements. For example, the device may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 or more heating elements. If the device comprises a plurality of heating elements, the heating elements may be spaced apart. The heating element may be spaced longitudinally of the device cavity between an upstream end and a downstream end of the device cavity. The heating elements may be spaced apart in a transverse direction of the device cavity, parallel to the longitudinal direction.

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

In some implementations of the device of this aspect, the device includes at least one heating element extending from the first housing portion and at least one heating element extending from the second housing portion. Advantageously, providing a heating element on both the first and second housing parts allows the heating element to be inserted into the aerosol-forming substrate from different sides, which can reduce temperature changes of the aerosol-forming substrate. Also, movement of the first and second housing portions between the open and closed positions allows the aerosol-forming substrate to be inserted into, and easily removed from, such devices.

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

In some embodiments, the first and second housing portions may be slidably coupled together. In this embodiment, the first and second housing portions may be provided with complementary rails that enable the second housing portion to slide relative to the first housing portion between an open position and a closed position.

In some implementations, the second housing portion may be removably coupled to the first housing portion. In this embodiment, the first and second housing portions may be in an open position when the second housing portion is removed from the first housing portion. In this embodiment, the first and second housing portions may be in a closed position when the second housing portion is removably coupled to the first housing portion.

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

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

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

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

Preferably, the second cavity is substantially the same as the first cavity and has the same shape and size. For example, the first cavity may be a substantially hemispherical cylinder, the second cavity may be a substantially hemispherical cylinder, and the first and second cavities may be substantially hemispherical when the first and second housing portions are in the closed position. to form a cylindrical device cavity. The first and second cavities may have any suitable size and shape to receive any suitable amount of an aerosol-forming substrate.

In all other aspects, the aerosol-generating device of this aspect may be identical to the aerosol-generating device described above with respect to the previous aspect.

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

According to a further aspect of the present invention, there is provided an aerosol-generating system, the aerosol-generating system comprising:

an aerosol-generating device according to the previous aspect; and

an aerosol-generating article comprising an aerosol-forming substrate.

An aerosol-generating article used in combination with an aerosol-generating device of this aspect may comprise the same features as the aerosol-generating article described above with respect to the previous aspect of the present invention. However, it will be appreciated that other aerosol-generating articles may also be suitable for use in such systems with the devices of the previous aspects. For example, an aerosol-generating article having an outer diameter that is substantially constant along its length may be suitable for use with the device of the previous aspect.

These and other features and advantages of the present invention will become more apparent in view of the following detailed description of preferred embodiments, given by way of illustration and non-limiting example only, with reference to the accompanying drawings:
1 shows a schematic diagram of an aerosol-generating article according to a first embodiment of the invention;
2 shows a schematic diagram of an aerosol-generating article according to a second embodiment of the present invention;
3 shows a schematic diagram of an aerosol-generating system according to a third embodiment of the present invention, the aerosol-generating system comprising the aerosol-generating article of FIG. 1 .
4 shows a schematic diagram of an aerosol-generating system according to a fourth embodiment of the present invention;
5 shows a schematic diagram of an aerosol-generating system according to a fifth embodiment of the present invention;
6 shows a schematic diagram of an aerosol-generating system according to a sixth embodiment of the present invention;
7 shows a schematic diagram of an aerosol-generating device according to a seventh embodiment of the present invention;
8 shows a schematic diagram of an aerosol-generating system according to an eighth embodiment of the invention, comprising the aerosol-generating device of FIG. 7 ;

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

The outer diameter D1 of the filter is larger than the outer diameter D2 of the substrate.

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

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

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

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

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

As shown in FIG. 3 , when the aerosol-generating system 40 is in use, power is provided to the heating element 31 to heat the aerosol-forming substrate 13 to a temperature at which volatile compounds are released from the substrate 13 . do. A user aspirating on a downstream segment 14, such as filter 15, of article 10 allows air to pass through air inlet 36 at the distal end of device cavity 32 into airflow passageway 35, article 10 is drawn out of the device cavity 32 along the airflow passage 35 in the longitudinal direction of the The volatile compound released from the heated aerosol-forming substrate 13 develops into the airflow passage 35 as schematically represented by the curved arrow in FIG. 3 and cools to form an aerosol that can be inhaled by a user. The aerosol is entrained in the air drawn through the airflow passageway 35 and out of the device cavity 32 through the filter 15 of the article 10 towards the downstream end 12, as indicated by arrow A1. flows

In the embodiment of FIG. 3 , the downstream segment outer diameter D1 is equal to the device cavity inner diameter D4 . The airflow passage is thus defined at its downstream edge by a downstream segment 14 , which in this embodiment corresponds to the filter 15 . Accordingly, the aerosol exiting the airflow passage 35 needs to flow through the filter 15 .

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

In the aerosol-generating system 40 of FIG. 5 , the aerosol-generating article 10 has a filter 15 in this embodiment, wherein the aerosol-generating article 10 has a downstream segment D1 that is greater than the device cavity inner diameter D4. ) differs from that of FIGS. 1 and 3 in that it includes a downstream segment 14 . This downstream segment configuration can further ensure that the upstream edge of the filter 15 defines the downstream edge of the airflow passage 35 . In addition, a layer 23 of thermally conductive material is disposed on the substrate interior surface 18 . The thermally conductive material layer 23 substantially covers the substrate interior surface 18 , which surrounds the interior cavity 16 and extends the entire length of the interior cavity 16 . This may improve the distribution of heat from the heating element 31 to the substrate 13 . The thermally conductive material layer 23 can also create a physical separation between the aerosol-forming substrate 13 and the heating element 31 received within the interior cavity 16 , which is the substrate 13 proximate the heating element 31 . It is possible to reduce the risk of overheating the aerosol-forming substrate 13 in the area of The thermally conductive material layer 23 may also increase the rigidity of the tubular aerosol-forming substrate 13 , which may be reduced by a reduction in the thickness of the substrate 13 by the provision of the interior cavity 16 .

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

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

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

The aerosol-generating device 30 of FIG. 6 is configured within the device cavity 32 , on the device cavity interior surface 33 , and within the airflow passageway 35 when the aerosol-forming substrate 13 is received within the device cavity 32 . It further comprises a disposed sensor 37 . The sensor 37 may provide relevant data to the device and/or user, such as the start of the puff, the duration of the puff, the temperature of the aerosol or the concentration of a particular component of the aerosol within the airflow passage 35 .

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

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

The first housing portion 301 includes a first cavity 303 , and the second housing portion 302 includes a second cavity 304 . In this embodiment, the first cavity 303 is a substantially hemispherical cylindrical cavity and the second cavity 304 is a substantially hemispherical cylindrical cavity. In the closed position, the first cavity 303 and the second cavity 304 are aligned to form a device cavity 305 for receiving the aerosol-forming substrate 130 . In this embodiment, the device cavity 305 surrounds the aerosol-forming substrate 130 about the longitudinal direction (X) when the aerosol-forming substrate 130 is received within the device cavity 305 . That is, the device cavity 305 encloses or forms a tubular cavity surrounding the aerosol-forming substrate 130 , the tubular cavity having a length extending in the longitudinal direction (X). The tubular cavity may be closed at the end. In the open position, as shown in FIG. 7 , the first cavity 303 and the second cavity 304 are rotated to form an opening 306 through which the aerosol-forming substrate 130 moves in the longitudinal direction (X). and may be inserted into each of the first and second cavities 303 and 304 in different directions. In this embodiment, the aerosol-forming substrate 130 may be inserted into either of the first and second cavities 303 , 304 in a direction P1 substantially perpendicular to the longitudinal direction X.

The aerosol-generating device 300 includes a plurality of internal heating elements 310 . The internal heating element 310 is configured to at least partially penetrate the aerosol-forming substrate. In this embodiment, the internal heating element 310 is a fin-shaped heating element 310 . The first housing portion 301 includes a plurality of fin-shaped heating elements 310 extending into the first cavity 303 , and the second housing portion 302 includes a plurality of fins extending into the second cavity 304 . and a shape heating element 310 . Specifically, in the illustrated embodiment, the device 300 includes twelve heating elements 310 , namely six heating elements 310 extending from the first housing portion 301 into the first cavity 303 , and a second heating element 310 . Two heating elements 310 extending from the housing portion 302 into the second cavity 304 . The fin-shaped heating element 310 extends substantially transversely within the chamber 305 . The fin-shaped heating 310 element is arranged to extend substantially parallel to each other and perpendicular to the longitudinal direction X of the cavity when the first and second housing portions 301 , 302 are in the closed position. Although fin-shaped heating elements are described and illustrated herein, it will be understood that any of a variety of shapes may be used. For example, the heating element may have the shape of any one or combination of blades, pins, spikes, or any other shape configured to facilitate insertion of the heating element into the aerosol-forming substrate. For example, the heating element may have a tapered end or a pointed end. The heating elements in the first cavity 303 may be identical to each other or may vary. The heating elements in the second cavity 304 may be the same as each other or may vary. The heating element in the first cavity 303 may have the same shape as compared to the heating element in the second cavity 304 or may have a different shape. While twelve heating elements are described with reference to the illustrated embodiment, it will be understood that other numbers of heating elements may be used. While the illustrated invention describes heating elements within both cavities 303 , 304 , it will be appreciated that in some implementations, there may be only heating elements extending from one cavity.

Each of the first and second housing portions 301 , 302 further includes an air inlet 360 . The air inlet 360 is arranged at one end of the device cavity 305 , and is arranged so that outside air can be drawn into the device cavity 305 .

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

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

When the aerosol-forming substrate 130 is disposed within the first cavity 303 and the first and second housing portions 301 , 302 are in the open positions, the fin-shaped heating element 310 of the first housing portion 301 is perforates the aerosol-forming substrate. When the first housing portion 301 and the second housing portion 302 are moved to the closed position, the aerosol-forming substrate remains within the cylindrical device cavity 305 , and the fin-shaped heating element of the second housing portion 302 ( 310 also perforates the aerosol-forming substrate 130 . As shown in FIG. 8 , the fin-shaped heating elements 310 are spaced apart from each other in both the longitudinal X and transverse directions. In this way, the fin-shaped heating element 310 is arranged to heat different portions of the aerosol-forming substrate 130 . Advantageously, this should ensure that all aerosol-forming substrates 130 are heated to the desired temperature during use of the system 400 .

In use, when the user aspirates the filter 150 of the aerosol-generating article 100 , air is drawn into the device cavity through the air inlet 360 at the upstream end 308 of the device cavity. In this embodiment, the air inlet 360 faces the central longitudinal axis of the device chamber. Air drawn into the device cavity from the air inlet 360 enters the interior cavity 160 of the aerosol-forming substrate 130 and along the interior cavity 160 towards the filter 150 as indicated by arrow A10. It is aspirated and discharged from the filter 150 at the downstream end 120 of the aerosol-generating article 100 delivered to the user.

When power is provided to the plurality of heating elements 310 , the plurality of heating elements 310 heat the aerosol-forming substrate 130 to a temperature at which the volatile compound is released from the substrate 130 , which in turn heats the substrate 130 . It is discharged from the substrate 130 into the interior cavity 160 and cooled to form an aerosol that can be inhaled by a user. The aerosol is entrained in the air drawn through the interior cavity 160 and is drawn out of the interior cavity 160 through a filter 150 and delivered to the user at the downstream end 120 .

Claims (14)

An aerosol-generating system comprising:
an aerosol-generating article having an upstream end and a downstream end, the aerosol-generating article defining a longitudinal direction between the upstream end and the downstream end, the aerosol-generating article comprising:
an upstream segment disposed at the upstream end of the aerosol-generating article, the upstream segment comprising an aerosol-forming substrate, the aerosol-forming substrate comprising an exterior surface of the substrate having an outer diameter of the substrate; and
a downstream segment disposed at the downstream end of the aerosol-generating article and having a downstream segment outer diameter, the downstream segment outer diameter comprising a downstream segment greater than the substrate outer diameter; and
an aerosol-generating device, said aerosol-generating device comprising:
A device cavity comprising a device cavity interior surface having a device cavity inner diameter, the device cavity configured to receive at least an aerosol-forming substrate of the aerosol-generating article; and
at least one heating element configured to heat the aerosol-forming substrate when the aerosol-forming substrate is received within the device cavity;
When the aerosol-forming substrate of the aerosol-generating article is received within the device cavity, an airflow passage is defined between an outer surface of the substrate and an inner surface of the device cavity, the airflow passageway extending along the length of the aerosol-forming substrate in the longitudinal direction extended to, an aerosol-generating system. The aerosol-generating system of claim 1 , wherein the aerosol-forming substrate comprises a substrate interior surface having a substrate inner diameter, the substrate interior surface defining an interior cavity extending longitudinally within the aerosol-forming substrate. 3. The aerosol-generating system of claim 2, wherein the inner diameter of the substrate is from about 60% to about 90% of the outer diameter of the substrate. 4. The aerosol-generating system of claim 2 or 3, wherein a layer of thermally conductive material is disposed on the inner surface of the substrate. 5. The aerosol-generating system according to any one of claims 1 to 4, wherein the upstream segment and the downstream segment are arranged in coaxial alignment with the longitudinal axis of the aerosol-forming article. 6 . The aerosol-generating system according to claim 1 , wherein the downstream segment comprises a filter. 7. The aerosol-generating system of claim 6, wherein the downstream segment further comprises at least one of a cooling element and a spacing element disposed between the aerosol-forming substrate and the filter. 8. The aerosol-generating system of any one of claims 1-7, wherein the outer diameter of the substrate is from about 50% to about 98% of the outer diameter of the downstream segment. 9. The aerosol-generating system according to any one of claims 1 to 8, wherein the outer surface of the substrate has a transverse cross-section with a circular shape or an oval shape. 10. The aerosol-generating system according to any one of claims 1 to 9, wherein the aerosol-forming substrate comprises a tobacco cast leaf. 11. The aerosol-generating system of any preceding claim, wherein the aerosol-forming substrate has a composition that is substantially homogeneous in the longitudinal direction. 11 . The aerosol-forming substrate according to claim 1 , wherein the aerosol-forming substrate comprises a first longitudinally extending aerosol-forming substrate segment and a second aerosol-forming substrate segment adjacent to the first aerosol-forming substrate segment in the longitudinal direction. An aerosol-generating system comprising a substrate segment. 13. The device according to any one of the preceding claims, wherein the aerosol-generating device cavity defines a longitudinal direction between an upstream end of the device cavity and a downstream end of the device cavity, and wherein the at least one heating element comprises the device. An aerosol-generating system comprising a first heating element and a second heating element spaced apart from each other in the longitudinal direction of the cavity. 14. The method according to any one of claims 1 to 13,
and an outer diameter of the downstream segment of the aerosol-generating article is substantially equal to or greater than the inner diameter of the device cavity.

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