WO2023052463A1 - Aerosol generation article - Google Patents

Aerosol generation article Download PDF

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Publication number
WO2023052463A1
WO2023052463A1 PCT/EP2022/077037 EP2022077037W WO2023052463A1 WO 2023052463 A1 WO2023052463 A1 WO 2023052463A1 EP 2022077037 W EP2022077037 W EP 2022077037W WO 2023052463 A1 WO2023052463 A1 WO 2023052463A1
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WO
WIPO (PCT)
Prior art keywords
article
susceptor
insulator
heating element
housing
Prior art date
Application number
PCT/EP2022/077037
Other languages
French (fr)
Inventor
Andrew Robert John ROGAN
Original Assignee
Jt International Sa
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jt International Sa filed Critical Jt International Sa
Publication of WO2023052463A1 publication Critical patent/WO2023052463A1/en

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Classifications

    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24DCIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00Cigars; Cigarettes
    • A24D1/20Cigarettes specially adapted for simulated smoking devices
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24FSMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/20Devices using solid inhalable precursors
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24FSMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46Shape or structure of electric heating means
    • A24F40/465Shape or structure of electric heating means specially adapted for induction heating

Definitions

  • the present disclosure relates to aerosol generation devices and consumable articles for aerosol generation devices, in particular to induction heatable articles.
  • the article may comprise tobacco or other suitable aerosol substrate materials to be heated, rather than burned, to generate an aerosol for inhalation.
  • reduced-risk or modified-risk devices also known as vaporisers
  • vaporisers have grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco.
  • Various devices and systems are available that heat or warm aerosolisable substances as opposed to burning tobacco in conventional tobacco products.
  • a commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn device.
  • Devices of this type generate an aerosol or vapour by heating an aerosol substrate that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range 150°C to 350°C. Heating an aerosol substrate, but not combusting or burning it, releases an aerosol that comprises the components sought by the user but not the toxic and carcinogenic by-products of combustion and burning.
  • the aerosol produced by heating the tobacco or other aerosolisable material does not typically comprise the burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and so the substrate does not therefore require the sugars and other additives that are typically added to such materials to make the smoke and/or vapour more palatable for the user.
  • One such method of heating aerosol substrates employs an inductive heating system, where an induction coil (also referred to as an inductor) is provided with the device and a susceptor is provided with or near the aerosol substrate. Electrical energy is provided to the inductor when a user activates the device which in turn creates an electromagnetic field. The susceptor couples with the field and generates heat which is transferred to the substrate and causes it to generate an aerosol.
  • the present invention seeks to solve at least some of the above problems.
  • an aerosol generation article comprising: a housing, a substrate arranged within the housing, the substrate configured to generate an aerosol when heated; at least one heating element arranged within the housing and adjacent the substrate; wherein each heating element comprises: a susceptor; and an insulator; wherein the susceptor and the insulator, with the insulator at least partially surrounding the susceptor, are configured such that, in use, when an electromagnetic field is applied by an aerosol generation device, the heating element heats the adjacent substrate without damaging the housing of the article.
  • the insulator is arranged between the susceptor and the housing so the susceptors can be heated to even higher temperatures, so as to more quickly heat the substrate and generate an aerosol, without burning or otherwise damaging the housing of the article.
  • the susceptor of the heating element can be inductively heated to higher temperatures without damaging the article, and in particular without damaging the housing of the article.
  • having a susceptor and insulator form individual, at least partially insulated heating elements in this way is particularly beneficial when manufacturing aerosol generation articles comprising these heating elements. Heating elements configured in this manner can be simply incorporated into existing processes for manufacturing aerosol generation articles, advantageously including high-speed processes such as linear combining processes, thereby also saving manufacturing costs.
  • the insulator is a solid component of insulator material.
  • the insulator provided the beneficial effects discussed above as well increasing the strength of the article, and in particular the structural strength of the article.
  • the insulator material should also be resistant to burning or heat damage at typical operation temperatures of the aerosol generation device.
  • the solid insulator material may comprise a ceramic such as aluminium oxide or silicon dioxide, or calcium oxide or PEEK.
  • the insulator directly contacts the susceptor. More preferably, the insulator directly contacts the susceptor where the insulator surrounds the susceptor. This configuration further increases both the strength of the article and the effectiveness of the insulation, as well as being straightforward to incorporate into aerosol generation article manufacturing processes.
  • the article is an elongate shape such that an article axis is defined between two longitudinally opposing ends of the article.
  • the susceptor comprises a first end and a second end
  • the heating element is arranged within the housing such that the first end and the second end are axially aligned along the article axis.
  • the heating element can be easily incorporated into an article during the manufacturing process.
  • the first end and second end of the susceptor are aligned with the article axis, they are positioned away from the housing of the article and are less likely to damage the housing from heating.
  • the insulator surrounds the susceptor such that the first end and the second end of the susceptor are exposed by the insulator.
  • the insulator surrounds all of the susceptor except for the opposing ends of the susceptor, such that the first end and the second end of the susceptor are not covered by the insulator. As the first end and the second end of the susceptor are less likely to damage the housing, they do not need to be covered by the insulator. In this way, less insulator material is used in the heating element, saving costs and reducing the volume occupied by the heating element.
  • the insulator fully encapsulates the susceptor. That is, the insulator fully surrounds an exterior surface of the susceptor. In this way, the maximum thermal protection is provided to the housing of the article while still allowing the heating element to heat the substrate.
  • the susceptor is a cylindrical tube shape.
  • the cylindrical shape corresponds to the shape of typical aerosol generation articles and so allows for easy integration of the heating element into such articles, as well as even heating of substrate.
  • the tube shape allows the inductively generated eddy currents to flow continuously whilst reducing the amount of susceptor material that is not resistively heated by the eddy currents flowing near the surface, thereby increasing the speed at which the susceptor heats to the desired temperature when an electromagnetic field is applied.
  • a thickness of the tube walls is between 50pm and 150pm. It has been found that such thicknesses provide the desired balance between optimum an optimum heating profile and ease of manufacture
  • the susceptor is a flat plate shape.
  • the susceptor is a hollow cube shape.
  • the susceptor comprises multiple strands of susceptor material.
  • the minimum thickness of a portion of the susceptor is between 50pm and 150pm.
  • the insulator is substantially the same shape as the susceptor.
  • the insulator may also be cylindrically shaped.
  • a larger cylindrical shape in order to at least partially surround the susceptor.
  • the length of the insulator e.g. along a longitudinal axis of the heating element, is substantially the same or greater than the length of the susceptor (as measured along the same axis typically).
  • the insulator comprises a plurality of projections of insulator material extending from the heat element.
  • the projections increase the surface area to volume ratio of the insulator and so increase the efficiency of heat dissipation from the susceptor away from the housing.
  • the projections may be arranged to define channels or gaps (e.g. between adjacent projections) for air to flow through the article.
  • the plurality of projections extend from the heating element perpendicularly to a longitudinal axis of the article.
  • this longitudinal axis of the article is the article axis discussed above.
  • an outer diameter of the heating element is substantially equal to an inner diameter of the housing. That is, as the insulator at least partially surrounds the susceptor, the insulator directly contacts the interior of the housing. In this way, an article that evenly heats substrate may be more easily fabricated.
  • the outer diameter of the heating element is between 5mm and 8mm.
  • a length of a heating element is greater than or equal to 6mm.
  • the heating element may be easily manufactured and incorporated into existing aerosol generation article manufacturing processes than heating elements of shorter length, while still providing space for efficient substrate heating within the article.
  • the length of the heating element is measured from a first end of the heating element to a second end of the heating element, wherein, when the heating element is arranged within the article, the first end and second end of the heating element are axially aligned with a longitudinal axis of the article.
  • the length of the heating element is greater than or equal to 6mm, and less than 8mm so as to more efficiently heat the substrate nearby the heating element.
  • the at least one heating element comprises a plurality of heating elements. In this way, portions of substrate within the article can be more evenly and efficiently heated.
  • the plurality of heating elements are axially aligned with a longitudinal axis of the article and sequentially arranged along a length of the article, and wherein the substrate is arranged between adjacent heating elements.
  • portions of substrate are sequentially divided by heating elements such that portions of substrate and heating elements alternate along the length of the article. This provides efficient and even heating of the substrate.
  • this longitudinal axis of the article is the article axis discussed above.
  • an aerosol generation system comprising: the aerosol generation article of the first aspect; and an aerosol generation device comprising a heating chamber and at least one induction coil; wherein, in use, the device is configured to receive the article in the heating chamber such that the induction coil is aligned with the susceptor.
  • the induction coil when the article is received in the device and the device is operated by a user, the induction coil generates an alternating and time-varying electromagnetic field that couples with the susceptor(s) of the article, causing the susceptor(s) to heat the adjacent substrate.
  • the device may comprise a single induction coil configured to extend along at least the majority of the length of the heating chamber or, alternatively, may comprises a plurality of induction coils that are each arranged to align with at least one susceptor of a received article.
  • Figure 1 is a schematic cross-section of an aerosol generation article according to the invention.
  • Figure 2 is a schematic cross-section of an aerosol generation system comprising an aerosol generation device and an aerosol generation article according to the invention, wherein the aerosol generation article is being introduced to the aerosol generation device.
  • FIG. 3A is a schematic illustration of a heating element for an aerosol generation article according to the invention
  • Figure 3B is a schematic cross-section of the heating element
  • FIGS. 4A-4D are schematic illustrations of a susceptor for an aerosol generation article according to the invention.
  • Figure 5A is a schematic illustration of a insulator for an aerosol generation article according to the invention
  • Figures 5B and 5C are schematic cross-sections of insulators for an aerosol generation article according to the invention
  • Figures 6A and 6B are schematic illustrations of aerosol generation articles according to the invention.
  • vapour is generally understood to refer to a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas.
  • aerosol and ‘vapour’ may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.
  • Figure 1 is a schematic cross-section of an aerosol generation article 1 (article) according to the invention.
  • the aerosol generation article 1 comprises an housing 10, such as a paper wrapper, that houses various components of the article 1 .
  • the article 1 is an elongate shape such that an article axis 2 is defined by the article 1 between the two longitudinally opposing ends of the article 1.
  • An elongated cylinder shape is the preferred shape for the article 1 though the skilled person will appreciate that the article 1 may be formed in any shape that is sized to fit the components described in the various embodiments set out herein and to allow the article 1 to be received by a corresponding aerosol generation device 100.
  • the article 1 may be a cuboidal shape.
  • the aerosol generation article 1 comprises an aerosol substrate 20 (substrate), such as tobacco, arranged within the housing 10.
  • the article also includes a plurality of heating elements 4 arranged within the housing 10 and positioned adjacently to the substrate 20. In use, the heating elements 4 are configured to heat, without burning, the substrate 20 so as to form an aerosol for inhalation by a user.
  • heating elements 4 shown in Figures 1 , 3A, 3B, 6A and 6B are substantially shaped as short cylinders, other sizes and shapes may be used to alter the properties of the heating element 4 and tune the heating effects provided and therefore the aerosol generated.
  • the number of and positioning of heating elements 4 within the article 1 can also be adapted to tune the generated aerosol.
  • an article 1 may comprise only a single heating element 4 that is shaped to extend along a relatively large portion of the article 1 so as to evenly heat the substrate in this way.
  • a smaller sized article 1 will typically not contain as much substrate 20 as a larger article and so is anticipated to use need heating elements 4 in order to produce the desired aerosol.
  • using a large number of relatively small sized heating elements 4 evenly spaced throughout the article 1 may provide more even heat distribution than a smaller number of relatively large sized heating elements 4, though articles 1 using these larger heating elements are easier to manufacture.
  • Each heating element 4 comprises a susceptor 30 and an insulator 40, where the insulator 40 at least partially surrounds the susceptor 30 such that each heating element 4 is an at least partially insulated heating element 4.
  • the susceptor 30 is electrically conductive and comprises a susceptor material such as mild steel, stainless steel, aluminium, iron, etc.
  • the insulator 40 is a thermal insulator and so prevents the heating element 4 overheating and damaging the housing 10 during use.
  • the insulator 40 comprises an insulator material and is preferably a ceramic like aluminium oxide or silicon dioxide, other insulator materials include calcium oxide and PEEK.
  • the insulator 40 can completely surround and encapsulate the susceptor 30 or may only partially surround the susceptor 30.
  • the susceptor 30 is a cylindrically shaped tube with only the outer face of the tube being covered by the insulator 40 and the ends 31 ,32 of the susceptor 30 still exposed by the insulator 40, such that the insulator 40 forms another larger cylindrical tube around the susceptor 30.
  • the heating element 4 is arranged within the article 1 such that a first end 31 of the susceptor 30 and a second end 32 of the susceptor are axially aligned along the article axis 2 to provide more even heating.
  • the heating element 4 is arranged such that the insulator 40 is closer to the housing 10 than the susceptor 30 is to the housing 10. That is, the sides of the susceptor 30 closest to the housing 10 are the sides surrounded by the insulator 40.
  • an electromagnetic field is applied to the susceptor 30 and generates eddy currents and/or magnetic hysteresis losses in the susceptor 30 causing it to heat up.
  • the heat is then transferred from the susceptor 30 to the substrate 20, for example through conduction, convention, and radiation, which results in the substrate 20 heating and generating the aerosol for inhalation.
  • the thermal insulation properties of the insulator 40 prevent excess heat being transmitted (e.g. conducted) to the housing 10 of the article 1.
  • the article 1 further comprises a filter 3 at an end of the article 1 to alter the properties of a generated aerosol and enhance the user experience.
  • the filter 3 also acts as a mouthpiece from which a user can directly inhale a generated aerosol, however in other examples of the article 1 the mouthpiece and filter 3 are separate elements.
  • the article 1 may include a filter 3 but not a mouthpiece, or vice versa, or neither a filter 3 nor a mouthpiece. If still used with an aerosol generation system used with the article 1 then these elements could instead be provided separately to the article 1 such as a mouthpiece that is comprised within an aerosol generation device 100.
  • the aerosol generation article 1 is configured to be coupled with an aerosol generation device 100.
  • Figure 2 shows an example of an aerosol generation system comprising an aerosol generation article 1 and an aerosol generation device 100, where the article 1 is being introduced into a heating chamber 110 of the device 100.
  • the heating chamber 110 defines an interior volume with substantially similar shape as the article 1 the device is configured to receive, in order to provide a secure fit between the components.
  • the article 1 is an elongate cylinder shape
  • the interior volume of the heating chamber 110 should also have an elongate cylinder shape with substantially the same (or slightly larger) diameter than the article 1.
  • the device 100 also includes a plurality of induction coils 120, arranged around the heating chamber 110, which act as electromagnetic field generators. During use, a high-frequency alternating current is applied to the coils 120, causing them to generate an alternating and time-varying electromagnetic field that couples with the susceptors 30 of an article 1 received in the heating chamber 110, causing the susceptors 30 to heat up as discussed above.
  • the device 100 includes a plurality of separate coils 120 that are sized and positioned to align with the susceptors 30 of a received article 1 . This limits the size of the field generated by the coils while still providing the requisite heating, thereby leading to an efficient use of energy and power.
  • this is not required as another example device 100 may have a single coil 120 extending along a larger portion of the heating chamber 110 (or a plurality of larger coils 120) so the same device 100 can create a field that would be effective when used in combination various different articles 1 that have different heating element 4 configurations.
  • the heating element 4, susceptor 30, and insulator 40 can take on a variety on forms.
  • the susceptor 30 is thin or, if it forms a larger shape, has thin walls, thickness between 50pm and 150pm.
  • a susceptor 30 with thickness around 50pm has been found to provide optimum heating effects in combination with an electromagnetic field altering with frequency around 300kHz to 500kHz.
  • Such thin susceptors 30 are effective due to the skin effect where generated eddy currents are found in higher proportions closest to the surface of the susceptor 30.
  • a thicker susceptor 30 or susceptor 30 with thicker walls will still heat the substrate 20 and generate an aerosol but will take longer to heat up to the desired temperature.
  • susceptors 30, such as hollow structures, are difficult to manufacture with wall thicknesses of 50pm so these susceptors 30 may also be used with thicker walls (e.g. 120pm) to balance the heating properties with ease and cost of manufacture.
  • FIGS 4A, 4B, 4C, and 4D show several different examples of susceptors 30A- D according to the invention.
  • the susceptor 30A is hollow, circular tube shape.
  • the tube shape allows the generated currents to flow continuously whilst reducing the amount of susceptor material that is not heated resistively due to the eddy currents flowing near the surface.
  • the susceptor 30B is a flat plate shape.
  • the susceptor 30C comprises a plurality of individual strands of susceptor material.
  • the susceptor 30C is a cube shape, this could be a hollow cube shape or a solid structure without a cavity.
  • the shape of the insulator 40 of a heating element 4 substantially corresponds to the shape of the susceptor 30, or to the shape of the article 1 cross-section perpendicular to the article axis 2.
  • figure 5A shows a perspective view of a cylindrically shaped insulator 40 for use in combination with a cylindrically shaped susceptor 30.
  • Figure 5B shows a top view of the same insulator 40.
  • the dimensions of the insulator substantially correspond to those of the heating element 4.
  • the length of the insulator 40 i.e. when fitted inside an article 1 , the length along the article axis 2 is greater than or equal to 6mm.
  • the outer diameter of the insulator 40 (or the outer width depending on the shape of the insulator 40) at the point of largest diameter is substantially the same as the inner diameter of the housing 10. This helps to ensure the heating element 4 remains in place within the article 1 , providing consistent and efficient heating of the substrate 20 without damaging the housing 10.
  • the outer diameter of the insulator 40, and therefore the heating element 4 is between 5mm and 8mm.
  • the outer diameter of the susceptor 30 is between 5mm and 7mm
  • the thickness of the insulator 40 i.e. the distance between the outer diameter of the susceptor 30 and the outer diameter the of the insulator 40
  • the thickness of the insulator 40 is between 0.1 mm and 3mm.
  • the insulator 40 comprises projections 41 such as fins of insulator material extending from the heating element 4.
  • An example of such a heating element 4 is shown in Figure 5C.
  • the insulator projections 41 increase the surface area to volume ratio of the insulator 40 and so further assist dissipating heat from the susceptor 30 (e.g. that has been conducted by the insulator 30) without overheating and damaging the housing 10.
  • the projections 41 are configured to extend towards the housing 10 of the article 1.
  • the insulator projections 41 may contact the interior of the housing 10 or extend towards the housing 10 but not contact the housing 10.
  • insulator projections 41 contact the interior of the housing 10 will strengthen the article 1 , helping to reduce accidental damage to the article 1 by a user.
  • These projections 41 can extend directly from the susceptor 30 or may extend from a portion of the insulator 40 that at least partially surrounds the susceptor 30.
  • the projections 41 can also be used to create gaps for air flow through the article 1 and control the aerosol inhalation experience.
  • the heating elements 4 may be comprised in the article 1 in a wide range of configurations.
  • Figure 1 shows a schematic cross-section of an aerosol generation article 1 comprising a plurality of heating elements 4 that have a cylindrical tube shape.
  • the cavity within the hollow susceptors 30 may contain substrate 20 for heating or, alternatively, the cavities may be substantially empty and provide air gaps between portions of substrate 20 separated by adjacent heating elements 4.
  • the susceptor 30 of the heating element 4 has a solid cylinder shape without a cavity.
  • the insulator 40 comprises separate projections 41 of insulator material extending from the heating element 4 towards to the interior edges of the housing 10 in order to define the air flow path through the article 1.
  • Figure 6B shows another example where the susceptor 30 of the heating element 4 has a solid cylindrical shape without a cavity, and the insulator 40 surrounds the outer diameter of the susceptor 30 but does not extend to the article housing 10, further reducing the risk of damaging the housing 10 from heating.
  • the configuration of the heating elements 4 allow them to be fabricated separately to an aerosol generating article 1 and easily incorporated into existing article 1 manufacturing processes. This includes high-speed article 1 manufacturing processes such as a linear combining process.
  • the exact method of fabricating the heating elements 4 will depend on their intended configuration. For example, a long tube of susceptor material could be coated or over moulded with insulator material and subsequently cut into individual heating elements 4 where the outer diameter of the susceptor 30 is covered by an insulator 40 but the first end 31 and second end 32 of the susceptor 30 are left uncovered and exposed.
  • the same long tube of susceptor material is cut into individual susceptor 30 components that are subsequently coated or over moulded with insulator material to form the heating elements 4. This technique is preferable when a heating element 4 with an insulator 40 that fully encapsulates the susceptor 30 is desired.
  • An example process of manufacturing an aerosol generating article 1 comprises feeding the substrate 20 onto a continuous web of the housing 10 in an unwrapped state. If the finished article 1 is intended to comprise other components such as a filter 3 or mouthpiece then these are also fed onto the housing 10 web. After the substrate 20 is disposed on the web, the heating elements 4 are inserted onto the housing 10 web, separating portions of substrate 10. Preferably, cavities are created in the substrate 20 in order to define a space for the heating element 4 to be inserted. When all the interior components of the article 1 have been arranged on the housing 10 web, the housing 10 web is wrapped around the interior components to securely enclose them within the housing 10, forming a continuous rod. The continuous rod is cut into individual rods. In some examples the individual rods may be the finished aerosol generating articles 1 while in other examples the individual rods are further processed (e.g. a second wrapping is applied or laser perforation is applied to a filter of the individual rod).

Abstract

An aerosol generation article is disclosed. The article comprises a housing, a substrate arranged within the housing, the substrate configured to generate an aerosol when heated; at least one heating element arranged within the housing and adjacent the substrate; wherein each heating element comprises: a susceptor; and an insulator; wherein the susceptor and the insulator, with the insulator at least partially surrounding the susceptor, are configured such that, in use, when an electromagnetic field is applied by an aerosol generation device, the heating element heats the adjacent substrate without damaging the housing of the article.

Description

AEROSOL GENERATION ARTICLE
TECHNICAL FIELD
The present disclosure relates to aerosol generation devices and consumable articles for aerosol generation devices, in particular to induction heatable articles. The article may comprise tobacco or other suitable aerosol substrate materials to be heated, rather than burned, to generate an aerosol for inhalation.
BACKGROUND
The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat or warm aerosolisable substances as opposed to burning tobacco in conventional tobacco products.
A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn device. Devices of this type generate an aerosol or vapour by heating an aerosol substrate that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range 150°C to 350°C. Heating an aerosol substrate, but not combusting or burning it, releases an aerosol that comprises the components sought by the user but not the toxic and carcinogenic by-products of combustion and burning. Furthermore, the aerosol produced by heating the tobacco or other aerosolisable material does not typically comprise the burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and so the substrate does not therefore require the sugars and other additives that are typically added to such materials to make the smoke and/or vapour more palatable for the user. One such method of heating aerosol substrates employs an inductive heating system, where an induction coil (also referred to as an inductor) is provided with the device and a susceptor is provided with or near the aerosol substrate. Electrical energy is provided to the inductor when a user activates the device which in turn creates an electromagnetic field. The susceptor couples with the field and generates heat which is transferred to the substrate and causes it to generate an aerosol.
However, there are various problems associated with using inductive heating systems in aerosol generation systems. It is difficult to generate a precise heat profile in the region of the susceptor and, as a result, it is not easily possible to quickly and efficiently heat an aerosol substrate without burning other areas of the consumable article or aerosol generation device. Existing attempts to create a safe and efficient heat profile cannot readily be integrated into existing high speed production machinery and so cannot be easily produced.
The present invention seeks to solve at least some of the above problems.
SUMMARY
According to a first aspect of the invention, there is provided an aerosol generation article comprising: a housing, a substrate arranged within the housing, the substrate configured to generate an aerosol when heated; at least one heating element arranged within the housing and adjacent the substrate; wherein each heating element comprises: a susceptor; and an insulator; wherein the susceptor and the insulator, with the insulator at least partially surrounding the susceptor, are configured such that, in use, when an electromagnetic field is applied by an aerosol generation device, the heating element heats the adjacent substrate without damaging the housing of the article.
The insulator is arranged between the susceptor and the housing so the susceptors can be heated to even higher temperatures, so as to more quickly heat the substrate and generate an aerosol, without burning or otherwise damaging the housing of the article. In this way, as the insulator surrounds at least part of the susceptor, the susceptor of the heating element can be inductively heated to higher temperatures without damaging the article, and in particular without damaging the housing of the article. In addition to the benefits during use of the article, having a susceptor and insulator form individual, at least partially insulated heating elements in this way is particularly beneficial when manufacturing aerosol generation articles comprising these heating elements. Heating elements configured in this manner can be simply incorporated into existing processes for manufacturing aerosol generation articles, advantageously including high-speed processes such as linear combining processes, thereby also saving manufacturing costs.
Preferably, the insulator is a solid component of insulator material. In this way, the insulator provided the beneficial effects discussed above as well increasing the strength of the article, and in particular the structural strength of the article. The insulator material should also be resistant to burning or heat damage at typical operation temperatures of the aerosol generation device. The solid insulator material may comprise a ceramic such as aluminium oxide or silicon dioxide, or calcium oxide or PEEK.
Preferably, the insulator directly contacts the susceptor. More preferably, the insulator directly contacts the susceptor where the insulator surrounds the susceptor. This configuration further increases both the strength of the article and the effectiveness of the insulation, as well as being straightforward to incorporate into aerosol generation article manufacturing processes.
Preferably, the article is an elongate shape such that an article axis is defined between two longitudinally opposing ends of the article.
Preferably, the susceptor comprises a first end and a second end, and the heating element is arranged within the housing such that the first end and the second end are axially aligned along the article axis. In this way, the heating element can be easily incorporated into an article during the manufacturing process. Furthermore, as the first end and second end of the susceptor are aligned with the article axis, they are positioned away from the housing of the article and are less likely to damage the housing from heating.
Optionally, the insulator surrounds the susceptor such that the first end and the second end of the susceptor are exposed by the insulator. Optionally, the insulator surrounds all of the susceptor except for the opposing ends of the susceptor, such that the first end and the second end of the susceptor are not covered by the insulator. As the first end and the second end of the susceptor are less likely to damage the housing, they do not need to be covered by the insulator. In this way, less insulator material is used in the heating element, saving costs and reducing the volume occupied by the heating element.
Optionally, the insulator fully encapsulates the susceptor. That is, the insulator fully surrounds an exterior surface of the susceptor. In this way, the maximum thermal protection is provided to the housing of the article while still allowing the heating element to heat the substrate.
Optionally, the susceptor is a cylindrical tube shape. The cylindrical shape corresponds to the shape of typical aerosol generation articles and so allows for easy integration of the heating element into such articles, as well as even heating of substrate. In addition, the tube shape allows the inductively generated eddy currents to flow continuously whilst reducing the amount of susceptor material that is not resistively heated by the eddy currents flowing near the surface, thereby increasing the speed at which the susceptor heats to the desired temperature when an electromagnetic field is applied.
Preferably, a thickness of the tube walls is between 50pm and 150pm. It has been found that such thicknesses provide the desired balance between optimum an optimum heating profile and ease of manufacture Optionally, the susceptor is a flat plate shape. Optionally, the susceptor is a hollow cube shape. Optionally, the susceptor comprises multiple strands of susceptor material. Preferably, the minimum thickness of a portion of the susceptor is between 50pm and 150pm.
Optionally, the insulator is substantially the same shape as the susceptor. For example, when the susceptor exhibits a cylindrical shape, the insulator may also be cylindrically shaped. In particular, a larger cylindrical shape in order to at least partially surround the susceptor. When the insulator exhibits substantially the same shape as the susceptor, the length of the insulator, e.g. along a longitudinal axis of the heating element, is substantially the same or greater than the length of the susceptor (as measured along the same axis typically).
Optionally, the insulator comprises a plurality of projections of insulator material extending from the heat element. In this way, the projections increase the surface area to volume ratio of the insulator and so increase the efficiency of heat dissipation from the susceptor away from the housing. The projections may be arranged to define channels or gaps (e.g. between adjacent projections) for air to flow through the article.
Preferably, the plurality of projections extend from the heating element perpendicularly to a longitudinal axis of the article. When the article is an elongate shape this longitudinal axis of the article is the article axis discussed above.
Preferably, an outer diameter of the heating element is substantially equal to an inner diameter of the housing. That is, as the insulator at least partially surrounds the susceptor, the insulator directly contacts the interior of the housing. In this way, an article that evenly heats substrate may be more easily fabricated.
Preferably, the outer diameter of the heating element is between 5mm and 8mm.
Preferably, a length of a heating element is greater than or equal to 6mm. In this way, the heating element may be easily manufactured and incorporated into existing aerosol generation article manufacturing processes than heating elements of shorter length, while still providing space for efficient substrate heating within the article. The length of the heating element is measured from a first end of the heating element to a second end of the heating element, wherein, when the heating element is arranged within the article, the first end and second end of the heating element are axially aligned with a longitudinal axis of the article. Optionally, the length of the heating element is greater than or equal to 6mm, and less than 8mm so as to more efficiently heat the substrate nearby the heating element.
Preferably, the at least one heating element comprises a plurality of heating elements. In this way, portions of substrate within the article can be more evenly and efficiently heated.
Preferably, the plurality of heating elements are axially aligned with a longitudinal axis of the article and sequentially arranged along a length of the article, and wherein the substrate is arranged between adjacent heating elements. In this way, portions of substrate are sequentially divided by heating elements such that portions of substrate and heating elements alternate along the length of the article. This provides efficient and even heating of the substrate. When the article is an elongate shape this longitudinal axis of the article is the article axis discussed above.
According to a second aspect of the invention, there is provided an aerosol generation system comprising: the aerosol generation article of the first aspect; and an aerosol generation device comprising a heating chamber and at least one induction coil; wherein, in use, the device is configured to receive the article in the heating chamber such that the induction coil is aligned with the susceptor.
In this way, when the article is received in the device and the device is operated by a user, the induction coil generates an alternating and time-varying electromagnetic field that couples with the susceptor(s) of the article, causing the susceptor(s) to heat the adjacent substrate. The device may comprise a single induction coil configured to extend along at least the majority of the length of the heating chamber or, alternatively, may comprises a plurality of induction coils that are each arranged to align with at least one susceptor of a received article.
BRIEF DESCRIPTION OF THE DRAWINGS
Examples of the present invention will now be described with reference to the accompanying drawings, in which:
Figure 1 is a schematic cross-section of an aerosol generation article according to the invention;
Figure 2 is a schematic cross-section of an aerosol generation system comprising an aerosol generation device and an aerosol generation article according to the invention, wherein the aerosol generation article is being introduced to the aerosol generation device.
Figure 3A is a schematic illustration of a heating element for an aerosol generation article according to the invention, Figure 3B is a schematic cross-section of the heating element;
Figures 4A-4D are schematic illustrations of a susceptor for an aerosol generation article according to the invention;
Figure 5A is a schematic illustration of a insulator for an aerosol generation article according to the invention, Figures 5B and 5C are schematic cross-sections of insulators for an aerosol generation article according to the invention;
Figures 6A and 6B are schematic illustrations of aerosol generation articles according to the invention.
DETAILED DESCRIPTION As described herein, a vapour is generally understood to refer to a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms ‘aerosol’ and ‘vapour’ may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.
Figure 1 is a schematic cross-section of an aerosol generation article 1 (article) according to the invention.
In Figure 1 , the aerosol generation article 1 comprises an housing 10, such as a paper wrapper, that houses various components of the article 1 . In the depicted embodiment the article 1 is an elongate shape such that an article axis 2 is defined by the article 1 between the two longitudinally opposing ends of the article 1. An elongated cylinder shape is the preferred shape for the article 1 though the skilled person will appreciate that the article 1 may be formed in any shape that is sized to fit the components described in the various embodiments set out herein and to allow the article 1 to be received by a corresponding aerosol generation device 100. For example, the article 1 may be a cuboidal shape.
The aerosol generation article 1 comprises an aerosol substrate 20 (substrate), such as tobacco, arranged within the housing 10. The article also includes a plurality of heating elements 4 arranged within the housing 10 and positioned adjacently to the substrate 20. In use, the heating elements 4 are configured to heat, without burning, the substrate 20 so as to form an aerosol for inhalation by a user.
Although the heating elements 4 shown in Figures 1 , 3A, 3B, 6A and 6B are substantially shaped as short cylinders, other sizes and shapes may be used to alter the properties of the heating element 4 and tune the heating effects provided and therefore the aerosol generated. Similarly, the number of and positioning of heating elements 4 within the article 1 can also be adapted to tune the generated aerosol. For example, an article 1 may comprise only a single heating element 4 that is shaped to extend along a relatively large portion of the article 1 so as to evenly heat the substrate in this way. A smaller sized article 1 will typically not contain as much substrate 20 as a larger article and so is anticipated to use need heating elements 4 in order to produce the desired aerosol. Moreover, using a large number of relatively small sized heating elements 4 evenly spaced throughout the article 1 may provide more even heat distribution than a smaller number of relatively large sized heating elements 4, though articles 1 using these larger heating elements are easier to manufacture.
Each heating element 4 comprises a susceptor 30 and an insulator 40, where the insulator 40 at least partially surrounds the susceptor 30 such that each heating element 4 is an at least partially insulated heating element 4. The susceptor 30 is electrically conductive and comprises a susceptor material such as mild steel, stainless steel, aluminium, iron, etc. The insulator 40 is a thermal insulator and so prevents the heating element 4 overheating and damaging the housing 10 during use. The insulator 40 comprises an insulator material and is preferably a ceramic like aluminium oxide or silicon dioxide, other insulator materials include calcium oxide and PEEK. The insulator 40 can completely surround and encapsulate the susceptor 30 or may only partially surround the susceptor 30. In the example of Figure 1 , shown in more detail in Figures 3A and 3B, the susceptor 30 is a cylindrically shaped tube with only the outer face of the tube being covered by the insulator 40 and the ends 31 ,32 of the susceptor 30 still exposed by the insulator 40, such that the insulator 40 forms another larger cylindrical tube around the susceptor 30. Preferably, the heating element 4 is arranged within the article 1 such that a first end 31 of the susceptor 30 and a second end 32 of the susceptor are axially aligned along the article axis 2 to provide more even heating. Preferably, when the susceptor 30 is only partially surrounded by the insulator 40, the heating element 4 is arranged such that the insulator 40 is closer to the housing 10 than the susceptor 30 is to the housing 10. That is, the sides of the susceptor 30 closest to the housing 10 are the sides surrounded by the insulator 40. During use, an electromagnetic field is applied to the susceptor 30 and generates eddy currents and/or magnetic hysteresis losses in the susceptor 30 causing it to heat up. The heat is then transferred from the susceptor 30 to the substrate 20, for example through conduction, convention, and radiation, which results in the substrate 20 heating and generating the aerosol for inhalation. During this process, the thermal insulation properties of the insulator 40 prevent excess heat being transmitted (e.g. conducted) to the housing 10 of the article 1.
The article 1 further comprises a filter 3 at an end of the article 1 to alter the properties of a generated aerosol and enhance the user experience. In the articles 1 shown the filter 3 also acts as a mouthpiece from which a user can directly inhale a generated aerosol, however in other examples of the article 1 the mouthpiece and filter 3 are separate elements. In addition, in yet other examples the article 1 may include a filter 3 but not a mouthpiece, or vice versa, or neither a filter 3 nor a mouthpiece. If still used with an aerosol generation system used with the article 1 then these elements could instead be provided separately to the article 1 such as a mouthpiece that is comprised within an aerosol generation device 100.
The aerosol generation article 1 is configured to be coupled with an aerosol generation device 100. Figure 2 shows an example of an aerosol generation system comprising an aerosol generation article 1 and an aerosol generation device 100, where the article 1 is being introduced into a heating chamber 110 of the device 100. The heating chamber 110 defines an interior volume with substantially similar shape as the article 1 the device is configured to receive, in order to provide a secure fit between the components. For example, if the article 1 is an elongate cylinder shape then the interior volume of the heating chamber 110 should also have an elongate cylinder shape with substantially the same (or slightly larger) diameter than the article 1.
The device 100 also includes a plurality of induction coils 120, arranged around the heating chamber 110, which act as electromagnetic field generators. During use, a high-frequency alternating current is applied to the coils 120, causing them to generate an alternating and time-varying electromagnetic field that couples with the susceptors 30 of an article 1 received in the heating chamber 110, causing the susceptors 30 to heat up as discussed above.
In the device 100 shown in the example of Figure 2, the device 100 includes a plurality of separate coils 120 that are sized and positioned to align with the susceptors 30 of a received article 1 . This limits the size of the field generated by the coils while still providing the requisite heating, thereby leading to an efficient use of energy and power. However, this is not required as another example device 100 may have a single coil 120 extending along a larger portion of the heating chamber 110 (or a plurality of larger coils 120) so the same device 100 can create a field that would be effective when used in combination various different articles 1 that have different heating element 4 configurations.
The heating element 4, susceptor 30, and insulator 40 can take on a variety on forms. Preferably, the susceptor 30 is thin or, if it forms a larger shape, has thin walls, thickness between 50pm and 150pm. A susceptor 30 with thickness around 50pm has been found to provide optimum heating effects in combination with an electromagnetic field altering with frequency around 300kHz to 500kHz. Such thin susceptors 30 are effective due to the skin effect where generated eddy currents are found in higher proportions closest to the surface of the susceptor 30. A thicker susceptor 30 or susceptor 30 with thicker walls will still heat the substrate 20 and generate an aerosol but will take longer to heat up to the desired temperature. However, it has been found that some shapes of susceptors 30, such as hollow structures, are difficult to manufacture with wall thicknesses of 50pm so these susceptors 30 may also be used with thicker walls (e.g. 120pm) to balance the heating properties with ease and cost of manufacture.
Figures 4A, 4B, 4C, and 4D show several different examples of susceptors 30A- D according to the invention. The susceptor 30A is hollow, circular tube shape. The tube shape allows the generated currents to flow continuously whilst reducing the amount of susceptor material that is not heated resistively due to the eddy currents flowing near the surface. The susceptor 30B is a flat plate shape. The susceptor 30C comprises a plurality of individual strands of susceptor material. The susceptor 30C is a cube shape, this could be a hollow cube shape or a solid structure without a cavity.
Preferably, the shape of the insulator 40 of a heating element 4 substantially corresponds to the shape of the susceptor 30, or to the shape of the article 1 cross-section perpendicular to the article axis 2. For example, figure 5A shows a perspective view of a cylindrically shaped insulator 40 for use in combination with a cylindrically shaped susceptor 30. Figure 5B shows a top view of the same insulator 40.
As the insulator 40 of the heating element 4 surrounds the insulator 30, the dimensions of the insulator substantially correspond to those of the heating element 4. Preferably, the length of the insulator 40 (i.e. when fitted inside an article 1 , the length along the article axis 2) is greater than or equal to 6mm. Preferably, the outer diameter of the insulator 40 (or the outer width depending on the shape of the insulator 40) at the point of largest diameter is substantially the same as the inner diameter of the housing 10. This helps to ensure the heating element 4 remains in place within the article 1 , providing consistent and efficient heating of the substrate 20 without damaging the housing 10. For example, the outer diameter of the insulator 40, and therefore the heating element 4, is between 5mm and 8mm. In another example, the outer diameter of the susceptor 30 is between 5mm and 7mm, and the thickness of the insulator 40 (i.e. the distance between the outer diameter of the susceptor 30 and the outer diameter the of the insulator 40) is between 0.1 mm and 3mm.
In some examples of the invention, the insulator 40 comprises projections 41 such as fins of insulator material extending from the heating element 4. An example of such a heating element 4 is shown in Figure 5C. The insulator projections 41 increase the surface area to volume ratio of the insulator 40 and so further assist dissipating heat from the susceptor 30 (e.g. that has been conducted by the insulator 30) without overheating and damaging the housing 10. When arranged correctly within an article 1 , the projections 41 are configured to extend towards the housing 10 of the article 1. The insulator projections 41 may contact the interior of the housing 10 or extend towards the housing 10 but not contact the housing 10. Having the insulator projections 41 contact the interior of the housing 10 will strengthen the article 1 , helping to reduce accidental damage to the article 1 by a user. These projections 41 can extend directly from the susceptor 30 or may extend from a portion of the insulator 40 that at least partially surrounds the susceptor 30. The projections 41 can also be used to create gaps for air flow through the article 1 and control the aerosol inhalation experience.
It will be apparent to the skilled person that the heating elements 4 may be comprised in the article 1 in a wide range of configurations. For example, Figure 1 shows a schematic cross-section of an aerosol generation article 1 comprising a plurality of heating elements 4 that have a cylindrical tube shape. The cavity within the hollow susceptors 30 may contain substrate 20 for heating or, alternatively, the cavities may be substantially empty and provide air gaps between portions of substrate 20 separated by adjacent heating elements 4. In Figure 6A, the susceptor 30 of the heating element 4 has a solid cylinder shape without a cavity. As aerosol cannot be drawn through the susceptor 30 and the heating element 4 extends across both sides of the housing 10, the insulator 40 comprises separate projections 41 of insulator material extending from the heating element 4 towards to the interior edges of the housing 10 in order to define the air flow path through the article 1. Figure 6B shows another example where the susceptor 30 of the heating element 4 has a solid cylindrical shape without a cavity, and the insulator 40 surrounds the outer diameter of the susceptor 30 but does not extend to the article housing 10, further reducing the risk of damaging the housing 10 from heating.
The configuration of the heating elements 4 allow them to be fabricated separately to an aerosol generating article 1 and easily incorporated into existing article 1 manufacturing processes. This includes high-speed article 1 manufacturing processes such as a linear combining process. The exact method of fabricating the heating elements 4 will depend on their intended configuration. For example, a long tube of susceptor material could be coated or over moulded with insulator material and subsequently cut into individual heating elements 4 where the outer diameter of the susceptor 30 is covered by an insulator 40 but the first end 31 and second end 32 of the susceptor 30 are left uncovered and exposed. In a similar but alternative example, the same long tube of susceptor material is cut into individual susceptor 30 components that are subsequently coated or over moulded with insulator material to form the heating elements 4. This technique is preferable when a heating element 4 with an insulator 40 that fully encapsulates the susceptor 30 is desired.
An example process of manufacturing an aerosol generating article 1 according to the present invention comprises feeding the substrate 20 onto a continuous web of the housing 10 in an unwrapped state. If the finished article 1 is intended to comprise other components such as a filter 3 or mouthpiece then these are also fed onto the housing 10 web. After the substrate 20 is disposed on the web, the heating elements 4 are inserted onto the housing 10 web, separating portions of substrate 10. Preferably, cavities are created in the substrate 20 in order to define a space for the heating element 4 to be inserted. When all the interior components of the article 1 have been arranged on the housing 10 web, the housing 10 web is wrapped around the interior components to securely enclose them within the housing 10, forming a continuous rod. The continuous rod is cut into individual rods. In some examples the individual rods may be the finished aerosol generating articles 1 while in other examples the individual rods are further processed (e.g. a second wrapping is applied or laser perforation is applied to a filter of the individual rod).

Claims

1 . An aerosol generation article comprising: a housing, a substrate arranged within the housing, the substrate configured to generate an aerosol when heated; at least one heating element arranged within the housing and adjacent the substrate; wherein each heating element comprises: a susceptor; and an insulator, wherein the insulator comprises a solid insulator material; wherein the susceptor and the insulator, with the insulator at least partially surrounding the susceptor and contacting the susceptor, are configured such that, in use, when an electromagnetic field is applied by an aerosol generation device, the heating element heats the adjacent substrate without damaging the housing of the article.
2. The article of claim 1 , wherein the article is an elongate shape such that an article axis is defined between two longitudinally opposing ends of the article.
3. The article of claim 2, wherein the susceptor comprises a first end and a second end, and the heating element is arranged within the housing such that the first end and the second end are axially aligned along the article axis.
4. The article of claim 3, wherein the insulator surrounds the susceptor such that the first end and the second end of the susceptor are exposed by the insulator.
5. The article of any of claims 1 to 3, wherein the insulator fully encapsulates the susceptor.
6. The article of any preceding claim, wherein the susceptor is a cylindrical tube shape.
7. The article of claim 6 wherein a thickness of the tube walls is between 50pm and 150pm.
8. The article of any preceding claim, wherein the insulator is substantially the same shape as the susceptor.
9. The article of any of claims 1 to 7, wherein the insulator comprises a plurality of projections of insulator material extending from the heating element.
10. The article of claim 9, wherein the plurality of projections extend from the heating element perpendicularly to a longitudinal axis of the article.
11. The article of any preceding claim, wherein an outer diameter of the heating element is between 5mm and 8mm.
12. The article of any preceding claim, wherein a length of the heating element is greater than or equal to 6mm.
13. The article of any preceding claim, wherein the at least one heating element comprises a plurality of heating elements.
14. The article of claim 13, wherein the plurality of heating elements are axially aligned with a longitudinal axis of the article and sequentially arranged along a length of the article, and wherein the substrate is arranged between adjacent heating elements.
15. An aerosol generation system comprising: the aerosol generation article of any preceding claim; and an aerosol generation device comprising a heating chamber and at least one induction coil; wherein, in use, the device is configured to receive the article in the heating chamber such that the induction coil is aligned with the susceptor.
PCT/EP2022/077037 2021-09-30 2022-09-28 Aerosol generation article WO2023052463A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21200046.7 2021-09-30
EP21200046 2021-09-30

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170055584A1 (en) * 2015-08-31 2017-03-02 British American Tobacco (Investments) Limited Article for use with apparatus for heating smokable material
WO2017072148A1 (en) * 2015-10-30 2017-05-04 British American Tobacco (Investments) Limited Article for use with apparatus for heating smokable material
WO2020007879A1 (en) * 2018-07-04 2020-01-09 British American Tobacco (Investments) Limited Aerosol-generating consumable

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170055584A1 (en) * 2015-08-31 2017-03-02 British American Tobacco (Investments) Limited Article for use with apparatus for heating smokable material
WO2017072148A1 (en) * 2015-10-30 2017-05-04 British American Tobacco (Investments) Limited Article for use with apparatus for heating smokable material
WO2020007879A1 (en) * 2018-07-04 2020-01-09 British American Tobacco (Investments) Limited Aerosol-generating consumable

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