Aerosol-generating products

Abstract

An aerosol generating article (1, 2) for use with an aerosol generating device (102) comprises: a substantially flat aerosol generating substrate (14); at least one air flow channel (16) extending along the substantially flat aerosol generating substrate (14); and a wrapping member (22) surrounding the substantially flat aerosol generating substrate (14) and the at least one air flow channel (16). The at least one air flow channel (16) comprises two or more parts (16a, 16b) having different cross-sections.

Description

Technology Field

[0001] The present disclosure generally relates to aerosol generating articles, and more specifically, to an aerosol generating article used in conjunction with an aerosol generating device for heating the aerosol generating article to generate an aerosol for a user to inhale. The present disclosure may particularly apply to an aerosol generating article for use in conjunction with a hand-held aerosol generating device. Background Technology

[0002] The popularity and use of reduced-risk or improved-risk devices (also known as aerosol generators or vapor generators) have grown rapidly in recent years as an alternative to the use of traditional tobacco products. A variety of devices and systems are available that generate aerosols that users can inhale by heating or warming aerosol-generating materials.

[0003] Generally available devices with reduced or improved risk are substrate-heated aerosol generating devices or so-called heat-not-burn devices. These types of devices generate aerosols or vapors by heating an aerosol generating substrate to a temperature typically in the range of 150°C to 300°C. When the aerosol generating substrate is heated to a temperature within this range without burning or combusting it, it typically cools and condenses to generate vapors that form an aerosol that can be inhaled by the user of the device.

[0004] Currently available aerosol generating devices can provide heat to an aerosol generating substrate using one of several different approaches, including resistance heating using a resistance heating element and induction heating using an induction coil and an induction-heatable susceptor.

[0005] Regardless of the approach used to heat the aerosol generating substrate, the characteristics of the aerosol generated by the aerosol generating device depend on various factors, including the composition of the aerosol generating article used in conjunction with the aerosol generating device. Therefore, there is a desire to provide an aerosol generating article that can optimize the characteristics of the aerosol generated during the use of the aerosol generating article and is simultaneously easy to use in combination with the aerosol generating device. means of solving the problem

[0006] According to a first aspect of the present disclosure, an aerosol generating article used in conjunction with an aerosol generating device is provided, and such aerosol generating article,

[0007] A substantially flat aerosol generating substrate;

[0008] At least one air flow channel extending along a substantially flat aerosol generating substrate; and

[0009] A substantially flat aerosol generating substrate and a wrapping member surrounding at least one air flow channel

[0010] Including;

[0011] At least one air flow channel comprises two or more parts having different cross-sections.

[0012] An aerosol generating article is used with an aerosol generating device to heat an aerosol generating material without burning the aerosol generating material, in order to volatilize at least one component of the aerosol generating material and thereby generate heated vapor that cools and condenses to form an aerosol for a user of the aerosol generating device to inhale. The aerosol generating device is a handheld portable device.

[0013] In general terms, vapor is a substance in the gaseous phase at a temperature below its critical temperature, meaning that the vapor can condense into a liquid by increasing its pressure without decreasing its temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets in air or another gas. However, it should be noted that the terms 'aerosol' and 'vapor' may be used interchangeably in this specification, particularly in relation to the form of an inhalable medium produced for a user to inhale.

[0014] Improved delivery of vapor and / or aerosol can be achieved by providing at least one air flow channel having two or more parts with different cross-sections. Additionally, by surrounding at least one air flow channel with a wrapping member, vapor and / or aerosol generated during the use of an aerosol generating article within an aerosol generating device flows internally along at least one air flow channel within the article before being inhaled by the user. Accordingly, the formation of condensation material on the internal surface of the aerosol generating device is substantially prevented or at least minimized, which can provide many advantages. For example, this helps reduce residue accumulation within the aerosol generating device and helps reduce the frequency of cleaning and maintenance tasks that the user of the device must perform. This can also ensure that the maximum possible amount of vapor and / or aerosol is delivered to the user and help the delivered vapor and / or aerosol have optimal characteristics.

[0015] At least one air flow channel may comprise two or more parts having different cross-sectional shapes. Alternatively or additionally, at least one air flow channel may comprise two or more parts having different cross-sectional areas. This can facilitate the generation of vapor and effectively deliver vapor and / or aerosol to the user to facilitate inhalation.

[0016] The aerosol generating article may comprise a distal end, an inlet end, and a longitudinal axis that may extend between the inlet end and the distal end. The inlet end is located at the end of the aerosol generating article opposite to the distal end. More specifically, the inlet end is located downstream of the distal end with respect to the direction of air flow through the aerosol generating article, for example, during use of the aerosol generating article in an aerosol generating device. At least one air flow channel may extend in a first direction that may be substantially parallel to the longitudinal axis. Air may flow along at least one air flow channel from the distal end to the inlet end during use of the aerosol generating article, thereby allowing the maximum amount of volatile components to be released into the air from the heated aerosol generating material as the air flows through the air flow channel. This may subsequently allow the maximum possible amount of vapor and / or aerosol to be generated and delivered to the user during use of the aerosol generating article.

[0017] At least two or more parts of at least one air flow channel may include an upstream part and a downstream part. The upstream part and the downstream part correspond to the direction of air flow through the aerosol generating article. In other words, the upstream part is positioned at the distal end of the aerosol generating article and the downstream part is positioned at the inlet end of the aerosol generating article; that is, the downstream part is positioned downstream of the upstream part with respect to the direction of air flow through the aerosol generating article, for example, during use of the aerosol generating article in an aerosol generating device. The downstream part may have a larger cross-sectional area than the upstream part. This arrangement can facilitate the generation of vapor and facilitate the cooling and condensation of the generated vapor to produce an aerosol having characteristics suitable for inhalation by a user.

[0018] An upstream portion of at least one air flow channel may include a groove that can be formed within the surface of a substantially flat aerosol generating substrate. A downstream portion of at least one air flow channel may include a slit that can be formed at one end of a substantially flat aerosol generating substrate.

[0019] A substantially flat aerosol generating substrate may have a flat rectangular shape having a pair of main surfaces. A wrapping member may include a pair of rectangular sheets that can be attached to each of the pair of main surfaces. Due to the flat rectangular shape of the aerosol generating substrate, the aerosol generating article may have an aesthetically pleasing appearance. The aerosol generating substrate can be easily covered by the wrapping member, thereby ensuring that the user does not come into direct contact with the aerosol generating substrate during handling of the aerosol generating article. The flat rectangular shape can also facilitate the packaging and storage of multiple aerosol generating articles.

[0020] An aerosol-generating article may include a support member capable of forming a mouth-end portion of the article. The support member may have a tubular shape, for example, a rectangular tubular shape, to accommodate the aerosol-generating material and the downstream end of at least one air flow channel, for example, a portion of at least one air flow channel having a larger cross-sectional area. The support member may be self-supporting and may include, for example, cardboard or plastic material. The support member can advantageously deliver vapor and / or aerosol generated during use of the article directly to the user's mouth. The support member enables heated vapor generated during use of the aerosol-generating article to cool and condense to form an aerosol having optimal characteristics for inhalation by the user.

[0021] The wrapping member may comprise a material that is substantially non-electrically conductive and non-magnetically permeable, and may comprise, for example, a paper wrapper. The use of a paper wrapper can facilitate the manufacture and handling of aerosol-generating articles and can enhance aerosol generation.

[0022] The wrapping member may have a porous inner surface that can be faced toward the aerosol generating substrate to absorb condensate. The porous inner surface may also help ensure that the formation of condensate on the inner surface of the aerosol generating device is substantially prevented or at least minimized. The wrapping member may have an anti-stick outer surface that can be faced away from the aerosol generating substrate. For example, the wrapping member may include an anti-stick coating on the outer surface. The anti-stick outer surface may help ensure that the wrapping member does not stick to the surface of the aerosol generating device when heated. Both the porous inner surface and the anti-stick outer surface may help reduce the accumulation of residue within the aerosol generating device, thereby reducing the frequency of cleaning and maintenance tasks that the user of the device must perform.

[0023] The aerosol generating substrate may comprise a non-liquid aerosol generating material, for example, any type of solid or semi-solid material. Exemplary types of aerosol generating solids include powders, granules, pellets, pieces, strands, particles, gels, strips, loose leaves, cut leaves, cut fillers, porous materials, foam materials, or sheets. The aerosol generating substrate may comprise plant-derived materials, and in particular may comprise tobacco. Advantageously, it may comprise, for example, tobacco and reconstituted tobacco comprising one or more of cellulose fibers, tobacco stem fibers, and inorganic fillers such as CaCO3.

[0024] Consequently, an aerosol generating device intended for use with an aerosol generating article may be referred to as a "heated tobacco device," a "non-combustible heated tobacco device," a "device for vaporizing tobacco products," etc., and is interpreted as a device suitable for achieving such effects. The features disclosed herein may be equally applicable to a device designed to vaporize any aerosol generating material.

[0025] The aerosol generating substrate may include an aerosol forming agent. Examples of aerosol forming agents include polyhydric alcohols and mixtures thereof, such as glycerin or propylene glycol. Generally, the aerosol generating substrate may include an aerosol forming agent in an amount of about 5% to about 50% based on dry weight. In some embodiments, the aerosol generating substrate may include an aerosol forming agent in an amount of about 10% to about 20% based on dry weight, and possibly about 15% based on dry weight.

[0026] An aerosol generating article may be configured to be used with an electric-operated aerosol generating device comprising a heater. The heater may be a resistance heater or an induction heater. Upon heating, the aerosol generating material may release a volatile compound. The volatile compound may include flavor compounds such as nicotine or tobacco flavoring agents. Brief explanation of the drawing

[0027] FIG. 1 is a schematic longitudinal cross-sectional view of a first embodiment of an aerosol-generating article. Figure 2 is a schematic cross-sectional view along line AA of Figure 1. Figure 3 is a schematic cross-sectional view along line BB of Figure 1. FIG. 4 is a schematic longitudinal cross-sectional view of a second embodiment of an aerosol-generating article. FIG. 5 is a schematic cross-sectional view of an aerosol generating system including an aerosol generating device and an aerosol generating article according to the present disclosure. Specific details for implementing the invention

[0028] Now, with reference to the attached drawings, embodiments of the present disclosure will be described merely as examples.

[0029] First, referring to FIGS. 1 through 3, a first embodiment of an aerosol generating article (1) for use with an electric-operated aerosol generating device (102) is illustrated, and such an example will be described later in this specification with reference to FIG. 5. The aerosol generating article (1) is substantially planar and has a distal end (10) and an inlet end (12) (or proximal end) at opposite ends of the aerosol generating article (1). The inlet end (12) is located downstream of the distal end (10) with respect to the direction of air flow through the aerosol generating article (1), as indicated by three arrows in FIG. 1. A longitudinal axis extends between the distal end (10) and the inlet end (12) to define the longitudinal direction of the aerosol generating article (1).

[0030] The aerosol generating article (1) comprises a substantially flat aerosol generating substrate (14). The aerosol generating substrate (14) comprises a bulk or mass of aerosol generating material and has a flat rectangular shape having a pair of opposing main surfaces (14a, 14b). The aerosol generating article (1) is a consumable or disposable article, and the aerosol generating substrate (14) may comprise tobacco or tobacco material.

[0031] In the illustrated embodiment, the aerosol generating article (1) comprises a plurality of air flow channels (16), each comprising a plurality of grooves (18) formed within the main surface (14a) of the aerosol generating substrate (14). The grooves (18) are arranged side by side and parallel to each other, and the grooves (18) extend longitudinally between the distal end (10) and the inlet end (12) substantially parallel to the longitudinal axis. The grooves (18) form a longitudinal fluted surface (20). The grooves (18) may be formed in any suitable manner, for example, by pressing the main surface (14a) of the aerosol generating substrate (14) with a suitably formed pressing tool. Although three grooves (18) are illustrated in the embodiment of FIGS. 1 and 2, it will be understood that any suitable number of grooves (18) may be provided, for example, depending on the desired resistance-to-draw of the aerosol generating article (1). It should be noted that the home (18) may have any suitable cross-sectional shape, including, but not limited to, a rectangular, square, trapezoidal, or semicircular shape as shown in FIGS. 2 and FIGS. 3.

[0032] Each air flow channel (16) comprises a first portion (16a) and a second portion (16b) having different cross-sections. In the example illustrated in FIGS. 1 to 3, the second portion (16b) is positioned downstream of the first portion (16a). The first portion (16a) (or upstream portion) has a first cross-sectional area, and the second portion (16b) (or downstream portion) has a second cross-sectional area larger than the first cross-sectional area. The first portion (16a) of each air flow channel (16) comprises a first groove portion (18a) formed within the main surface (14a) of the aerosol generating substrate (14). The second portion (16b) of each air flow channel (16) comprises a second groove portion (18b) formed within the main surface (14a) of the aerosol generating substrate (14). The second groove portion (18b) is wider and deeper than the first groove portion (18a), resulting in the aforementioned larger second cross-sectional area. The second groove portion (18b) (i.e., the second portion (16b) of each air flow channel (16)) terminates within a slit (19) formed at one end (30) of the aerosol generating substrate (14).

[0033] The aerosol generating article (1) further comprises a wrapping member (22) that surrounds an aerosol generating substrate (14) and a groove (18) forming an air flow channel (16). Thus, the aerosol generating substrate (14) and the groove (18) are completely surrounded by the wrapping member (22), and such wrapping member may comprise, for example, cigarette paper or a similar material. The wrapping member (22) comprises a pair of rectangular sheets (24, 26) each attached to the main surface (14a, 14b) of the aerosol generating substrate (14). The rectangular sheets (24, 26) are generally formed by a single sheet of material that may have overlapping soft parts that are wrapped around the aerosol generating substrate (14) and bonded to each other to secure the wrapping member (22) in place around the aerosol generating substrate (14) and the groove (18).

[0034] In an exemplary and non-limiting embodiment, the aerosol generating substrate (14) may have a length of about 18.0 mm (in the longitudinal direction of the aerosol generating article (1)), a width of about 11.8 mm, and a thickness (or depth) of about 1.2 mm. The aerosol generating substrate (14) may be spaced inward from the distal end (10) of the aerosol generating article (1) by a short distance, for example, about 3.0 mm, as shown in FIG. 1. The aerosol generating article (1) may have a width of about 12.0 mm and a thickness (or depth) of about 1.4 mm to accommodate the aerosol generating substrate (14) within the wrapping member (22). The aerosol generating article (1) may have any suitable length between the distal end (10) and the inlet end (12) by changing the length of the portion of the wrapping member (22) extending between the downstream end of the aerosol generating substrate (14) and the inlet end (12). When vapor flows through this portion of the wrapping member (22) while the aerosol generating article (1) is being used within the aerosol generating device (102), the vapor may be cooled and condensed to form an aerosol for the user to inhale. Accordingly, the length of the portion of the wrapping member (22) extending between the downstream end of the aerosol generating substrate (14) and the inlet end (12) of the aerosol generating article (1) may be selected at the time of manufacture to provide an aerosol having desired characteristics.

[0035] In some embodiments, the wrapping member (22) comprises a porous inner surface (22a) facing toward the aerosol generating substrate (14) and capable of absorbing condensation that may be formed during heat treatment. Alternatively or additionally, the wrapping member (22) may comprise an anti-adhesion outer surface (22b) facing away from the aerosol generating substrate (14) to reduce the risk that the wrapping member (22) may adhere to the surface of the aerosol generating device (102) when heated. The anti-adhesion outer surface (22b) may comprise an anti-adhesion coating on the outer surface (22b) of the wrapping member (22).

[0036] Now, referring to FIG. 4, a second embodiment of an aerosol-generating article (2) is illustrated. The aerosol-generating article (2) is similar to the aerosol-generating article (1) described above with reference to FIG. 1 to 3, and uses the same reference numerals to identify corresponding features.

[0037] The aerosol generating article (2) includes a support member (28) disposed at the mouth-end portion (12) of the aerosol generating article (2) to form a mouth-end portion (34) that can be contacted by the user's lips during use of the aerosol generating article (2) within the aerosol generating device (102). The support member (28) generally comprises a self-supporting material such as cardboard or plastic material and has a rectangular tube shape when viewed in cross-section to accommodate the downstream end of the groove (18) formed within the aerosol generating substrate (14) and the surface (14a). A wrapping member (22) also surrounds the support member (28).

[0038] Now, referring to FIG. 5, an aerosol generating system (100) is illustrated, comprising a first embodiment of an aerosol generating device (102) and an aerosol generating article (1) as described above with reference to FIG. 1 through 3. It will be understood that the aerosol generating device (102) may be used in combination with an alternative aerosol generating article according to the present disclosure, such as a second embodiment of an aerosol generating article (2) described above with reference to FIG. 4.

[0039] The aerosol generating device (102) includes a receiving chamber (106) and a heater (104) disposed within the device body (108) to provide heat to the receiving chamber (106). The heater (104) may be a resistance heater or, alternatively, an induction heater comprising an electromagnetic field generator comprising a susceptor and an induction coil.

[0040] When in use, the user inserts an aerosol generating article (1) into a receiving chamber (106). The aerosol generating device (102) may include a cover (110) and a pivot mounting part (112) that allows the cover (110) to move between a closed position and an open position (not shown) as illustrated in FIG. 5. As will be understood by those skilled in the art, the user must pivot the cover (110) to an open position that allows the aerosol generating article (1) to be inserted into the receiving chamber (106), and then pivot the cover back to a closed position as illustrated in FIG. 5 to maintain the aerosol generating article (1) in its proper position within the receiving chamber (106).

[0041] The aerosol generating device (102) includes a power source (114), such as a rechargeable battery, and a controller (116), all of which are connected to a heater (104). The heater (104) may be operated manually, such as through a user interface such as a button on the aerosol generating device (102), or may be operated automatically in response to the user sucking from the mouthpiece (118) of the aerosol generating device (102). The aerosol generating device (102) includes one or more air inlets (120) that allow air to flow into the aerosol generating article (1) and through a groove (18) formed on the surface of the aerosol generating substrate (14). The direction of air flow is indicated by an arrow in FIG. 5.

[0042] When an aerosol generating article (1) is placed in a receiving chamber (106), power is supplied from the power source (114) to the heater (104) (by manual or automatic operation of the heater (104) as described above), thereby non-combustibly heating the aerosol generating material (14) to release one or more volatile components. The volatile components are mixed into the air flowing through the groove (18) and thus form vapor. As the vapor flows through the groove (18), it cools and condenses to form an aerosol that is inhaled by a user through the mouthpiece (118) of the aerosol generating device (102).

[0043] When the aerosol generating material (14) is depleted and no longer emits enough volatile components to produce an aerosol of acceptable quality, the cover (110) can be pivoted to an open position, the aerosol generating article (1) can be removed from the receiving chamber (106), and a replacement aerosol generating article (1) can be inserted in its place.

[0044] When the aerosol generating device (102) is used with an aerosol generating article having a support member (28), for example, with a second embodiment of the aerosol generating article (2) described above with reference to FIG. 4, the support member (28) may protrude from the open end (106a) of the receiving chamber (106), and accordingly, the user's lips may come into contact with the mouth-end portion (34) of the aerosol generating article (3) formed by the support member (28).

[0045] Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications to these embodiments may be made without departing from the scope of the appended claims. Accordingly, the scope and scope of the claims should not be limited by the exemplary embodiments described above.

[0046] Any combination of the aforementioned features within all possible variations is incorporated into this disclosure unless otherwise specified herein or otherwise clearly contradictory in the context.

[0047] Unless clearly required otherwise by the context, throughout the description and claims of the invention, terms such as “comprising,” “comprising,” etc., should be interpreted in an inclusive sense, that is, “comprising but not limited thereto,” rather than in an exclusive or restrictive sense.

Claims

Claim 1 An aerosol generating article (1, 2) for use with an aerosol generating device (102), comprising: a planar aerosol generating substrate (14); at least one air flow channel (16) extending along the planar aerosol generating substrate (14); and a wrapping member (22) surrounding the planar aerosol generating substrate (14) and the at least one air flow channel (16), wherein the at least one air flow channel (16) comprises two or more parts (16a, 16b) having different cross-sections. Claim 2 In claim 1, the aerosol generating article comprises a distal end (10), an inlet end (12), and a longitudinal axis extending between the inlet end (12) and the distal end (10), and the at least one air flow channel (16) extends in a first direction parallel to the longitudinal axis. Claim 3 An aerosol-generating article according to claim 1 or 2, wherein the two or more parts (16a, 16b) comprise an upstream part (16a) and a downstream part (16b), and the downstream part (16b) has a larger cross-sectional area than the upstream part (16a). Claim 4 An aerosol generating article according to claim 1 or 2, wherein the two or more portions (16a, 16b) comprise an upstream portion (16a) and a downstream portion (16b), the upstream portion (16a) of the at least one air flow channel (16) comprises a groove (18a) formed within the surface (14a) of the planar aerosol generating substrate (14), and the downstream portion (16b) of the at least one air flow channel (16) comprises a slit (19) formed at one end (30) of the planar aerosol generating substrate (14). Claim 5 An aerosol generating article according to claim 1 or 2, wherein the planar aerosol generating substrate (14) has a flat rectangular shape having a pair of main surfaces (14a, 14b), and the wrapping member (22) comprises a pair of rectangular sheets (24, 26) each attached to the pair of main surfaces (14a, 14b). Claim 6 In claim 1 or 2, the aerosol generating article comprises a support member (28) forming an inlet-end portion (34) of the article, and the support member (28) has a tube shape to accommodate the downstream end of the aerosol generating substrate (14) and the at least one air flow channel (16). Claim 7 An aerosol generating article according to claim 1 or 2, wherein the wrapping member (22) has a porous inner surface (22a) facing toward the aerosol generating substrate (14) to absorb condensate, and an anti-adhesion outer surface (22b) facing toward away from the aerosol generating substrate (14). Claim 8 In claim 7, the wrapping member (22) comprises an anti-adhesion coating on the outer surface (22b), an aerosol generating article.

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