Electrically operated aerosol generating system with a tubular aerosol generating article

Abstract

An electrically operated aerosol generating system (1) comprises a main unit (3) and a tubular aerosol generating article (2). The main unit comprises a heating portion (10) at an outer surface of the main unit (3). The heating portion (10) comprises one or more electric heaters (11). The tubular aerosol generating article (2) comprises: a tubular aerosol-forming substrate (4); and an internal channel (5). The internal channel (5) of the tubular aerosol generating article (2) is configured to receive the heating portion (10) of the main unit (3). The one or more electric heaters (11) of the main unit (3) are arranged to heat the tubular aerosol-forming substrate (4) when the tubular aerosol generating article (2) is received on the heating portion (10) of the main unit (3).

Description

Technical Field

[0001] The present invention relates to an electrically operated aerosol generating system. In particular, the present invention relates to an electrically operated aerosol generating system comprising a tubular aerosol generating article and a main unit. Background Art

[0002] Known handheld electrically operated aerosol generating systems typically include an aerosol generating device or main unit, the main unit including a battery, control electronics and an electric heater, the electric heater being used to heat an aerosol generating article specifically designed for use with the aerosol generating device. In some instances, the aerosol generating article includes an aerosol-forming substrate, such as a tobacco rod or a tobacco filter segment. For example, an aerosol-forming substrate of tobacco typically includes one or more volatile compounds that form an aerosol when heated inside the aerosol generating device. When the aerosol generating article is inserted into the aerosol generating device, the heater contained in the aerosol generating device is inserted into or around the aerosol-forming substrate. In some electrically operated aerosol generating systems, the aerosol generating article may include a sealed box containing an aerosol-forming substrate such as loose tobacco.

[0003] There is a need to reduce the size of existing aerosol generating systems. There is a need to provide an aerosol generating system that generates an improved aerosol. Summary of the invention

[0004] According to a first aspect of the present invention, there is provided an electrically operated aerosol generating system, the electrically operated aerosol generating system comprising a main unit and a tubular aerosol generating article. The main unit comprises a heating portion at an outer surface of the main unit. The heating portion comprises one or more electric heaters. The tubular aerosol generating article comprises: a tubular aerosol-forming substrate; and an internal passage. The internal passage of the tubular aerosol generating article is configured to receive the heating portion of the main unit. The one or more electric heaters of the main unit are arranged to heat the tubular aerosol-forming substrate when the tubular aerosol generating article is received on the heating portion of the main unit.

[0005] As used herein, the term 'aerosol-generating article' refers to an article comprising an aerosol-forming substrate which, when heated, releases volatile compounds that can form an aerosol.

[0006] As used herein, the term 'main unit' is used to describe a device that interacts with a tubular aerosol-generating article to generate an aerosol. The main unit typically comprises an electrical energy supply, and associated circuitry for operating one or more heating elements.

[0007] The tubular aerosol generating article is configured to be received on the main unit. Specifically, the internal passage of the tubular aerosol generating article is configured to receive the heating portion of the main unit. The tubular aerosol generating article is typically configured to be removably received on the main unit. In other words, the tubular aerosol generating article is configured to be removable from the main unit without damaging the tubular aerosol generating article or the main unit. The tubular aerosol generating article may be slidably received on the main unit. The internal passage of the tubular aerosol generating article may be configured to slidably receive the heating portion of the main unit.

[0008] As used herein, the terms 'inner' and 'outer' refer to the relative positions of parts of the tubular aerosol-generating article or main unit.

[0009] As used herein, the term 'inner surface' refers to a surface of an article or a main unit that faces the interior of the article or the main unit. For example, the internal passage of the tubular aerosol generating article may be defined by the inner surface. Similarly, the term 'outer surface' refers to a surface of the article or the main unit that faces the outside or outward from the system. For example, the heating portion of the main unit is arranged at the outer surface of the main unit. Therefore, one or more electric heaters are arranged at the outer surface of the main unit and can be visible to the user when the tubular aerosol generating article is not received on the heating portion of the main unit. Specifically, the heating portion of the main unit is arranged at a certain position along the length of the main unit and can be arranged at the outer surface of the main unit, the outer surface being the radially outermost surface of the main unit. In other words, the heating portion is generally arranged at a surface of the main unit that is farther away from the central longitudinal axis of the main unit than any other part of the main unit at a specific position along the length of the main unit. Therefore, when the tubular aerosol generating article is not received on the heating portion of the main unit, the outer surface of the main unit can be visible to the user.

[0010] The aerosol generating system may comprise one or more air flow paths. In use, a user may draw or blow on the aerosol generating system to draw air through the one or more air flow paths of the aerosol generating system. The main unit may comprise one or more air channels. The main unit may comprise one or more air channels but the heating portion. The one or more air channels of the main unit may form part of the one or more air flow paths of the aerosol generating system.

[0011] The one or more air passages of the main unit may provide a chamber in which ambient air and vapour from the heated aerosol-forming substrate may mix, cool and form an aerosol. This may improve the aerosol delivered to a user.

[0012] The one or more air channels of the main unit may enable the length of the tubular aerosol-generating article to be reduced, as the tubular aerosol-generating article may not be required to provide space for cooling and mixing vapour with air. This may enable the overall length of the aerosol generating system to be reduced.

[0013] The main unit may further comprise one or more air inlets. The one or more air inlets may be arranged so that air can enter the one or more air channels of the main unit. The one or more air inlets may be arranged at the heating portion of the main unit. The one or more air inlets may be arranged so that when the tubular aerosol generating article is received on the main unit, the one or more air inlets are covered by the tubular aerosol generating article. The one or more air inlets may be arranged to direct vapour from the heated aerosol-forming substrate into the one or more air channels of the main unit.

[0014] The heating portion of the main unit may include two or more electric heaters spaced apart on the heating portion. The two or more heaters may be spaced apart around the circumference of the heating portion. The two or more heaters may be spaced apart along the length of the heating portion. The one or more air inlets may be arranged in the space between the two or more electric heaters. This may enable vapour from the heated aerosol-forming substrate to be drawn into the one or more air channels of the main unit through the one or more air inlets.

[0015] The main unit may further comprise one or more air outlets. The one or more air outlets may be arranged to enable air to exit the one or more air channels of the main unit. The one or more air outlets may be arranged at a proximal end of the main unit.

[0016] As used herein, the terms 'proximal' and 'distal' are used to describe the relative positions of components or parts of an aerosol generating system, an aerosol generating article or a main unit of the present invention. As used herein, the 'proximal' end of the system is the end on which a user may draw in order to inhale an aerosol generated by the aerosol generating system during use. The 'proximal' end may also be referred to as a mouth end. The 'distal' end of an aerosol generating system is the end opposite the 'proximal' end. The 'distal' end is the end that is farthest from the user during use.

[0017] The one or more air passages of the main unit may extend through the heating portion of the main unit between the one or more air inlets and the one or more air outlets. The one or more air passages of the main unit may extend through the proximal portion of the main unit. The one or more air passages may extend through the heating portion of the main unit. The one or more air passages of the main unit may extend substantially in the direction of the length of the heating portion of the main unit.

[0018] The heating portion of the main unit may be substantially cylindrical. The heating portion of the main unit may be tubular. The tubular heating portion may include an internal passage. The internal passage of the tubular heating portion may be an air passage of the main unit.

[0019] The tubular aerosol generating article may include a portion of the one or more air flow paths that pass through the system. The tubular aerosol generating article may include one or more air inlets. The one or more air inlets may be configured to enable ambient air to be drawn into the tubular aerosol generating article. The one or more air inlets may be configured to direct the drawn ambient air into the tubular aerosol-forming substrate. The one or more air inlets may be arranged at the outer surface of the tubular aerosol generating article. In the case where the tubular aerosol generating article includes one or more outer layers surrounding the tubular aerosol-forming substrate, the one or more air inlets may include one or more eyelets, holes, slits or any suitable apertures in the one or more outer layers. The one or more air inlets may be arranged at the end of the tubular aerosol generating article or arranged towards the end of the tubular aerosol generating article. The one or more air inlets may be arranged at the end face of the tubular aerosol generating article. The one or more air inlets may be arranged at both ends of the tubular aerosol generating article or arranged towards both ends of the tubular aerosol generating article.

[0020] The system may further comprise a mouthpiece.The mouthpiece may be configured such that when a user draws suction on the mouthpiece, the user draws air through the one or more air channels of the main unit.

[0021] In some embodiments, the main unit may comprise the mouthpiece. Where the main unit comprises the mouthpiece, the mouthpiece may comprise the one or more air outlets.

[0022] Where the main unit comprises a mouthpiece, when a user draws or blows on the mouthpiece of the main unit, ambient air may be drawn into the one or more air flow paths of the aerosol generating system through the one or more air inlets of the tubular aerosol-generating article. Air may be drawn into the inner surface of the internal passage through the tubular aerosol-forming substrate and into the one or more air channels of the main unit through the one or more air inlets of the main unit arranged at the heating portion. Air may be drawn into the mouthpiece of the main unit through the one or more air channels of the main unit and out of the mouthpiece to be inhaled by the user.

[0023] In use, when the main unit is turned on, the circuit of the main unit can detect that the user draws on the mouthpiece of the main unit and supplies power to one or more of the electric heaters. The one or more powered or activated electric heaters can heat at least a portion of the tubular aerosol-forming substrate of the tubular aerosol-generating article. The volatile components of the heated aerosol-forming substrate can be vaporized, and the vapor can be entrained in the air drawn through the tubular aerosol-forming substrate. Air and vapor can be drawn out of the tubular aerosol-forming substrate at the inner surface of the internal passage and into the one or more air channels of the main unit through the one or more air inlets of the main unit. As the vapor is drawn through the one or more air channels of the main unit, the vapor can cool to form an aerosol. The aerosol can be drawn into the mouthpiece of the main unit and drawn out of the mouthpiece through the one or more air outlets to be delivered to the user for inhalation.

[0024] In other embodiments, the tubular aerosol-generating article may include the mouthpiece. Where the tubular aerosol-generating article includes the mouthpiece, when the tubular aerosol-generating article is received on the heating portion of the main unit, the one or more air outlets of the main unit may be directed towards the mouthpiece of the tubular aerosol-generating article. The one or more air outlets may be arranged to face the mouthpiece of the aerosol-generating article when the aerosol-generating article is received on the main unit.

[0025] Where the tubular aerosol generating article comprises a mouthpiece, the tubular aerosol generating article may further comprise a barrier between the aerosol forming substrate and the mouthpiece. The barrier may be substantially impermeable to gases, such as air and vapour generated by the heated aerosol forming substrate. The barrier may substantially inhibit or prevent air and vapour generated by the heated aerosol forming substrate from being drawn directly through the aerosol forming substrate and into the mouthpiece without passing through the one or more air passages of the main unit. This may improve the cooling of the vapour generated by the heated aerosol forming substrate. This may improve the aerosol generated by the aerosol generating system.

[0026] Where the tubular aerosol generating article comprises a mouthpiece, when a user draws or blows on the mouthpiece, ambient air may be drawn into the one or more air flow paths of the aerosol generating system through the one or more air inlets of the tubular aerosol generating article. Air may be drawn into the inner surface of the internal passage through the tubular aerosol-forming substrate and into the one or more air passages of the main unit through the one or more air inlets of the main unit. Air may be drawn through the one or more air passages of the main unit and leave the main unit through the one or more air outlets. Air may be drawn into the mouthpiece of the tubular aerosol generating article and leave the mouthpiece to the user for inhalation.

[0027] In use, when the main unit is turned on, the circuit of the main unit can detect that the user draws on the mouthpiece of the tubular aerosol generating article, and supply power to one or more of the electric heaters. The one or more powered or activated electric heaters can heat at least a portion of the tubular aerosol-forming substrate of the tubular aerosol generating article. The volatile components of the heated aerosol-forming substrate can be vaporized, and the vapor can be entrained in the air drawn through the tubular aerosol-forming substrate. Air and vapor can be drawn out of the tubular aerosol-forming substrate at the inner surface of the internal passage and into the one or more air channels of the main unit through the one or more air inlets of the main unit. As the vapor is drawn through the one or more air channels of the main unit, the vapor can cool to form an aerosol. The aerosol can be drawn out of the one or more air channels of the main unit into the mouthpiece of the tubular aerosol-forming article through the one or more air outlets of the main unit, and leave the mouthpiece to be delivered to the user for inhalation.

[0028] The main unit may include one or more additional air inlets. The one or more additional air inlets may be arranged adjacent to the heating portion. Thus, when the tubular aerosol generating article is received on the heating portion, the one or more air inlets may not be covered by the tubular aerosol generating article. The one or more additional inlets may enable ambient air to be drawn directly into the one or more air channels of the main unit. This may facilitate cooling of the vapour drawn from the heated aerosol-forming substrate into the one or more air channels. This may facilitate aerosol formation.

[0029] Ambient air can be drawn into the one or more air channels of the main unit through the one or more other air inlets at a relatively faster rate than the speed at which air and vapor are drawn into the one or more air channels through the one or more air inlets arranged at the heating portion and covered by the tubular aerosol generating article. The relatively fast air from the one or more other air inlets can cause air and vapor to be drawn through the one or more air inlets arranged at the heating portion at a faster rate. This can increase the amount of aerosol drawn from the tubular aerosol generating article and delivered to the user in one puff on the aerosol generating system. This can improve the user's experience.

[0030] The one or more additional air inlets may be arranged proximal to the heating portion. The one or more additional air inlets may be arranged between the heating portion and the proximal end of the main unit. The one or more additional air inlets may be arranged distal to the heating portion. The one or more additional air inlets may be arranged between the heating portion and the distal end of the main unit. The one or more additional air inlets may be arranged both proximal and distal to the heating portion. The one or more additional air inlets may be arranged at either side of the heating portion.

[0031] The aerosol generating system of the present invention comprises a tubular aerosol generating article, which comprises a tubular aerosol forming substrate. The tubular configuration of the aerosol generating article and the aerosol forming substrate can promote improved conductive heat transfer from one or more electric heaters of the main unit to the aerosol forming substrate. Compared with a conventional body or filter segment having an aerosol forming substrate of equal size without internal channels, the tubular aerosol forming substrate can have a larger surface area to volume ratio. The tubular shape of the aerosol forming substrate can reduce the maximum thickness of the aerosol forming substrate. This can promote the propagation of heat through the aerosol forming substrate. This can promote aerosol generation.

[0032] The tubular aerosol generating article may have any suitable shape and size. The tubular aerosol generating article may be substantially cylindrical. The tubular aerosol generating article may be substantially elongated. The tubular aerosol generating article may include a cylindrical open hollow tube of an aerosol-forming substrate. The tubular aerosol generating article may have any suitable cross-section. For example, the cross-section of the tubular aerosol generating article may be substantially circular, cylindrical, square or rectangular.

[0033] The tubular aerosol-generating article may have a width of between about 5 mm and about 20 mm, between about 5 mm and about 12 mm, or about 8 mm.

[0034] The tubular aerosol-generating article may have a length of between about 10 mm and about 100 mm, or between about 10 mm and about 50 mm, between about 30 mm and about 60 mm, or about 45 mm.

[0035] The length of the tubular aerosol-generating article may be substantially similar to the length of the heating portion of the main unit. The length of the tubular aerosol-generating article may be equal to or greater than the length of the heating portion of the main unit, such that when the tubular aerosol-generating article is received on the heating portion of the main unit, the tubular aerosol-generating article covers the one or more electric heaters.

[0036] As used herein, the term 'width' is used to describe the maximum dimension in the transverse direction of an aerosol generating system, a tubular aerosol generating article and a main unit. When used herein, the term 'length' is used to describe the maximum dimension in the longitudinal direction of an aerosol generating system, a tubular aerosol generating article and a main unit.

[0037] As used herein, the term 'longitudinal' is used to describe the direction between the proximal or mouth end and the distal end of the aerosol generating system, and the term 'transverse' is used to describe the direction perpendicular to the longitudinal direction.

[0038] The tubular aerosol-generating article comprises an internal passage. As used herein, the term 'inner passage' refers to a passage extending through at least part of the article. The internal passage may be surrounded by an annular body and may extend substantially along the longitudinal axis of the article.

[0039] The internal passage of the tubular aerosol-generating article may have any suitable shape, and may have any suitable cross-section. For example, the cross-section of the internal passage may be substantially circular, cylindrical, square or rectangular.

[0040] The internal channel may be arranged substantially centrally in the tubular aerosol-generating article. Thus, the thickness of the tubular aerosol-forming substrate may be substantially uniform around the circumference of the tubular aerosol-generating article. This may achieve uniform heating of the tubular aerosol-forming substrate around the circumference of the tubular aerosol-generating article.

[0041] The internal channel may have a width of between about 2 mm and about 18 mm, between about 2 mm and about 10 mm, or about 4 mm.

[0042] The width of the inner channel of the tubular aerosol-generating article may be substantially similar to the width of the heating portion of the main unit. Thus, when the tubular aerosol-generating article is received on the heating portion, the inner surface of the inner channel may contact or abut the outer surface of the heating portion of the main unit. The width of the inner channel of the tubular aerosol-generating article may be less than the width of the heating portion of the main unit, so that the tubular aerosol-generating article is received on the heating portion by a friction or interference fit.

[0043] Tubular aerosol formation substrate can be a solid aerosol formation substrate. Tubular aerosol formation substrate can be a solid aerosol formation substrate at room temperature. Tubular aerosol formation substrate can include tobacco-containing material, and the tobacco-containing material contains volatile tobacco flavor compounds released from the substrate when heated. Tubular aerosol formation substrate can include non-tobacco material. Tubular aerosol formation substrate can include tobacco-containing material and non-tobacco material.

[0044] The solid aerosol-forming substrate may comprise, for example, one or more of a powder, granules, pellets, shreds, tow, ribbon or sheet containing one or more of herb leaves, tobacco leaves, tobacco ribs, expanded tobacco and homogenised tobacco.

[0045] The solid aerosol-forming substrate may contain tobacco or non-tobacco volatile flavour compounds which are released upon heating of the solid aerosol-forming substrate.

[0046] The solid aerosol-forming substrate may be provided on or embedded in a thermally stable carrier. The carrier may be in the form of a powder, granules, pellets, fragments, tows, strips or sheets. The solid aerosol-forming substrate may be deposited over the entire surface of the carrier. The solid aerosol-forming substrate may be deposited in a pattern to provide non-uniform fragrance delivery during use.

[0047] The tubular aerosol-forming substrate may include a collection textured sheet of homogenized tobacco material. The tubular aerosol-forming substrate may include a collection textured sheet of homogenized tobacco material, the sheet including one or more of a plurality of spaced-apart notches, protrusions, and perforations. The use of a textured sheet of homogenized tobacco material may promote the collection of homogenized tobacco material sheets to form a tubular aerosol-forming substrate.

[0048] As used herein, the term 'sheet' refers to a laminated element whose width and length are significantly greater than its thickness. As used herein, the term 'aggregation' is used to describe that a sheet is substantially transverse to the longitudinal axis of a tubular aerosol generating article and is wound, folded or otherwise compressed or contracted. As used herein, the term 'texturized sheet' refers to a sheet that has been curled, embossed, recessed, perforated or otherwise deformed. As used herein, the term 'homogenized tobacco material' refers to a material formed by agglomerated granular tobacco.

[0049] Tubular aerosol formation substrate can include the gathered curled sheet of homogenized tobacco material. As used herein, the term 'curled sheet' refers to a sheet with a plurality of substantially parallel ridges or corrugations. Preferably, substantially parallel ridges or corrugations extend along or parallel to the longitudinal axis of the tubular aerosol generating article. This can promote the curled sheet of homogenized tobacco material to gather to form the tubular aerosol generating article. However, it should be understood that the curled sheet of the homogenized tobacco material included in the tubular aerosol generating article can alternatively or additionally have a plurality of substantially parallel ridges or corrugations, and the ridges or corrugations are arranged at an acute angle or an obtuse angle relative to the longitudinal axis of the tubular aerosol generating article.

[0050] The tubular aerosol-forming substrate may include one or more aerosol forming agents. The tubular aerosol-forming substrate may include a single aerosol forming agent. The tubular aerosol-forming substrate may include two or more aerosol forming agents. The tubular aerosol-forming substrate may have an aerosol forming agent content greater than about 5% by dry weight. The aerosol-forming substrate may have an aerosol forming agent content between about 5% and about 30% by dry weight. The tubular aerosol-forming substrate may have an aerosol forming agent content of about 20% by dry weight.

[0051] As used herein, the term 'aerosol former' refers to any suitable known compound or mixture of compounds that promotes the formation of an aerosol in use and is substantially resistant to thermal degradation at the operating temperature of the tubular aerosol-generating article. Suitable aerosol formers include, but are not limited to: polyols such as propylene glycol, triethylene glycol, 1,3-butylene glycol and glycerol; esters of polyols such as mono-, di- or tri-acetates of glycerol; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0052] The tubular aerosol-generating article may comprise one or more layers surrounding a tubular aerosol-forming substrate. For example, a tubular aerosol-generating article may comprise one or more wrappers wrapped around a tubular aerosol-forming substrate.

[0053] The one or more layers may include a thermally insulating material. Wrapping a layer of thermally insulating material around the tubular aerosol-forming substrate may facilitate retaining heat from one or more electrical conductors within the tubular aerosol-generating article. This may improve the conductive heat transfer efficiency of the aerosol-generating system. As used herein, the term 'thermally insulating material' is used to describe a material having a bulk thermal conductivity of less than about 50 milliwatts per meter Kelvin (mW / (m·K)) at 23°C and having a relative humidity of 50% as measured using a modified transient plane source (MTPS) method. The thermally insulating material may also have a bulk thermal diffusivity of less than or equal to about 0.01 square centimeters per second (cm2 / s) as measured using a laser flash method.

[0054] The one or more layers may comprise a material that is substantially impermeable to gases, such as air. Surrounding the tubular aerosol-forming substrate with a layer of material that is substantially impermeable to gases may facilitate retaining vapour generated by the tubular aerosol-generating article within the aerosol-generating system and may facilitate directing the vapour towards a user.

[0055] The one or more layers may comprise any suitable material. The one or more layers may comprise a paper-like material. The one or more layers may comprise cigarette paper. The one or more layers may comprise tipping paper.

[0056] The inner passage of the tubular aerosol-forming substrate may be the inner passage of the tubular aerosol-generating article. Thus, when the tubular aerosol-generating article is received on the heating portion of the main unit, the one or more electric heaters of the main unit may be adjacent to or in contact with the tubular aerosol-forming substrate. However, in some embodiments, the tubular aerosol-generating article may include one or more layers surrounding the inner surface of the inner passage of the tubular aerosol-forming substrate. The one or more inner layers may include substantially the same material as described above with respect to the one or more outer layers.

[0057] At least one end of the internal passage of the tubular aerosol-generating article may be open and configured to receive the heating portion of the main unit.The internal passage of the tubular aerosol-generating article may comprise two open ends configured to receive the heating portion of the main unit.

[0058] The tubular aerosol-generating article may comprise additional components.

[0059] The tubular aerosol-generating article may include a mouthpiece. The mouthpiece may be arranged at a proximal end of the tubular aerosol-generating article. Where the tubular aerosol-generating article includes a mouthpiece, the tubular aerosol-generating article may include a proximal end including the mouthpiece and a distal end including an open end of an internal passage, the open end being configured to receive a heating portion of the main unit.

[0060] The mouthpiece may be a single segment or single component mouthpiece. The mouthpiece may be a multi-segment or multi-component mouthpiece. The mouthpiece may include a material having a low or very low filtration efficiency. The mouthpiece may include a filter comprising one or more segments comprising any suitable filter material. Suitable filter materials are known in the art and include, but are not limited to, cellulose acetate and paper. The mouthpiece may include one or more segments comprising absorbents, adsorbents, flavorants and other aerosol modifiers and additives or combinations thereof. The mouthpiece may have a width substantially equal to the width of the tubular aerosol generating article.

[0061] Where the tubular aerosol-generating article comprises a mouthpiece, the tubular aerosol-generating article may be configured such that the main unit terminates inside the tubular aerosol-generating article. When the tubular aerosol-generating article is received on the heating portion of the main unit, the proximal end of the main unit may abut or contact the mouthpiece. When the tubular aerosol-generating article is received on the heating portion of the main unit, the proximal end of the main unit may be spaced from the mouthpiece.

[0062] The tubular aerosol-generating article may comprise additional components, including at least one of an aerosol-cooling element and a transfer element arranged between the tubular aerosol-forming substrate and the mouthpiece.

[0063] The tubular aerosol-generating article may comprise a cooling element arranged between the tubular aerosol-forming substrate and the mouthpiece. The cooling element may comprise a plurality of longitudinally extending passages. The cooling element may comprise a sheet of aggregate material selected from the group consisting of: metal foil, polymeric material, and substantially non-porous paper or cardboard.

[0064] The tubular aerosol-generating article may include a transfer element or a spacer element arranged between the tubular aerosol-forming substrate and the mouthpiece. The transfer element may facilitate cooling the aerosol generated by the heated tubular aerosol-forming substrate. The transfer element may also facilitate adjusting the length of the aerosol-generating system to a desired value, for example, to a length similar to the length of a conventional cigarette. The transfer element may include at least one open tubular hollow body formed of one or more suitable materials, which are substantially thermally stable at the temperature of the aerosol generated by heat transfer from the combustible heat source to the aerosol-forming substrate. Suitable materials are known in the art and include, but are not limited to, paper, cardboard, plastics (such as cellulose acetate), ceramics, and combinations thereof.

[0065] Where the tubular aerosol-generating article comprises one or more layers or wrappers surrounding the tubular aerosol-forming substrate, the one or more layers or wrappers may also surround additional components, such as any of the mouthpiece, cooling element and transfer element.

[0066] According to a second aspect of the present invention, there is provided a tubular aerosol generating article for use in an electrically operated aerosol generating system according to the first aspect of the present invention. The tubular aerosol generating article comprises: a tubular aerosol-forming substrate; an internal passage configured to receive a heating portion of a main unit; a mouthpiece; and a substantially air-impermeable barrier arranged between the tubular aerosol-forming substrate and the mouthpiece.

[0067] The aerosol generating system of the present invention also includes a main unit. The main unit may include a housing. The housing may include any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composite materials containing one or more of those materials, or thermoplastic materials suitable for food or medical applications, such as polypropylene, polyetheretherketone (PEEK) and polyethylene. The material may be light and not brittle. The main unit may include a proximal portion and a distal portion. The proximal portion and the distal portion of the main unit may have different shapes and sizes.

[0068] The proximal portion of the main unit may include a heating portion at an outer surface. As used herein, the term 'heating portion' is used to describe a portion of the main unit that includes one or more electrical heaters. The extent of the heating portion is determined by the extent of the heater on the outer surface of the main unit.

[0069] The heating portion may have any suitable shape and size. The shape and size of the heating portion may be substantially similar to the shape and size of the interior passage of the tubular aerosol-generating article. The shape and size of the heating portion may be complementary to the shape of the interior passage of the tubular aerosol-generating article.

[0070] The heating portion may be substantially cylindrical. The heating portion may be substantially elongated. The heating portion may have any suitable cross-section. For example, the cross-section of the heating portion may be substantially circular, oval, square or rectangular. The shape of the heating portion may be substantially similar to the shape of the interior passage of the tubular aerosol generating article. The shape of the heating portion may be complementary to the shape of the interior passage of the tubular aerosol generating article.

[0071] In the case where the cross-section of the heating portion and the tubular aerosol-generating article is not circularly symmetrical, the tubular aerosol-generating article may be received on the heating portion in a specific rotational orientation. In the case where the cross-section of the heating portion and the tubular aerosol-generating article is circularly symmetrical, this may not require maintaining a specific rotational orientation of the tubular aerosol-generating article so that the tubular aerosol-generating article is received by the heating portion.

[0072] The heating portion may have a width of between about 2 mm and about 18 mm, between about 2 mm and about 10 mm, or about 4 mm. The heating portion may have a length of between about 10 mm and about 100 mm, between about 10 mm and about 50 mm, or about 45 mm.

[0073] The main unit may include any suitable number of electric heaters. The main unit may include one electric heater. The main unit may include two or more electric heaters. The main unit may include two, three, four, five, six, seven, eight or nine electric heaters. Where the main unit includes two or more electric heaters, the two or more electric heaters may be spaced around the circumference of the heating portion. The two or more electric heaters may be spaced along the length of the heating portion. Where the heating portion includes three or more electric heaters, the three or more electric heaters may be spaced evenly across the heating portion. The three or more electric heaters may be spaced unevenly across the heating portion.

[0074] The one or more electric heaters may have any suitable shape. The one or more electric heaters may be elongated. The one or more electric heaters may extend substantially the length of the heating portion. The one or more electric heaters may be substantially annular. The one or more electric heaters may include one or more annular rings. The one or more rings may substantially surround a portion of the outer surface of the main unit. The one or more rings may substantially surround a portion of the proximal end of the heating portion. The one or more rings may substantially surround a portion of the distal end of the heating portion.

[0075] The one or more electric heaters may include a resistive material. Suitable resistive materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made of ceramic materials and metal materials. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, alloys containing nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, and iron, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, and iron-manganese-aluminum-based alloys. In the composite material, the resistive material may be optionally embedded in, encapsulated by, or coated with an insulating material or vice versa, depending on the kinetics of energy transfer and the desired external physicochemical properties. Examples of suitable composite heater elements are disclosed in US-A-5 498 855 , WO-A-03 / 095688 and US-A-5 514 630 .

[0076] The distal portion of the main unit may have any suitable shape and size.

[0077] The distal portion may be substantially cylindrical. The distal portion may be substantially elongated. The distal portion may have any suitable cross-section. For example, the cross-section of the distal portion may be substantially circular, oval, square or rectangular. The distal portion may be configured to be gripped by a user during use of the aerosol generating system.

[0078] The width of the distal portion of the main unit may be greater than the width of the proximal portion of the main unit. This may provide a larger space in the distal portion than in the proximal portion and may enable the distal portion to accommodate a power source and circuitry.

[0079] The width of the distal portion of the main unit may be similar to the width of the tubular aerosol-generating article. Thus, when the tubular aerosol-generating article is received on the heating portion of the main unit, the aerosol-generating system may form a substantially cylindrical unit having a substantially uniform width along its length. This may enable the aerosol-generating system to resemble a conventional smoking article, such as a cigar or cigarette.

[0080] The distal portion may have a width of between about 5 mm and about 20 mm, between about 5 mm and about 12 mm, or about 8 mm. The distal portion may have a length of between about 10 mm and about 100 mm, between about 10 mm and about 50 mm, or about 45 mm.

[0081] The main unit may include a shoulder between the heating portion and the distal portion of the main unit. The shoulder may connect the outer surface of the proximal portion of the main unit to the outer surface of the distal portion of the main unit. The shoulder may include an angled, inclined or chamfered surface that engages the proximal portion of the main unit with the distal portion of the main unit. The shoulder may include a wall extending substantially radially outward from the outer surface of the proximal portion of the main unit to the outer surface of the distal portion of the main unit.

[0082] The proximal portion of the main unit may be configured such that when the tubular aerosol-generating article is received on the heating portion, the distal end of the tubular aerosol-generating article may abut or contact the shoulder. Thus, the shoulder may act as a stop to inhibit movement of the tubular aerosol-generating article beyond the heating portion in a distal direction relative to the main unit. This may facilitate positioning of the tubular aerosol-generating article on the heating portion of the main unit in a desired position along the length of the main unit.

[0083] The main unit may further comprise a distal stop. The distal stop may be arranged distal to the heating portion of the main unit. The distal stop may be configured to engage with the distal end of the tubular aerosol generating article when the tubular aerosol generating article is received on the heating portion. In the case where the main unit comprises a shoulder between the proximal portion and the distal portion, the distal stop may be arranged between the heating portion and the shoulder.

[0084] The main unit may include one or more power sources. The one or more power sources may be arranged in the distal portion of the main unit. The one or more power sources may include a battery. The battery may be a lithium-based battery, for example, a lithium-cobalt, lithium iron phosphate, lithium titanate or lithium-polymer battery. The battery may be a nickel-metal hydride battery or a nickel-cadmium battery. The one or more power sources may include other forms of charge storage devices, such as capacitors. The one or more power sources may need to be recharged and may be configured for many charge and discharge cycles. The one or more power sources may have a capacity that allows storage of enough energy for one or more user experiences; for example, one or more power sources may have enough capacity to allow continuous generation of aerosol within a cycle of about six minutes (corresponding to the typical time spent smoking a conventional cigarette) or within a cycle of multiples of six minutes. In another example, the one or more power sources may have enough capacity to allow discrete activation of a predetermined number of puffs or heating devices and actuators.

[0085] The main unit may include a circuit configured to control the supply of power from one or more power sources to one or more electric heaters. In the case where the main unit includes two or more electric heaters, the circuit may be configured to supply power to all electric heaters simultaneously. In the case where the main unit includes two or more electric heaters, the circuit may be configured to supply power to each electric heater individually. The circuit may be configured to selectively supply power to each electric heater. The circuit may be configured to supply power to the electric heaters in sequence. The circuit may be configured to supply power to selected electric heaters in the electric heaters in a predetermined order. For example, the circuit may be configured to supply power to one heater per puff. In another example, the circuit may be configured to supply power to a first heater within a predetermined time period, and then to a second heater within a predetermined time period. This can achieve selective heating of a portion of an aerosol-forming substrate. This can achieve changes in the aerosol supplied to the user during the puff. This can enable portions of the aerosol-forming substrate to be heated to different temperatures. This can enable the aerosol-generating system to retain an unheated portion of the aerosol-forming substrate for each puff experienced by the user.

[0086] The main unit may include a user input, such as a switch or button. This may enable a user to switch the main unit on and off. The switch or button may activate the aerosol generating device. The switch or button may initiate aerosol generation. The switch or button may prepare the circuit to wait for input from the puff detector.

[0087] The circuit may include a sensor or puff detector to detect air flow through the aerosol generating system indicative of a user taking a puff. The circuit may be configured to provide supply power to the one or more electric heaters when the sensor senses the user taking a puff.

[0088] The main unit may include a mouthpiece. The mouthpiece may be arranged at a proximal end of the main unit. The mouthpiece may be configured to allow a user to suck, blow or draw on the mouthpiece to draw air and vapour through one or more air flow paths of the aerosol generating system.

[0089] The mouthpiece may comprise a retaining device according to the invention.For example, the mouthpiece may comprise one or more of the one or more protrusions.In another example, the mouthpiece may comprise a second magnetic material.

[0090] The mouthpiece may be removably stowed on the main unit. Where the mouthpiece is removable from the main unit, the mouthpiece may include a cover arranged to overlap the tubular aerosol-generating article when the tubular aerosol-generating article is stowed on the heating portion of the main unit. The cover may further facilitate retaining heat around the tubular aerosol-generating article and may inhibit vapor from exiting the tubular aerosol-generating article through an outer surface of the tubular aerosol-generating article.

[0091] According to a third aspect of the invention, there is provided a main unit for an electrically operated aerosol generating system according to the first aspect of the invention, the main unit comprising: a heating portion at an outer surface of the main unit, the heating portion comprising one or more electric heaters.

[0092] The main unit may further include one or more air passages through the heating portion and one or more air inlets arranged at the heating portion. The main unit may further include a mouthpiece configured such that when a user draws suction on the mouthpiece, the user draws air through the one or more air passages of the main unit.

[0093] When the electrically operated aerosol generating system is assembled for use and the tubular aerosol generating article is received on the heating portion of the main unit, the aerosol generating system may have a substantially cylindrical shape. The aerosol generating system may have an overall length of between about 70 mm and about 200 mm, or between about 70 mm and about 150 mm, or about 120 mm. The aerosol generating system may have a width of between about 5 mm and about 20 mm, between about 5 mm and about 10 mm, or about 8 mm.

[0094] The main unit may be configured to be durable. The main unit may be configured to be reusable.

[0095] The tubular aerosol-generating article may be configured as a disposable component. The tubular aerosol-generating article may be configured to be discarded after a single user experience. In contrast, the main unit may be configured to be durable and reusable. The main unit may include relatively expensive and durable components of an aerosol-generating system, such as a power source, a heater, and circuitry.

[0096] The tubular aerosol-generating article may be manufactured, stored and sold separately from the main unit. Each tubular aerosol-generating article may be packaged individually. Similar to conventional smoking articles such as cigarettes, a plurality of the tubular aerosol-generating articles may be packaged together for sale.

[0097] The aerosol generating system may be an electrically operated smoking system.The overall dimensions of the aerosol generating system may be similar to a conventional smoking article, such as a cigarette, cigar, cigarillo or any other such smoking article. BRIEF DESCRIPTION OF THE DRAWINGS

[0098] Embodiments according to the present invention will now be described in detail by way of example only with reference to the accompanying drawings, in which:

[0099] Figure 1 is a schematic illustration of an electrically operated aerosol generating system according to a first embodiment of the present invention;

[0100] Figure 2 yes Figure 1 Schematic illustration of an electrically operated aerosol generating system of , showing a tubular aerosol generating article fully stowed on a main unit;

[0101] Figure 3 yes Figure 1 Schematic illustration of an electrically operated aerosol generating system of , showing air flow through the aerosol generating system when the tubular aerosol generating article is fully stowed on the main unit and the user draws on the mouthpiece;

[0102] Figure 4 is a schematic illustration of an electrically operated aerosol generating system according to a second embodiment of the present invention;

[0103] Figure 5 is a schematic illustration of the main units for an electrically operated aerosol generating system according to a third aspect of the invention;

[0104] Figure 6 is a schematic illustration of a tubular aerosol generating article for use in an electrically operated aerosol generating system according to a fourth aspect of the invention;

[0105] Figure 7 yes Figure 6 Schematic illustration of a tubular aerosol generating article;

[0106] Figure 8 It is stored on the main unit Figure 6 Schematic illustration of a tubular aerosol generating article;

[0107] Fig. 9 is a schematic illustration of a tubular aerosol generating article for use in an electrically operated aerosol generating system according to a fifth aspect of the invention;

[0108] Fig.10 It is stored on the main unit Fig. 9 Schematic illustration of a tubular aerosol generating article;

[0109] Fig.11is a schematic illustration of a tubular aerosol-generating article for use in an electrically-operated aerosol-generating system according to the sixth aspect of the invention. DETAILED DESCRIPTION

[0110] Figures 1 to 3 An electrically operated aerosol generating system according to a first aspect of the invention is shown in .The electrically operated aerosol generating system 1 comprises a tubular aerosol generating article 2 and a main unit 3 .

[0111] The tubular aerosol-generating article 2 comprises a cylindrical open hollow tube of an aerosol-forming substrate 4. An internal channel 5 extends centrally through the tubular aerosol-forming substrate 4 and extends the length of the tubular aerosol-forming substrate 4, such that both ends of the internal channel 5 are open. The two open ends of the internal channel 5 are configured to receive the proximal portion 7 of the main unit 3.

[0112] The tubular body of the aerosol-forming substrate 4 comprises one or more gathered tobacco sheets surrounded by an outer wrapper (not shown) which covers the cylindrical outer surface of the tubular body of the aerosol-forming substrate 4. The outer wrapper is formed of a material that is substantially impermeable to gas, such that the outer wrapper substantially prevents ambient air from being drawn into the tubular aerosol-generating article 2 through the cylindrical outer surface. The outer wrapper also substantially prevents vapour from the heated aerosol-forming substrate 4 from leaving the tubular aerosol-generating article 2 via the cylindrical outer surface.

[0113] The outer wrapper does not extend over the annular end face 6 of the tubular aerosol-forming substrate 4, such that the annular end face 6 of the tubular aerosol-forming substrate 4 is exposed to the surrounding air. Ambient air may be drawn into the tubular aerosol-generating article 2 through either annular end face 6. Similarly, the open end of the internal passage 5 is not covered by the outer wrapper, such that the proximal portion 7 of the main unit 3 may be inserted into either end of the internal passage 5.

[0114] The main unit 3 comprises a substantially cylindrical hollow housing formed of a rigid thermally insulating material, such as PEEK. The main unit 3 comprises a proximal portion 7 and a distal portion 8 separated by a shoulder 9.

[0115] The proximal portion 7 comprises a heating portion 10. The heating portion 10 extends over a portion of the outer surface of the proximal portion 7. The heating portion 10 comprises seven identical electric heaters 11. The seven electric heaters 11 are evenly spaced around the circumference of the heating portion 10. Each of the electric heaters 11 is elongated and arranged so that its length extends in a direction along the longitudinal axis A of the main unit 3. The length of each electric heater 11 is substantially similar to the length of the tubular aerosol generating article 2. Thus, when the tubular aerosol generating article 2 is received on the heating portion 10 of the main unit 3, the tubular aerosol generating article 2 overlaps and covers the electric heater 11 along its entire length. This allows a substantial portion of the heat generated by the electric heater 11 to be transferred to the aerosol-forming substrate 4 during use of the aerosol generating system, rather than to the surrounding air.

[0116] The heating portion 10 of the main unit 3 has a cylindrical cross-section that is substantially similar to the cross-section of the internal passage 5 of the tubular aerosol generating article 2. The width of the heating portion 10 is slightly greater than the width of the internal passage 5. Thus, the heating portion 10 of the main unit 3 can be inserted into the internal passage 5 of the tubular aerosol generating article by interference or friction fit. When the tubular aerosol generating article 2 is received on the heating portion 10, the interference or friction fit ensures contact between the electric heater 11 at the outer surface of the heating portion 10 of the main unit 3 and at the inner surface of the internal passage 5 of the tubular aerosol generating article 2. This contact promotes heat transfer between the electric heater 11 and the tubular aerosol-forming substrate 4. The interference or friction fit also provides some resistance to the movement of the tubular aerosol generating article 2 along the longitudinal axis A of the main unit 3. Therefore, the interference or friction fit helps to keep the tubular aerosol generating article 2 on the heating portion 10 of the main unit 3.

[0117] The proximal portion 7 of the main unit 3 further comprises a tapered mouthpiece 12 at the proximal end of the main unit 3 for a user to draw on to receive the aerosol generated by the aerosol generating system.

[0118] The distal portion 8 of the main unit 3 has a cylindrical cross-section that is substantially similar to the cylindrical cross-section of the tubular aerosol-generating article 2. The width of the distal portion 8 is substantially similar to the width of the tubular aerosol-generating article 2. Thus, when the tubular aerosol-generating article 2 is received on the heating portion 10 of the main unit 3, the electrically-operated aerosol-generating system 1 forms a substantially cylindrical unit having a uniform width or diameter that may be similar to a conventional cigarette or cigar, such as Figure 2 as shown in .

[0119] The distal portion 8 of the main unit 3 houses a battery (not shown) and an electric circuit (not shown) inside the hollow housing. The battery is arranged and configured to supply power to the electric heater 11 of the heating portion 10. The electric circuit is configured to control the supply of power from the battery to the electric heater 11. The electric circuit includes a sensor for detecting a user's puff on the mouthpiece 12.

[0120] The circuit is configured to supply power to the electric heaters 11 simultaneously or individually in a predetermined order. In other words, the circuit is configured to supply power to the electric heaters 11 in different heating modes, such as the simultaneous heating mode and the sequential heating mode. For example, in the simultaneous heating mode, the circuit is configured to supply power to all the electric heaters 11 when a spray is detected. In another example, in the sequential mode, the circuit is configured to supply power to a first heater in the electric heaters 11 when a first spray is detected, to supply power to a second heater in the electric heaters 11 when a second spray is detected, and then to sequentially supply power to individual heaters in the remaining electric heaters 11 for each detected spray until all heaters have been activated.

[0121] A button 13 is also provided on the distal portion 8 of the main unit 3. The circuit is configured to switch between heating modes when the button 13 is pressed. Successive pressing of the button 13 switches the heating mode of the circuit between sequential heating mode, simultaneous heating mode and no power mode (off).

[0122] The width of the distal portion 8 of the main unit 3 is greater than the width of the proximal portion 7. Thus, the main unit 3 comprises a shoulder 9 separating the proximal portion 7 from the distal portion 8. The shoulder 9 comprises a wall extending substantially radially outwardly from the distal end of the proximal portion 7 to the proximal end of the distal portion 8.

[0123] A distal stopper (not shown) is arranged on the proximal portion 7 of the main unit 3 between the heating portion 10 and the shoulder 9. The distal stopper is configured to engage with the distal end of the tubular aerosol-generating article 2 when the tubular aerosol-generating article 2 is fully received on the heating portion 10. The distal stopper substantially prevents the tubular aerosol-generating article 2 from moving beyond the heating portion 10 in a distal direction towards the distal portion 8.

[0124] It will be appreciated that in some embodiments, the shoulder 9 may act as a distal stop for the tubular aerosol-generating article 2. In these embodiments, the shoulder 9 may abut or contact the distal end of the tubular aerosol-generating article 2 when the tubular aerosol-generating article 2 is fully received on the heating portion 10.

[0125] like Figure 3As shown in FIG. 1 , the air passage 14 extends through the proximal portion 7 of the main unit 3. A plurality of air inlets 16 are arranged in the outer surface of the heating portion 10 between the electric heaters 11, and an air outlet 17 is provided in the mouthpiece 12. The plurality of air inlets 16 and the air outlet 17 are fluidly connected to the air passage 14 to enable air to be drawn through the air passage 14 when the user draws on the mouthpiece 12.

[0126] To assemble the electrically operated aerosol generating system 1 for use, the user aligns the main unit 3 with the internal passages of the tubular aerosol generating article 2 along a common longitudinal axis A, with either end of the tubular aerosol generating article 2 facing the proximal end of the main unit 3. The user moves the tubular aerosol generating article 2 toward the main unit 3 along the common axis A so that the proximal end of the main unit 3 is inserted into the distal open end of the internal passage 5. The user slides the tubular aerosol generating article 2 over the proximal portion 7 of the main unit 3 toward the distal portion 8 until the distal end of the tubular aerosol generating article 2 abuts a distal stopper (not shown). In this position, the tubular aerosol generating article 2 is fully received on the heating portion 10 of the main unit 3, and the tubular aerosol generating article 2 covers the electric heater 11 and the air inlet 16, as shown in FIG. Figure 2 and 3 as shown in .

[0127] In use, the user presses the button 13 to switch the main unit 3 from the off mode to the sequential heating mode. The user draws on the mouthpiece 12 of the main unit 3, and the circuit (not shown) detects the user's puff on the mouthpiece 12. Upon detecting the user's puff, the circuit supplies power from a power source (not shown) to one of the electric heaters 11. The powered electric heater 11 heats a portion of the tubular aerosol-forming substrate 4 of the tubular aerosol-generating article 2. When the portion of the aerosol-forming substrate 4 is heated, the volatile compounds of the aerosol-forming substrate vaporize and generate vapor.

[0128] When the user draws on the mouthpiece 12 of the main unit 3, ambient air is drawn into the tubular aerosol generating article 2 through the annular end face 6 of the tubular aerosol-forming substrate 4. The air drawn into the tubular aerosol generating article 2 is drawn through the tubular aerosol-forming substrate 4 toward the air inlet 16 of the main unit 3. Vapor generated by the heated aerosol-forming substrate is entrained in the air drawn through the aerosol-forming substrate 4. The entrained vapor is drawn out of the tubular aerosol-forming substrate 4 at the inner surface of the internal passage 5 and enters the air passage 14 of the main unit 3 through the air inlet 16. The entrained vapor is drawn through the air passage 14 in a proximal direction toward the mouthpiece 12. As the vapor is drawn through the air passage 14, the vapor cools and forms an aerosol. The aerosol is drawn out of the air passage 14 through the air outlet 17 in the mouthpiece 12 and delivered to the user for inhalation. The direction of the air flow through the electrically operated aerosol generating system 1 is determined by Figure 3 Indicated by the arrows shown in .

[0129] It should be understood that in some instances, the tubular aerosol generating article may include one or more air inlets at the cylindrical outer surface, the air inlet being in the form of one or more holes in the outer layer or wrapping paper surrounding the tubular aerosol-forming substrate. In these embodiments, air can be sucked into the tubular aerosol generating article through the holes in the cylindrical outer surface. The main unit may also include additional air inlets arranged on the far side or near side of the heating portion. When the tubular aerosol generating article is completely housed on the heating portion of the main unit, these additional air inlets may not be covered by the tubular aerosol generating article. Thus, these additional air inlets can make it possible to directly draw ambient air into the air channel of the main unit, and can help cool the vapor and aerosol before being inhaled by the user. This can improve the user's experience.

[0130] Figure 4 An electrically operated aerosol generating system 101 according to a second embodiment of the present invention is shown. The electrically operated aerosol generating system 101 comprises a tubular aerosol generating article 102 and a main unit 103. The tubular aerosol generating article 102 and the main unit 103 are substantially similar to those described above with respect to Figures 1 to 3 The tubular aerosol-generating article 2 and the main unit 3 are described herein and where identical features exist, like reference numerals have been used to refer to these features.

[0131] The main unit 103 comprises an additional air inlet 118 in the outer surface of the proximal portion, between the heating portion 110 and the shoulder 109. The additional air inlet 118 enables ambient air to be drawn directly into the air passage 114 of the main unit 103 when a user draws on the mouthpiece 112. The ambient air drawn directly into the air passage 114 may mix with vapour from the heated aerosol-forming substrate 104 drawn into the air passage 114 through the air inlet 116, and promote cooling of the vapour before it is drawn out of the air passage 114 at the air outlet 117.

[0132] Figure 5 1 and 2. A main unit 203 for an electrically operated aerosol generating system according to a third embodiment of the invention is shown. The main unit 203 is substantially similar to the one described above with respect to Figures 1 to 3 The main unit 3 is described and where identical features exist, similar reference numerals have been used to refer to these features.

[0133] The main unit 203 includes six annular electric heaters 211 surrounding the outer surface of the heating portion 210. The six annular electric heaters 211 form a ring around the outer surface of the heating portion 210 and are spaced at equal intervals along the length of the heating portion 210. The length of the heating portion 210 is substantially similar to that described above with respect to Figures 1 to 3 The length of the heating section 10 of the main unit 3 is described.

[0134] Figures 6 to 8 An electrically operated aerosol generating system 301 according to a fourth embodiment of the present invention is shown. The electrically operated aerosol generating system 301 comprises a tubular aerosol generating article 302 and a main unit 303. The tubular aerosol generating article 302 and the main unit 303 are substantially similar to those described above with respect to Figures 1 to 3 The tubular aerosol-generating article 2 and the main unit 3 are described herein and where identical features exist, like reference numerals have been used to refer to these features.

[0135] The tubular aerosol-generating article 302 further comprises a permeable cover 320 overlying a proximal end of the tubular aerosol-generating article 302 and an end cap 321 overlying an opposite distal end of the tubular aerosol-generating article 302 .

[0136] The penetrable cover 320 is formed of a laminate material composed of aluminum and plastic film and is secured to the proximal end of the tubular aerosol generating article 302 by an adhesive layer (not shown). The penetrable cover 320 includes four frangible sections in the form of score lines 322 extending across the width of the cover 320. The score lines 322 cross in the middle so that the penetrable cover 320 is divided into eight equal wedge-shaped pieces 323.

[0137] The end cap 321 is formed of a rigid plastic material and comprises a cavity configured to removably receive the distal end of the tubular aerosol-generating article 302 .

[0138] To assemble the electrically operated aerosol generating system 301 for use, the user removes the end cap 321 from the distal end of the tubular aerosol generating article 302 and inserts the proximal end of the main unit 303 into the open distal end of the interior passage of the tubular aerosol generating article 302. The user slides the main unit through the interior passage of the tubular aerosol generating article 302 until the proximal end of the main unit contacts the penetrable cover 320. The user applies a moderate force to the main unit 303 against the penetrable cover 320, which breaks the score line 322 and enables the tubular aerosol generating article 302 to be pushed further onto the proximal end of the main unit 303. The wedge 323 of the broken penetrable cover 320 remains attached to the tubular aerosol generating article and forms a partial seal on the proximal end of the main unit 303 when the tubular aerosol generating article 302 is fully received on the heated portion of the main unit 303, as shown in FIG. Figure 8 The partial seal may inhibit vapour from the heated tubular aerosol-forming substrate 304 from being released out of the proximal end of the tubular aerosol-generating article 302 .

[0139] Fig. 9 and 10 An electrically operated aerosol generating system 401 according to a fifth embodiment of the invention is shown. The electrically operated aerosol generating system 401 comprises a tubular aerosol generating article 402 and a main unit 403.

[0140] The tubular aerosol-generating article 402 comprises a cylindrical open hollow tube of an aerosol-forming substrate 404. An internal passage 405 extends centrally through the tubular aerosol-forming substrate 404 and extends the length of the tubular aerosol-forming substrate 404 such that both ends of the internal passage 405 are open.

[0141] The tubular aerosol-generating article 402 further comprises a mouthpiece 406. The mouthpiece 406 comprises a cylindrical body of cellulose acetate having a substantially circular cross-section and width similar to the tubular aerosol-forming substrate 404. The tubular aerosol-forming substrate 404 and the mouthpiece 406 are arranged in adjacent coaxial alignment such that the tubular aerosol-forming substrate 404 and the mouthpiece 406 are configured to form a rod. The proximal end of the tubular aerosol-forming substrate 404 abuts the distal end of the mouthpiece 406.

[0142] The tubular aerosol-forming substrate 404 and the mouthpiece 406 are surrounded by an outer wrapper 407. The outer wrapper 407 secures the tubular aerosol-forming substrate 404 to the mouthpiece 406. The outer wrapper 407 is formed of a material that is substantially gas-impermeable, such that the outer wrapper 407 substantially prevents ambient air from being drawn into the tubular aerosol-generating article 402 through the cylindrical outer surface. The outer wrapper 407 covers the cylindrical outer surfaces of the tubular aerosol-forming substrate 404 and the mouthpiece 406, but does not extend over the end faces, such that air can be drawn through the tubular aerosol-generating article 402 from the distal end 408 to the proximal end 409. A substantially air-impermeable barrier 410 is arranged between the proximal end of the tubular aerosol-forming substrate 404 and the distal end of the mouthpiece 406. The substantially air-impermeable barrier 410 comprises an annular layer of substantially air-impermeable material. The substantially air-impermeable barrier prevents air from being drawn directly between the tubular aerosol-forming substrate 404 and the mouthpiece 406 .

[0143] The distal end of the internal passage 405 is open and is configured to receive the proximal portion of the main unit 403. The proximal end of the internal passage 405 is arranged at the distal end of the mouthpiece 406.

[0144] The main unit 403 is substantially similar to the above Figure 4 and 5 The example shown in FIG. 4 shows a main unit 103 described in detail. However, the main unit 403 does not include a mouthpiece. The heater (not shown) of the main unit 403 extends to the proximal end of the main unit 403, so that the proximal end of the main unit is the proximal end of the heating portion. The main unit 403 includes an air outlet 417 at the proximal end of the heating portion.

[0145] The main unit 403 comprises a distal stopper (not shown) arranged between the distal end of the heating portion and a shoulder of the main unit 403. However, it will be appreciated that a distal stopper may not be required, as the proximal end of the main unit may abut the distal end of the mouthpiece 406 when the tubular aerosol-generating article 402 is fully received on the heating portion.

[0146] To assemble the electrically operated aerosol generating system 401 for use, the user aligns the main unit 403 with the internal passage 405 of the tubular aerosol generating article 402 along a common longitudinal axis, with the distal end 408 of the tubular aerosol generating article 402 facing the proximal end of the main unit 403. The user moves the tubular aerosol generating article 402 toward the main unit 403 along the common axis so that the proximal end of the main unit 403 is inserted into the open distal end of the internal passage 405. The user slides the tubular aerosol generating article 402 over the proximal portion of the main unit 403 in a distal direction toward the distal portion until the distal end 408 of the tubular aerosol generating article 402 abuts the distal stopper and the proximal end of the main unit 403 abuts the distal end of the mouthpiece 406. In this position, the tubular aerosol-generating article 402 is completely housed on the heating portion of the main unit 403, and the tubular aerosol-generating article 402 covers the electric heater, such as Fig.10 as shown in .

[0147] In use, the user presses a button to switch the main unit 403 from the off mode to the sequential heating mode. The user draws on the mouthpiece 406 of the tubular aerosol-generating article 402, and the circuitry (not shown) of the main unit 403 detects the user's puff on the mouthpiece 406. Upon detecting the user's puff, the circuitry supplies power from a power source (not shown) to one of the electric heaters. The powered electric heater heats a portion of the tubular aerosol-forming substrate 404 of the tubular aerosol-generating article 402. When the portion of the aerosol-forming substrate 404 is heated, the volatile compounds of the aerosol-forming substrate vaporize and generate vapor.

[0148] When a user draws on the mouthpiece 406 of the tubular aerosol-generating article, ambient air is drawn into the tubular aerosol-generating article 402 through the distal annular end face of the tubular aerosol-forming substrate 404. The air drawn into the tubular aerosol-generating article 402 is drawn through the tubular aerosol-forming substrate 404 towards the air inlet 416 of the main unit 403. Vapour generated by the heated aerosol-forming substrate is entrained in the air drawn through the aerosol-forming substrate 404. The entrained vapour is drawn out of the tubular aerosol-forming substrate 404 at the inner surface of the internal passage 405 and into the air channel 414 of the main unit 413 through the air inlet 416. The entrained vapour is drawn through the air channel 414 in a proximal direction towards the air outlet 417. As the vapour is drawn through the air channel 414, it cools and forms an aerosol. Ambient air is also drawn directly into the air passage 414 of the main unit 403 through the additional air inlet 418. The ambient air mixes with the vapor and aerosol and promotes cooling of the vapor and aerosol. The aerosol is drawn out of the air passage 414 through the air outlet 417 at the proximal end of the main unit 403 and drawn into the mouthpiece 406. The aerosol is drawn through the mouthpiece 406, out of the proximal end 409, and delivered to the user for inhalation. The direction of the air flow through the electrically operated aerosol generating system 401 is determined by Fig.10 Indicated by the arrows shown in .

[0149] It will be appreciated that in some embodiments the primary unit may not include additional air inlets.

[0150] Fig.11 A tubular aerosol generating article 502 for an electrically operated aerosol generating system according to a seventh embodiment of the present invention is shown. The tubular aerosol generating article 502 is substantially similar to the one described above with respect to Fig. 9 and 10 A tubular aerosol-generating article 502 is described, and where identical features exist, like reference numerals have been used to refer to those features.

[0151] The tubular aerosol-generating article 502 comprises a cylindrical open hollow tube of an aerosol-forming substrate 504. An internal passage 505 extends centrally through the tubular aerosol-forming substrate 504 and extends the length of the tubular aerosol-forming substrate 504 such that both ends of the internal passage 505 are open.

[0152] The tubular aerosol-generating article 502 further comprises a mouthpiece 506. The mouthpiece 506 comprises a cylindrical body of cellulose acetate having a substantially similar circular cross-section and width to the tubular aerosol-forming substrate 504.

[0153] The tubular aerosol-generating article 502 further comprises a cooling element 511 arranged between the tubular aerosol-forming substrate 504 and the mouthpiece 506. The cooling element 511 comprises a substantially cylindrical body formed from a gathered sheet of substantially non-porous paper.

[0154] The tubular aerosol-forming substrate 504, the cooling element 511 and the mouthpiece 506 are arranged in abutting coaxial alignment such that the aerosol-forming substrate 504, the cooling element 511 and the mouthpiece 506 form a rod. The proximal end of the tubular aerosol-forming substrate 504 abuts the distal end of the cooling element 511, and the proximal end of the cooling element 511 abuts the distal end of the mouthpiece 506.

[0155] The tubular aerosol-forming substrate 504, the cooling element 51 1 and the mouthpiece 506 are surrounded by an outer wrapper 507. The outer wrapper 507 secures the tubular aerosol-forming substrate 504, the cooling element 51 1 and the mouthpiece 506 together.

[0156] A substantially air-impermeable barrier 510 is arranged between the proximal end of the tubular aerosol-forming substrate 504 and the distal end of the cooling element 511. The substantially air-impermeable barrier 510 comprises an annular layer of substantially air-impermeable material. The substantially air-impermeable barrier prevents air from being drawn directly between the tubular aerosol-forming substrate 504 and the cooling element 511.

[0157] It will be appreciated that the examples described herein are simple examples and that the illustrated circuits may be modified to provide different or more complex functionality. It will be appreciated that features described herein with reference to one embodiment may be applied to other embodiments without departing from the scope of the invention.

Claims

1. An electrically operated aerosol generating system comprising: a main unit, the main unit comprising a heating portion at an outer surface of the main unit, the heating portion comprising one or more electric heaters, the heating portion having a length; as well as A tubular aerosol-generating article, the tubular aerosol-generating article comprising: a tubular aerosol-forming substrate; and Internal passage, in: the interior passage of the tubular aerosol-generating article is configured to receive the heating portion of the main unit; and the one or more electric heaters being arranged to heat the tubular aerosol-forming substrate when the tubular aerosol-generating article is received on the heating portion of the main unit; wherein the system comprises one or more air flow paths along which air can be drawn through the aerosol generating system, the one or more air flow paths comprising one or more air passages extending through the heating portion of the main unit substantially along the length of the heating portion; and The heating portion includes one or more air inlets in fluid communication with the air passage; and The heating portion includes two or more electric heaters spaced apart on the heating portion; and The one or more air inlets are arranged in a space between the two or more electric heaters.

2. An electrically operated aerosol generating system according to claim 1, wherein the heating portion has a circumference and the two or more heaters are spaced around the circumference of the heating portion.

3. An electrically operated aerosol generating system according to claim 2, wherein the heating portion has a length and the two or more heaters are spaced along the length of the heating portion.

4. An electrically operated aerosol generating system according to claim 2, wherein the main unit further comprises one or more air outlets, and the one or more air channels of the main unit extend through the heating portion of the main unit between the one or more air inlets and the one or more air outlets.

5. An electrically operated aerosol generating system according to claim 4, wherein the system further comprises a mouthpiece, the mouthpiece being configured such that when a user draws suction on the mouthpiece, the user draws air through the one or more air passages of the main unit.

6. An electrically operated aerosol generating system according to claim 5, wherein the main unit comprises the mouthpiece, and the mouthpiece comprises the one or more air outlets.

7. An electrically operated aerosol generating system according to claim 5, wherein the tubular aerosol generating article includes the mouthpiece, and when the tubular aerosol generating article is stored on the heating portion of the main unit, the one or more air outlets of the main unit are directed toward the mouthpiece.

8. An electrically operated aerosol generating system according to claim 5, wherein the tubular aerosol-generating article further comprises a substantially air-impermeable barrier arranged between the tubular aerosol-forming substrate and the mouthpiece.

9. An electrically operated aerosol generating system according to any one of claims 1 to 8, wherein the main unit further comprises one or more additional air inlets arranged adjacent to the heating portion.

10. A main unit for an electrically operated aerosol generating system according to claim 1, the main unit comprising a heating portion arranged at an outer surface of the main unit, the heating portion comprising one or more electric heaters, the heating portion having a length; The main unit comprises one or more air channels extending through the heating portion substantially along the length direction of the heating portion, the heating portion comprises one or more air inlets fluidly connected to the air channels, and the heating portion comprises two or more electric heaters spaced apart on the heating portion; and the one or more air inlets are arranged in the space between the two or more electric heaters.

Images