Aerosol-generating article with absorbent carrier

Abstract

The present invention provides an aerosol generating article (500), which includes an aerosol forming substrate (511) and an absorptive carrier (512) impregnated or impregnable with an aerosol forming agent. The aerosol generating article can be received in an aerosol generating device, which includes a heating element for heating the aerosol forming substrate. The system can be configured so that the absorptive carrier is arranged between the aerosol forming substrate and the heating element. When the aerosol generating article is heated, the aerosol forming agent impregnated in the absorptive carrier can improve aerosol formation.

Description

Technical Field

[0001] The present disclosure relates to aerosol-generating devices and aerosol-generating articles comprising aerosol-forming substrates for use in aerosol-generating devices; and more particularly, to absorbent carriers and aerosol formers for use in such aerosol-generating articles. Background Art

[0002] Traditional smoking articles, such as cigarettes and cigars, include tobacco that is burned to generate smoke that is inhaled by the consumer. One method of reducing the production of carbon monoxide and other combustion byproducts is to use an electric heater that heats the tobacco substrate to a temperature sufficient to generate an aerosol from the substrate without burning the substrate. Such heated, non-burning smoking articles reduce or eliminate the byproducts associated with tobacco combustion. However, such devices may suffer from a reduction in aerosol production compared to traditional smoking articles that burn tobacco. Some aerosol generating devices that use electronic cigarette liquids instead of tobacco have been proposed. Aerosol generating devices that use electronic cigarette liquids eliminate combustion byproducts, but deprive consumers of the traditional tobacco-based experience.

[0003] To experience a traditional flavor and smoking experience, users may prefer electrically heated smoking articles that include a substrate containing tobacco. Electrically heated smoking articles may include tobacco without or with e-liquid (also known as a hybrid aerosol generating element).

[0004] In some known types of aerosol generating devices, an aerosol is generated by transferring heat from a heat source to a physically separate aerosol generating article, which includes, for example, a substrate containing tobacco. The device is configured so that the heat source does not burn the substrate. During use, volatile compounds are released from the aerosol-forming substrate by heat transfer from the heat source and are entrained in the air exhausted by the aerosol generating article. As the released compounds cool, the compounds condense to form an aerosol that is inhaled by the user.

[0005] The generation of aerosol may refer to any of the following: visible aerosol, aerosol mass, aerosol volume or any combination thereof. Due to the reduction in the generation of aerosol, some electrically heated aerosol generating devices using tobacco-based substrates may not meet the user's expectations for the traditional smoking experience. For example, the generation of aerosol may start more slowly, thereby possibly enabling the user to take the first puff for a longer time. The user may also experience a reduction in aerosol generation, which may be more obvious during the first puff. The reduction in aerosol generation may be due to the low efficiency of heat conduction between the heater and the tobacco-based substrate. The low efficiency of heat conduction between the electric heater and the substrate may cause the amount of total aerosol material (TAM) to be reduced overall, especially during the first approximately 3-4 puffs.

[0006] It is desirable to provide an aerosol generating article for an electrically heated aerosol generating device that improves aerosolization. It is desirable to provide an aerosol generating article for an electrically heated aerosol generating device that increases the total aerosol mass. It is desirable to provide an aerosol generating article for an electrically heated aerosol generating device that shortens the time a user can take the first puff (time to first puff, also referred to as TT1P). It is also desirable to provide an aerosol generating system that allows the use of tobacco as an aerosol-forming substrate in an electrically heated aerosol generating device while achieving one or more of improved aerosolization, increased TAM, and shortened TT1P. Summary of the invention

[0007] Various aspects of the present invention relate to an aerosol generating system using an electrically heated heating element that is configured to heat but not burn an aerosol-forming substrate. The aerosol-forming substrate can be configured as part of an aerosol-generating article that can be received by the device. The aerosol-generating article may include an absorption carrier. The volatile aerosol former is impregnated in the absorption carrier or can be impregnated in the absorption carrier. The absorption carrier can be configured to be adjacent to the aerosol-forming substrate. The absorption carrier can be configured to be adjacent to the heating element. The absorption carrier can be configured to be adjacent to both the aerosol-forming substrate and the heating element. During use, the aerosol-generating article and the aerosol former in the absorption carrier are heated. The presence of the aerosol former in the gas phase enhances the condensation of compounds volatilized from the aerosol-generating article, thereby improving the formation of the aerosol.

[0008] According to one aspect of the present disclosure, an absorption carrier impregnated (or impregnable) with an aerosol former is provided as part of an aerosol generating article. An absorption carrier impregnated (or impregnable) with an aerosol former can improve aerosolization and release sensory active compounds from an aerosol forming substrate. The absorption carrier can be impregnated with one or more aerosol formers. Optionally, the absorption carrier can also be impregnated with one or more sensory active compounds or their precursors. Aerosol formers are compounds that contribute to aerosol formation during use. These compounds include, but are not limited to, glycerol and propylene glycol. Sensory active compounds are compounds that allow a sensory response to be triggered, such as flavor compounds. The aerosol generating article can be arranged for use with an aerosol generating device. The aerosol generating device is configured to receive the aerosol generating article and heat the aerosol forming substrate and the absorption carrier of the aerosol generating article.

[0009] The absorbent carrier may be in the form of a sheet. The term "sheet" as used herein refers to a material that is generally flat and has a width and height that is greater (e.g., several orders of magnitude greater) than the thickness of the material. An example of a sheet is a sheet of paper. It should be understood that the term "sheet" may also encompass materials that are thicker than paper.

[0010] The absorbent carrier may comprise fibers and may be made of paper or another cellulose-based sheet material.

[0011] In some embodiments, the aerosol former is impregnated into the absorption carrier. In some embodiments, the volatile aerosol former is impregnable and can be provided separately from the absorption carrier to be impregnated before use. For example, the user can impregnate the aerosol former in the absorption carrier. In some embodiments, the aerosol former can be provided inside the fragile element. The user can break the fragile element before intending to use the article. For example, the aerosol generating article may include a fragile film that contains the aerosol former. The fragile film can be arranged relative to the absorption carrier so that when the fragile film is broken, the aerosol former is released and absorbed by the absorption carrier. For example, the user can apply force, such as by squeezing, pressing or shaking the aerosol generating article. Therefore, the use of the aerosol former can be activated by the user as needed.

[0012] When the aerosol-forming substrate and the absorption carrier of the aerosol-generating article are heated during use, the aerosol-forming agent impregnated into (e.g., absorbed into) the absorption carrier partially or completely evaporates. The evaporated compound contributes to the formation of aerosol. The aerosol-forming agent can improve aerosolization by increasing the total aerosolized material produced by the aerosol-generating device, especially during the first few suctions. In this way, an aerosol generation device that is more similar to a burning smoking article can be obtained by using a tobacco-based substrate and using an absorption carrier impregnated with an aerosol-forming agent. This helps to retain the flavor, aroma, and ritual associated with traditional smoking as much as possible. Compared with conventional smoking, when the absorption carrier is not impregnated with a volatile aerosol-forming agent, a heat-not-burn aerosol-generating system can produce a relatively low amount of total aerosol mass, especially during the first few suctions.

[0013] As used herein, the term "aerosol" refers to a suspension of fine solid particles or liquid droplets in a gas (such as air), which may contain volatile aroma compounds.

[0014] The absorption carrier can act as a carrier or support for volatile compounds such as aerosol formers. The use of an absorption carrier impregnated with a volatile aerosol former in an aerosol generating article can shorten the time of the first puff, increase the total aerosol material (TAM), or simultaneously shorten the time of the first puff and increase TAM. TAM is preferentially increased, especially during the first few puffs, because an electrically heated aerosol generating device is usually used during the first few puffs when TAM is low. The aerosol generating article can be arranged for use with a heating element. The heating element can be arranged to heat the aerosol-forming substrate of the aerosol generating article. The heating element can be arranged to heat the absorption carrier of the aerosol generating article. The heating element can be arranged to heat both the aerosol-forming substrate of the aerosol generating article and the absorption carrier of the aerosol generating article.

[0015] According to some embodiments, the absorptive carrier impregnated or impregnable with an aerosol forming agent may be placed adjacent to a heating element. The heating element may be placed closer to the absorptive carrier than the substrate so that the aerosol forming agent in the absorptive carrier reaches a volatilization temperature first before the substrate.

[0016] In some embodiments, the heating element may comprise an external heating element.The external heating element may be arranged to heat the aerosol-generating article externally, for example from an outer surface of the aerosol-generating article.

[0017] In some embodiments, the aerosol-forming substrate may form a core that is at least partially surrounded by an absorptive carrier. The aerosol-forming substrate may form a core surrounded by an absorptive carrier. The absorptive carrier may be disposed between the aerosol-forming substrate core and a heating element, which may be an external heating element.

[0018] In some embodiments, the heating element may comprise an internal heating element. The internal heating element may be arranged to at least partially penetrate at least a portion of the aerosol-generating article. In use, the internal heating element may be aligned with the longitudinal axis of the aerosol-generating article.

[0019] In some embodiments, the absorption carrier can form a core that is at least partially surrounded by the aerosol-forming substrate. The absorption carrier can form a core surrounded by the aerosol-forming substrate. The absorption carrier core can be arranged between the aerosol-forming substrate and the heating element, which can be an internal heating element. For example, the internal heating element can be at least partially surrounded by the absorption carrier. The internal heating element can be surrounded by the absorption carrier. The absorption carrier can be arranged adjacent to the aerosol-forming substrate and the heating element.

[0020] In some embodiments, the absorbent carrier may define a hollow area, through-hole, or slot for receiving an internal heating element.

[0021] The heating element may include both an internal heating element and an external heating element. In use, the aerosol-forming substrate may be at least partially disposed within the external heating element and at least partially surrounding the internal heating element. The absorption carrier may be disposed between the aerosol-forming substrate and the external heating element. The absorption carrier may be disposed between the aerosol-forming substrate and the internal heating element. The absorption carrier may be disposed either between the aerosol-forming substrate and the external heating element or between the aerosol-forming substrate and the internal heating element. The absorption carrier may be disposed adjacent to the aerosol-forming substrate and adjacent to the external heating element. The absorption carrier may be disposed adjacent to the aerosol-forming substrate and the internal heating element. The absorption carrier may be disposed adjacent to the aerosol-forming substrate and both the external heating element and the internal heating element.

[0022] In some embodiments, the heating element may be provided as part of an aerosol generating device. In some embodiments, the heating element may be provided as part of an aerosol generating article. In some embodiments, the heating element may be provided as part of an aerosol generating article and may be provided as part of an aerosol generating device. In the case where the heating element comprises both an internal heating element and an external heating element, one or both of the internal heating element and the external heating element may be provided as part of an aerosol generating article. In the case where the heating element comprises both an internal heating element and an external heating element, one or both of the internal heating element and the external heating element may be provided as part of an aerosol generating device.

[0023] The aerosol generating device may be configured to heat the absorbent carrier and aerosol-forming substrate in the aerosol generating article by conduction. The shape and size of the aerosol generating article are preferably designed to allow contact with the heating element or minimize its distance from the heating element to provide efficient heat transfer from the heating element to the absorbent carrier and aerosol-forming substrate in the aerosol generating article. Heat may be generated by any suitable mechanism, such as by resistive heating or by induction.

[0024] In some embodiments, the aerosol-generating article is heated by induction heating. To facilitate induction heating, a susceptor may be provided on the aerosol-generating article or the aerosol-generating device or both. Suitable susceptor materials include or are made of: graphite; molybdenum; silicon carbide; niobium; Alloys (austenitic nickel-chromium based superalloys); metallized films; ceramics such as zirconia; transition metals such as Fe, Co, Ni or metalloid components such as B, C, Si, P, Al.

[0025] In the induction heating embodiment, the susceptor can take any suitable form or shape. For example, the susceptor can include powders, fragments, strips, sheets, plugs, blocks, blades, random shapes, etc., or combinations thereof. The susceptor can be part of an aerosol generating article. For example, the susceptor can be part of a wrapper or liner. The susceptor can include an insert. The susceptor can be distributed throughout the aerosol generating article. In some embodiments, the susceptor includes a wrapper, a liner, an insert, or a combination of materials distributed throughout the substrate. In one embodiment, the aerosol generating article body can be made of a material that can be used as a susceptor (e.g., aluminum). In another embodiment, the susceptor material is disposed in the cavity of the aerosol generating article. For example, the susceptor material can be uniformly distributed throughout the substrate. The susceptor material can be provided as part of the aerosol generating article in any form, such as powders, fragments, strips, sheets, plugs, blocks, blades, random shapes, etc., or combinations thereof. In some embodiments, the susceptor is part of an aerosol generating device. For example, the aerosol generating device can include an internal heater that includes a susceptor, such as a blade of a susceptor material. The aerosol generating device may comprise an external heater comprising a susceptor. In one embodiment, the inner wall of the heating chamber may be provided with a susceptor material, such as a susceptor coating or lining. To inductively heat the susceptor material, the aerosol generating device may comprise a coil to generate an alternating current to heat the susceptor.

[0026] The aerosol generating article may be provided in any suitable shape, which is configured to be received by the aerosol generating device. The aerosol generating device may be a smoking article, such as a generally rod-shaped smoking article or an article having any other suitable shape. The aerosol generating article may be configured to be received by a hookah device. The aerosol generating article may have a generally cubic, cylindrical, frustoconical or any other suitable shape. Preferably, the aerosol generating article has a generally cylindrical shape, such as an elongated cylindrical shape or a frustoconical shape.

[0027] The aerosol generating article may be a cartridge. The cartridge may comprise any suitable body defining a cavity in which the aerosol forming substrate is disposed. The body is preferably formed of one or more heat resistant materials, such as a heat resistant polymer or a metal. The body may comprise a thermally conductive material. For example, the body may comprise any of: aluminium, copper, zinc, nickel, silver, any alloys thereof and combinations thereof. Preferably, the body comprises aluminium.

[0028] The body may include a sidewall. According to one embodiment, the sidewall forms a cylinder defining a cavity. The cylinder may include a varying diameter, such as a diameter that is arranged to taper toward one end of the cylinder. The cylindrical sidewall may have a first end and a second end. The first end and the second end may be open ends. The body may also include one or more end walls that at least partially cover the two ends of the cylindrical sidewall. In some embodiments, the body includes a cylindrical sidewall that is open at one end and closed at the other end or open at both ends. The body may include one or more parts. For example, the sidewall and the endwall may be a single part of one piece. The sidewall and the endwall may be two parts configured to engage with each other in any suitable manner, such as threaded engagement or interference fit. The sidewall and the endwall may be two parts that are joined together, such as by welding or by an adhesive. The sidewall and the two opposing endwalls may be three separate parts configured to engage with each other in any suitable manner, such as threaded engagement, interference fit, welding or adhesive.

[0029] The body defines a cavity in which an aerosol-forming substrate and an absorptive carrier may be disposed. A portion of the body defining the cavity may include a heatable wall or surface. As used herein, "heatable wall" and "heatable surface" mean a wall or surface to which heat can be applied directly or indirectly. A heatable wall or surface may be used as a heat transfer surface. For example, a heatable wall or surface of a portion of the body defining the cavity is a surface through which heat can be transferred from the outside of the cavity through the body to the cavity or the inner surface of the cavity. In some embodiments, the aerosol-generating article is configured to receive an internal heating element. For example, when the aerosol-generating article is inserted into the aerosol-generating device, an elongated heating element such as a rod, blade or pin may be inserted into the aerosol-generating article. The elongated heating element may be part of the aerosol-generating device, or may be provided as a separate element coupled to the aerosol-generating device.

[0030] The absorptive carrier impregnated or impregnable with an aerosol-forming agent may be placed adjacent to the inner surface of the cavity of the aerosol-generating device. The absorptive carrier may be placed adjacent to both the inner surface of the cavity and the heating element. The aerosol-generating article may be configured such that the absorptive carrier is in contact with or adjacent to a heatable surface when the aerosol-generating article is in use. In one embodiment, the absorptive carrier is in direct contact with the heatable surface when the aerosol-generating article is in use.

[0031] The aerosol-forming substrate of the aerosol-generating article may occupy any suitable volume of the article. Where the aerosol-generating article comprises a cartridge, the aerosol-forming substrate may occupy any suitable volume of the cavity of the article. The volume of the aerosol-forming substrate in the aerosol-generating article may be varied by changing the amount, composition, shape, packing density or form of the aerosol-forming substrate placed in the aerosol-generating article.

[0032] Any suitable aerosol-forming substrate may be provided as part of the aerosol-generating article.

[0033] The aerosol-forming substrate is preferably a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be a solid, a paste, a gel, a slurry, a liquid, or may comprise any combination of two or more of a solid, a paste, a gel, a slurry and a liquid component.

[0034] Aerosol-forming substrate may include nicotine. Nicotine-containing aerosol-forming substrate may include a nicotine salt substrate. Aerosol-forming substrate may include plant-based materials. Aerosol-forming substrate preferably includes tobacco, and preferably, the tobacco-containing material contains volatile tobacco flavor compounds, which are released from the aerosol-forming substrate when heated. Aerosol-forming substrate may include homogenized tobacco material. Homogenized tobacco material may be formed by condensing particle tobacco. Alternatively or in addition, aerosol-forming substrate may include tobacco-free material. Aerosol-forming substrate may include homogenized plant-based materials.

[0035] The aerosol-forming substrate may include, for example, one or more of the following: powder, granules, pellets, fragments, strips, ribbons or sheets, the strips or sheets comprising one or more of the following: herb leaves, tobacco leaves, tobacco leaf vein segments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0036] The aerosol-forming substrate may comprise at least one aerosol-forming agent, which may be the same as or different from the aerosol-forming agent impregnated into the absorption carrier. The aerosol-forming agent may be any suitable known compound or mixture of compounds, which, in use, facilitates the formation of a dense and stable aerosol and is substantially resistant to thermal degradation at the operating temperature of the aerosol generating device. Suitable aerosol-forming agents are well known in the art and include, but are not limited to: polyols, such as triethylene glycol, 1,3-butylene glycol and glycerol; esters of polyols, such as glycerol mono-, di- or triacetate; and fatty acid esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanoic acid. Particularly preferred aerosol-forming agents are polyols or mixtures thereof, such as triethylene glycol, 1,3-butylene glycol and most preferably glycerol. The aerosol-forming substrate may include other additives and ingredients, such as flavorings. The aerosol-forming substrate preferably comprises nicotine and at least one aerosol-forming agent. In some embodiments, the aerosol former is glycerol or a mixture of glycerol and one or more other suitable aerosol formers, such as those listed above.

[0037] The aerosol-forming substrate may include any suitable amount of aerosol-forming agent. For example, the content of the aerosol-forming agent may be equal to or greater than 5% of the aerosol-forming substrate on a dry weight basis, and preferably greater than 30% by weight on a dry weight basis. The content of the aerosol-forming agent may be less than about 95% on a dry weight basis. Preferably, the content of the aerosol-forming agent is up to about 55%.

[0038] The aerosol-forming substrate can be provided on or embedded in a thermally stable carrier. The term "thermally stable" as used herein refers to a material that does not substantially degrade at temperatures to which the substrate is typically heated (e.g., about 150°C to about 300°C). The thermally stable carrier can be separate and distinct from the absorptive carrier. The thermally stable carrier can be used to provide support for the aerosol-forming substrate (e.g., molasses). The aerosol-forming substrate and the thermally stable carrier can be disposed in the center of the aerosol-generating article. On the other hand, the absorptive carrier can be used as a carrier for the aerosol former. The absorptive carrier and the aerosol former can be placed adjacent to the side walls, end walls, bottom, or both of the aerosol-generating article. The absorptive carrier and the aerosol former can at least partially surround the aerosol-forming substrate and the thermally stable carrier.

[0039] The heat-stable carrier can comprise a thin layer, on which substrate is deposited on the first major surface, the second major surface or the first major surface and the second major surface.The heat-stable carrier can be formed by, for example, paper or paper-like material, nonwoven carbon fiber mat, low-quality open mesh metal wire mesh (low mass open mesh metallic screen) or perforated metal foil or any other heat-stable polymer matrix.Alternately, the heat-stable carrier can be in powder, granule, pellet, fragment, thin strip, strip or sheet form.Carrier can be a nonwoven fabric or fiber bundle that has wherein been combined with tobacco component.Nonwoven fabric or fiber bundle can comprise, for example, carbon fiber, natural cellulose fiber or cellulose-derived fiber.In some embodiments, carrier can be omitted.

[0040] In some examples, the aerosol-forming substrate includes any suitable amount of one or more sugars. In particular, if the aerosol-generating device is a hookah device, it may be desirable for the aerosol-forming substrate to include one or more sugars. Preferably, the aerosol-forming substrate includes invert sugar, which is a mixture of glucose and fructose obtained by splitting sucrose. Preferably, the aerosol-forming substrate includes about 1% to about 40% by weight of sugar, such as invert sugar. In some examples, one or more sugars may be mixed with a suitable carrier such as corn starch or maltodextrin. In some embodiments, the aerosol-forming substrate does not contain added sugar.

[0041] In some examples, the aerosol-forming substrate comprises one or more sensory enhancers. Suitable sensory enhancers include flavoring agents and sensates, such as cooling agents. Suitable flavoring agents include natural or synthetic menthol, mint, spearmint, coffee, tea, spices (such as cinnamon, cloves, ginger or a combination thereof), cocoa, vanilla, fruit flavors, chocolate, eucalyptus, geranium, eugenol, agave, juniper, anethole, linalool and any combination thereof.

[0042] In some examples, the aerosol-forming substrate is in the form of a suspension. For example, the aerosol-forming substrate may include molasses. In particular, if the aerosol-generating device is a hookah device, the aerosol-forming substrate may include molasses. As used herein, "molasses" refers to an aerosol-forming substrate composition that contains about 20% or more sugar. For example, molasses may contain at least about 25% by weight of sugar, such as at least about 35% by weight of sugar. Typically, molasses will contain less than about 60% by weight of sugar, such as less than about 50% by weight of sugar.

[0043] Aerosol-forming substrates used with conventional hookah devices may be in the form of molasses, which may be heterogeneous and may contain lumps and cavities. Such cavities prevent direct thermal contact between the substrate and the heated surface, making heat conduction particularly inefficient. Thus, electronically heated hookah devices tend to depart from conventional molasses by using, for example, e-liquids or dry stones. As described in the present disclosure, because an absorptive carrier impregnated with a volatile aerosol former is used in an aerosol-generating article, a more conventional aerosol-forming substrate such as molasses may be used to maintain the typical ritual and hookah experience when electrical heating is used. The various substrates may be used interchangeably, such that conventional hookah substrates may be used in non-hooking aerosol-generating articles, and non-hooking substrates may be used in cartridges intended for use in hookah devices.

[0044] Any suitable amount of aerosol-forming substrate (e.g., molasses or tobacco substrate) can be provided as a part of an aerosol-generating article. The aerosol-generating article can include at least 0.4g, at least 0.5g, at least 0.8g, at least 1g, at least 1.5g, at least 2g, or at least 2.5g of aerosol-forming substrate. The aerosol-generating article can include at most 15g, at most 10g, at most 5g, or at most 4g of aerosol-forming substrate. In one embodiment, about 10g of aerosol-forming substrate is provided. The aerosol-forming substrate can be provided in a space limited by an absorption carrier.

[0045] The aerosol generating article may have any suitable size. For example, the length of the aerosol generating article may be about 15 cm or less, about 12 cm or less, about 10 cm or less, about 8 cm or less, or about 6 cm or less. The length may be about 1 cm or more, about 3 cm or more, about 4 cm or more, or about 5 cm or more. The outer diameter of the aerosol generating article may be about 5 mm or more, about 6 mm or more, about 7 mm or more, or about 8 mm or more. The outer diameter may be about 20 mm or less, about 15 mm or less, about 12 mm or less, or about 10 mm or less. In the case where the aerosol generating article includes a barrel, the body of the barrel may have a heatable surface area in the cavity. The heatable surface area in the cavity may be about 4 cm 2 or larger, about 6cm 2 or larger, about 8cm 2 or larger, or about 10cm 2 or larger. The heatable surface area can be about 50 cm 2 or smaller, about 40cm 2 or smaller, about 30cm 2 or smaller, or about 20cm 2 In a preferred embodiment, the body is cylindrical.

[0046] If the aerosol-generating article is a tube, such as a hookah, the length of the body of the tube may be about 15 cm or less. The inner diameter of the tube may be about 1 cm or more. The heatable surface area of ​​the tube in the cavity may be about 25 cm 2 To about 100cm 2 , such as about 70 cm 2 To about 100cm 2 The volume of the cavity can be about 10 cm 3 To about 50cm 3 The heatable surface area of ​​the body in the cavity may be about 20 cm 2 To about 100cm 2 Preferably, the body is cylindrical or frusto-conical.

[0047] Preferably, the aerosol-generating article includes an amount of aerosol-forming substrate that will provide a sufficient amount of aerosol for a smoking experience lasting from about 1 minute to about 60 minutes. In some embodiments, the amount of aerosol-forming substrate is sufficient to make the smoking experience at least about 30 seconds, at least about 1 minute, at least about 1.5 minutes, at least about 2 minutes, or at least about 3 minutes. The amount of aerosol-forming substrate can be sufficient to make the smoking experience at most 10 minutes, at most 8 minutes, at most 6 minutes, or at most 5 minutes. If the device is a hookah device, the smoking experience preferably lasts from about 20 minutes to about 50 minutes; and more preferably from about 30 minutes to about 40 minutes.

[0048] The aerosol generating article may be configured as a flow element. The aerosol generating article may be defined by one or more walls. For example, the aerosol generating article may have a cylindrical wall with an open end or an open first end and a second end. The aerosol generating article may have a cylindrical wall with one or more side walls covering the first end and the second end. The aerosol generating article may include ventilation holes in the cylindrical wall at the first end, the second end, or a combination thereof.

[0049] The aerosol generating article may include one or more ventilation holes. In particular, if the aerosol generating article is a cartridge, the aerosol generating article may include one or more ventilation holes. The ventilation holes may be inlets or outlets and may be disposed at the bottom, top, side, or combination thereof of the aerosol generating article. In some embodiments, the top of the aerosol generating article may define one or more holes to form one or more inlets of the aerosol generating article. The bottom of the aerosol generating article may define one or more holes to form one or more outlets of the aerosol generating article.

[0050] In some embodiments, the aerosol generating article includes one or more inlets and one or more outlets to allow air to flow through the aerosol forming substrate when the aerosol generating article is used in the aerosol generating device. One or more inlets and one or more outlets may include an open end of the aerosol generating article or a vent in the wall of the aerosol generating article. Preferably, the size and shape of one or more inlets and outlets are designed to provide a suitable suction resistance (RTD) to pass through the aerosol generating article. In some examples, the RTD of the aerosol generating article from one or more inlets to one or more outlets can be about 10mm H2O to about 50mm H2O, preferably about 20mm H2O to about 40mm H2O. The RTD of the sample refers to the static pressure difference between the two ends of the sample when the airflow crosses the sample under stable conditions, and under the stable conditions, the volume flow rate at the output end is 17.5 ml / sec. The RTD of the sample can be measured using the method specified in ISO standard 6565:2002, and keep good ventilation.

[0051] According to some embodiments of the present disclosure, an aerosol generating article includes an absorptive carrier impregnated or impregnable with an aerosol forming agent, which is disposed as a part of the aerosol generating article. In some embodiments, the absorptive carrier impregnated or impregnable with an aerosol forming agent is disposed inside the aerosol generating article. The absorptive carrier can be selected to absorb volatile compounds and serve as a carrier or support that can hold the volatile compounds in close proximity or contact with a heating surface or heating element of the aerosol generating article. The absorptive carrier can at least partially surround the aerosol forming substrate. The aerosol forming substrate can at least partially surround the absorptive carrier.

[0052] According to one embodiment, the absorption carrier is impregnated with one or more aerosol forming agents, and the one or more aerosol forming agents can help form aerosol when the absorption carrier is heated. Suitable aerosol forming agents include but are not limited to polyols, glycol ethers, polyol esters, esters and fatty acids. Aerosol forming agents can include glycerol, propylene glycol, erythritol, 1,3-butylene glycol, tetraethylene glycol, triethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triacetin, meso-erythritol, diacetin mixture, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenyl acetate, ethyl vanillate, tributyrin, lauryl acetate, lauric acid and myristic acid one or more. Preferably, aerosol forming agents include compounds with relatively high volatility and show relatively high hygroscopicity. In some embodiments, aerosol forming agents include glycerol (e.g., vegetable glycerin (VG)), propylene glycol or their combination.

[0053] The absorption carrier can include any suitable amount of one or more aerosol forming agents. For example, the absorption carrier can include 0.3g or more, 0.5g or more, 0.8g or more, 1g or more, 1.2g or more, or 1.5 or more aerosol forming agents. The absorption carrier can include up to 8g, up to 7g, up to 6g, up to 5.5g, up to 5g, up to 4.5g, or up to 4g aerosol forming agents. In one embodiment, the absorption carrier includes 0.5 to 5g aerosol forming agents.

[0054] The aerosol former may be impregnated into the absorption carrier. Alternatively or additionally, the aerosol former is impermeable and may be provided separately from the absorption carrier. The aerosol former provided separately from the absorption carrier may be impregnated into the absorption carrier before use. For example, the aerosol former may be arranged in a breakable or fragile element (such as a bead or capsule). The user may release the aerosol former from the breakable or fragile element before intending to use the article. The aerosol generating article may include a fragile film containing the aerosol former. The fragile film may be arranged to release the aerosol former into the absorption carrier when the fragile film is broken. In some embodiments, the user may break the fragile film or element by squeezing the aerosol generating article in the area of ​​the fragile film or element or by applying light pressure to the aerosol generating article. In some embodiments, when the aerosol generating article containing the fragile film or element is shaken violently, the fragile film or element may release the aerosol former.

[0055] The aerosol forming agent impregnated into (e.g., absorbed into) the absorption carrier can increase the number of condensation nuclei available at the beginning of the smoking experience. The increased number of condensation nuclei available at the beginning of the smoking experience can cause aerosol generation to start faster and cause more aerosol to be generated, especially during the first few puffs. For example, an absorption carrier impregnated with an aerosol forming agent can increase the amount of aerosol generated during the first 2, first 3, first 5, first 10, first 15, first 20, or first 30 puffs.

[0056] The use of an aerosol-forming agent impregnated into an absorption carrier can also shorten the time it takes for an aerosol-generating device to be ready for the first puff (i.e., the time to first puff or TT1P), which includes the appropriate or desired TAM (typically about 15 mg / puff). For example, when an aerosol-generating article without an absorption carrier impregnated with an aerosol-forming agent is used, the TT1P can be about 20 seconds. However, by using an aerosol-forming agent impregnated into an absorption carrier to increase the amount of aerosol available during the first few puffs, the TT1P can be shortened by at least about 2 seconds, at least about 5 seconds, at least about 10 seconds, or at least about 15 seconds. The TT1P can be shortened by up to about 20 seconds, up to about 18 seconds, up to about 15 seconds, or up to about 10 seconds. For a hookah device using a preheat time of about 4 minutes, when a cartridge using molasses without an absorption carrier impregnated with an aerosol-forming agent is used, the TT1P can be about 17 minutes. By using an aerosol former impregnated into the absorbent carrier to increase the amount of aerosol available during the first few puffs, the TT1P of a hookah device can be shortened from about 1 minute to about 15 minutes.

[0057] The absorption carrier can have any suitable form or shape. Preferably, the absorption carrier forms a sheet. The sheet can also be formed into a suitable shape. For example, the absorption carrier may include a cylindrical portion that is at least partially used as a lining of the inner surface of the cylindrical wall of the aerosol-generating article, or at least partially surrounds the aerosol-forming substrate, or both. In some embodiments, the absorption carrier is coated with an aerosol-forming substrate or is surrounded by an aerosol-forming substrate. The absorption carrier may also include a portion of another wall (such as an end wall) covering the aerosol-generating article. The absorption carrier may include flat (e.g., planar), curved, rolled, folded, pleated, curled, curled, curved, etc. portions, or may include a combination of various forms and shapes (e.g., flat portions and pleated or curved portions). In one embodiment, the absorption carrier has a rolled shape. For example, the absorption carrier can be laminated with an aerosol-forming substrate and rolled into a spiral cylindrical shape that includes a plurality of alternating layers of the absorption carrier and the aerosol-forming substrate. The rolled cylindrical shape may be placed inside an aerosol-generating article.

[0058] The absorption carrier can be made of porous materials. In some embodiments, the absorption carrier includes fibers. The absorption carrier can be made of refined cellulose materials. The term "refined cellulose material" used herein refers to a material based on cellulose (e.g., derived from plants) but processed (e.g., refined) to remove compounds, change the chemical structure of the material, or both. The removed compound can be a compound other than water, so that the refining process includes steps other than drying. Examples of suitable refined cellulose materials for absorption carriers include paper, filter paper, cardboard, paperboard, rayon (e.g., lyocell, viscose, modal), etc. According to some embodiments, the absorption carrier can include other fiber materials such as silk, wool, cotton, flax, etc.

[0059] The absorbent carrier can have any suitable thickness. For example, the absorbent carrier can have a thickness of about 0.1 mm or greater, about 0.2 mm or greater, about 0.5 mm or greater, or about 1 mm or greater. The absorbent carrier can have a thickness of at most about 5 mm, at most about 4 mm, at most about 3.5 mm, at most about 3 mm, at most about 2.5 mm, or at most about 2 mm. In one embodiment, the absorbent carrier has a thickness of about 0.1 mm to about 3 mm.

[0060] The absorbent carrier may have any suitable surface area. For example, the absorbent carrier may have a surface area of ​​about 1 cm 2 or larger, about 2cm 2 or larger, about 3cm 2 or larger, about 3.5cm 2 or larger, about 4cm 2 or larger, about 5cm 2 or larger, about 6cm 2 or larger, or about 8cm 2 or greater. The surface area of ​​the absorbent carrier may be up to about 50 cm 2 , up to about 40cm 2 , up to about 30cm 2 , up to about 25cm 2 , up to about 20cm 2 , up to about 18cm 2 , up to about 15cm 2 , or up to about 10cm 2 In one embodiment, the surface area of ​​the absorbent carrier is about 2 cm 2 To about 10cm 2 .

[0061] The absorbent carrier may also include a layer of thermally conductive or inductive material. For example, the absorbent carrier may be coated or laminated with a thermally conductive or inductive material. Examples of suitable thermally conductive or inductive materials include various metals, such as aluminum, copper, zinc, nickel, silver, stainless steel, or combinations thereof. Suitable inductive susceptor materials may also include or be made of: graphite; molybdenum; silicon carbide; niobium; Alloys (superalloys based on austenitic nickel-chromium); metallized films; ceramics such as zirconium oxide; transition metals such as Fe, Co, Ni or metalloid components such as B, C, Si, P, Al. Such thermally conductive or inductive materials can act as a heat bridge and provide a more uniform temperature distribution. If the absorber carrier is arranged in a rolled-up form, it is also advantageous to use a layer of thermally conductive or inductive material.

[0062] According to some embodiments, the aerosol generating article includes a body defining a cavity and an inner surface. The aerosol generating article may include a substrate and an absorption carrier impregnated or impregnable with an aerosol forming agent in the cavity. The absorption carrier may be arranged adjacent to the inner surface of the cavity, adjacent to the heating element, adjacent to the substrate, or any combination thereof. In one embodiment, when the aerosol generating article is used, the absorption carrier is in direct contact with the heating surface. The heating element may be an external heating element or an internal heating element, or may include both an internal heating element and an external heating element. The aerosol generating article may include at least 1g, at least 1.5g, at least 2g, or at least 2.5g of aerosol forming substrate. The aerosol generating article may include at most 15g, at most 10g, at most 5g, or at most 4g of aerosol forming substrate. The aerosol generating article may include 0.3g or more, 0.5g or more, 0.8g or more, 1g or more, 1.2g or more, or 1.5g or more of an aerosol forming agent impregnated or impregnable into the absorption carrier. The aerosol generating article can contain at most 8g, at most 7g, at most 6g, at most 5.5g, at most 5g, at most 4.5g or at most 4g of aerosol forming agent impregnated or impregnable into an absorptive carrier. The absorptive carrier can form a sheet, which is arranged adjacent to the substrate or around (e.g., at least partially around) the substrate, or both. For example, the absorptive carrier can form a sleeve shape, wherein the substrate is arranged inside. In one embodiment, the absorptive carrier is arranged to alternate layers (e.g., rolled up) with the substrate. The absorptive carrier can be flat, curved, rolled up, folded, pleated, curled, curled up, bent, etc., or can include a combination of various forms and shapes (e.g., a flat portion and a pleated or curved portion).

[0063] In some embodiments, the aerosol generating article may include one or more removable seals that cover one or more inlets or open ends of the aerosol generating article. The one or more seals are preferably sufficient to prevent air from flowing through the inlet or open end, and may be sufficient to prevent the contents of the aerosol generating article from leaking and extending the shelf life. The seal may include a peelable label, sticker, foil, etc. The label, sticker, or foil may be affixed to the aerosol generating article in any suitable manner, such as by adhesive, crimping, welding, or otherwise joining to the container. The seal may include a tongue that can be grasped to peel or remove the label, sticker, or foil from the aerosol generating article.

[0064] The aerosol-generating article may be used with any suitable electrically heated aerosol-generating device. Preferably, the aerosol-generating device is configured to sufficiently heat an aerosol-forming substrate in the aerosol-generating article to form an aerosol from the aerosol-forming substrate, but without burning the aerosol-forming substrate. One commercially available aerosol-generating heat-not-burn device is the Philip Morris International A device configured to receive and heat a heating rod. Some commercially available heating rods are Philip Morris International or HeatSticks include a tobacco substrate formed from a crimped tobacco sheet. The heating device includes a heating blade configured to pierce a tobacco substrate of a heating rod inserted into the device, so that the heating blade contacts and heats the tobacco substrate primarily by conduction, causing the volatile compounds of the aerosol-forming substrate to release vapor, which cools to form an aerosol that can be inhaled by the user. According to some embodiments of the present disclosure, the aerosol-generating article of the present invention can be used with According to some embodiments of the present disclosure, the aerosol-generating article of the present invention may be used with an electrically heated aerosol-generating device configured to receive and heat an aerosol-generating article comprising an aerosol-forming substrate strip to generate an aerosol.

[0065] In some embodiments, the aerosol generating device may include a housing having a container for receiving an aerosol generating article. The aerosol generating article may be shaped as an elongated article, and the shape of the container may be adapted to accommodate the shape of the aerosol generating article. The aerosol generating device may include a heating element for heating the aerosol-forming substrate. The heating element may be an external heating element that at least partially surrounds the aerosol generating article when the aerosol generating article is inserted into the container. The heating element may be an elongated element extending into the container and configured to penetrate the aerosol generating article when the aerosol generating article is received in the container of the device. The heating element may include an external heating element and an elongated element that at least partially surrounds the aerosol generating article when the aerosol generating article is inserted into the container, the elongated element extending into the container and configured to penetrate the aerosol generating article when the aerosol generating article is received in the container of the device. The heating element may be disposed in a cavity, such as a heating chamber.

[0066] An absorption carrier impregnated or impregnable with an aerosol forming agent may be arranged as part of an aerosol generating article so that when the aerosol generating article is received by an aerosol generating device, the absorption carrier is positioned adjacent to the inner surface of the heating chamber. An absorption carrier impregnated or impregnable with an aerosol forming agent may be arranged as part of an aerosol generating article so that when the aerosol generating article is received by an aerosol generating device, the absorption carrier is adjacent to the surface of the heating element of the aerosol generating device. An absorption carrier impregnated or impregnable with an aerosol forming agent may be arranged as part of an aerosol generating article so that when the aerosol generating article is received by an aerosol generating device, the absorption carrier is adjacent to both the inner surface of the heating chamber of the aerosol generating device and the surface of the heating element. The absorption carrier may be arranged adjacent to an aerosol forming substrate. The absorption carrier may be arranged between the aerosol forming substrate and the surface of the internal cavity, the surface of the heating element, or both. The absorption carrier may be arranged between the heating element and the aerosol forming substrate.

[0067] In use, when the aerosol generating article is received in the container of the aerosol generating device, the heat from the heating element of the device can be transferred to the body of the aerosol generating article. When the user draws on the mouthpiece of the aerosol generating device, air can be drawn into the container of the device through one or more air channels in the body of the device and from the distal end of the aerosol generating device to the proximal end of the aerosol absorbent article through the aerosol generating article. When the air passes through the heated aerosol generating article, the volatile compounds in the aerosol former can release vapor entrained in the air. After the aerosol forming substrate is heated to a sufficiently high temperature, the aerosol forming substrate also releases vapor into the air flowing through the aerosol generating article. In some embodiments, the aerosol forming substrate may need to be heated to a relatively higher temperature than the aerosol former (e.g., heated to a temperature higher than the evaporation temperature of the volatile compounds of the aerosol forming substrate). In some embodiments, the air is first heated by the heating element. The volatile compounds in the aerosol-forming agent and the aerosol-forming substrate are heated by the heated air and optionally also by the heating element, thereby releasing a vapor. The vapor cools and forms an aerosol as it flows through the article to the mouthpiece. The aerosol can then be delivered to the user at the mouthpiece for inhalation.

[0068] The heating element may include a resistive heating component, such as one or more resistance wires or other resistance elements. The resistance wires may be in contact with a thermally conductive material to distribute the generated heat over a wider area. Examples of suitable conductive materials include aluminum, copper, zinc, nickel, silver, and combinations thereof.

[0069] The heating element may comprise a susceptor for heating by the induction element. The induction element may comprise one or more induction coils configured to induce eddy currents and / or hysteresis losses in the susceptor material that result in heating of the susceptor. To assist induction heating, the aerosol generating article may be provided with a susceptor. Alternatively, the aerosol generating device may comprise a susceptor. Alternatively, both the aerosol generating article and the aerosol generating device may comprise a susceptor. Suitable susceptor materials are as described above.

[0070] The aerosol generating device may comprise control electronics operably coupled to the heating element. Where the heating element comprises a susceptor and a sensing element arrangement, the control electronics may be operably coupled to the sensing element. The control electronics may be configured to control the heating of the heating element. The control electronics may be configured to control a heating profile of the heating element over time. The control electronics may be arranged as part of the aerosol generating device, for example, inside the housing.

[0071] The control electronics may be provided in any suitable form and may, for example, include a controller or a memory and a controller. The controller may include one or more of: an Application Specific Integrated Circuit (ASIC) state machine, a digital signal processor, a gate array, a microprocessor, or an equivalent discrete or integrated logic circuit. The control electronics may include a memory containing instructions that cause one or more components of the circuit to implement functions or aspects of the control electronics. Functionality attributable to the control electronics in the present disclosure may be embodied as one or more of software, firmware, and hardware.

[0072] The electronic circuit may include a microprocessor, which may be a programmable microprocessor. The electronic circuit may be configured to regulate the supply of power. Power may be supplied to the heating element or the sensing element in the form of current pulses.

[0073] If the heating element is a resistive heating element, the control electronics may be configured to monitor the resistance of the heating element. The control electronics may be configured to control the power supply to the heating element depending on the resistance of the heating element. In this way, the control electronics may adjust the temperature of the resistive element.

[0074] If the heating component comprises an inductive element, and the heating element comprises a susceptor material, the control electronics may be configured to monitor aspects of the inductive coil. The control electronics may be configured to control the power supply to the inductive coil depending on the various aspects of the coil. In this way, the control electronics may adjust the temperature of the susceptor material.

[0075] The aerosol generating device may include a temperature sensor, such as a thermocouple, operably coupled to the control electronics to control the temperature of the heating element or substrate. The temperature sensor may be positioned at any suitable location. For example, the temperature sensor may be configured to be inserted into the aerosol-forming substrate or to be in contact with or in proximity to the heating element. The sensor may transmit a signal related to the sensed temperature to the control electronics, which may adjust the heating of the heating element to achieve a suitable temperature at the sensor.

[0076] Whether or not the aerosol generating device comprises a temperature sensor, the device is preferably configured to heat an aerosol-forming substrate of an aerosol-generating article received by the aerosol generating device to an extent sufficient to generate an aerosol without burning the aerosol-generating substrate.

[0077] The aerosol generating device may be configured to heat the aerosol-forming substrate to a temperature of at least about 150° C., at least about 180° C., or at least about 200° C. The aerosol generating device may be configured to heat the aerosol-forming substrate to a temperature of at most about 375° C., at most about 350° C., at most about 300° C., at most about 250° C., or at most about 230° C.

[0078] The control electronics may be operably coupled to a power source. The power source may be internal to the housing. The aerosol generating device may include any suitable power source. For example, the power source for the aerosol generating device may be a battery or a battery pack. The battery may be rechargeable and may also be removable and replaceable. Any suitable battery may be used.

[0079] The aerosol generating article may be a cartridge configured for use in a hookah device. Preferably, the hookah device is configured to heat the aerosol-forming substrate in the aerosol generating article sufficiently to form an aerosol from the aerosol-forming substrate, but without burning the aerosol-forming substrate. The hookah device may include a container for receiving the aerosol generating article. The hookah device includes a heating element configured to contact or approach the body of the aerosol generating article when the aerosol generating article is received in the container. In one example, the hookah device includes an aerosol generating element, which includes a cartridge container, a heating element, an aerosol outlet, and a fresh air inlet. The cartridge container is configured to receive a cartridge containing an aerosol-forming substrate and an absorptive carrier impregnated with an aerosol former. The heating element may define at least a portion of the surface of the container.

[0080] The hookah device includes a fresh air inlet channel connected to the container fluid. In use, when the absorbent carrier inside the cartridge is heated, the impregnated aerosol forming agent in the absorbent carrier evaporates. Air flowing through the cartridge from the fresh air inlet channel entrains the aerosol generated from the aerosol forming agent components and the aerosol forming substrate in the cartridge.

[0081] The hookah device may include any suitable vessel defining an internal volume configured to hold a liquid and defining an outlet in a headspace above the liquid level. The consumer may fill the vessel with the liquid. The liquid preferably comprises water, which may optionally be infused with one or more colorants, flavors, or colorants or flavors.

[0082] Aerosol entrained in the air exiting the aerosol outlet of the receptacle may travel through a conduit positioned in the receptacle. The conduit may be coupled to the aerosol outlet of the aerosol generating element of the hookah assembly and may have an opening below the liquid level of the vessel such that aerosol flowing through the vessel flows through the opening of the conduit and then through the liquid into the head space of the vessel and out of the head space outlet for delivery to a consumer. The head space outlet may be coupled to a hose including a mouthpiece for delivering the aerosol to the consumer. BRIEF DESCRIPTION OF THE DRAWINGS

[0083] Reference will now be made to the accompanying drawings, which depict one or more aspects described in the present disclosure. However, it should be understood that other aspects not depicted in the drawings fall within the scope and spirit of the present disclosure. Similar numbers used in the drawings refer to similar parts. However, it should be understood that the use of numbers in a given figure to refer to a part is not intended to limit the parts marked with the same number in another figure. In addition, the use of different numbers to refer to parts in different figures is not intended to indicate that the parts with different numbers cannot be the same or similar to the parts with other numbers. The figures are presented for the purpose of illustration and not limitation. The schematic diagrams presented in the figures are not necessarily drawn to scale.

[0084] Figure 1 is a schematic cross-sectional side view of an aerosol-generating article.

[0085] Figure 2 is a schematic cross-sectional side view of an aerosol generating device, wherein Figure 1 An aerosol-generating article is inserted therein.

[0086] Figure 3 is a schematic cross-sectional side view of an aerosol-generating article.

[0087] Figure 4 is a schematic cross-sectional side view of an aerosol generating device, wherein Figure 3 An aerosol-generating article is inserted therein.

[0088] Figure 5 is a schematic cross-sectional side view of an aerosol generating device having an external heating element and an internal heating element.

[0089] FIG. 6A to FIG. 6E is a schematic perspective view of a substrate portion of an aerosol-generating article.

[0090] Fig. 7A is a cross-sectional side view of an aerosol-generating article configured as a cartridge.

[0091] Figure 7B is a cross-sectional top view of an aerosol-generating article configured as a cartridge.

[0092] Figure 7C is a cross-sectional top view of an aerosol-generating article configured as a cartridge.

[0093] Figure 8 is a schematic cross-sectional view of a hookah device. DETAILED DESCRIPTION

[0094] Figure 1is a schematic cross-sectional side view of an exemplary aerosol-generating article 500 according to one embodiment. The illustrated aerosol-generating article 500 includes a plurality of coaxial elements. However, many of the elements are optional or preferred, and the aerosol-generating article 500 can be manufactured with or without them. The aerosol-generating article 500 includes at least one substrate element 510, the at least one substrate element including an aerosol-forming substrate 511, an absorbent carrier 512, and an aerosol-forming agent impregnated or impregnable in the absorbent carrier 512. The aerosol-generating article 500 may also include one or more support elements 521, 522 disposed adjacent to the substrate element 510. The first support element 521 may be located at the farthest or upstream end 552 of the aerosol-generating article. The second support element 522 may be located on the opposite side and immediately downstream of the substrate element 510. The support elements 521, 522 may be used to help maintain the aerosol-forming substrate 511 in a desired position within the substrate element 510. The support elements 521 , 522 may be air permeable or may include an air path 526 through the tubular element 524 to allow airflow through the aerosol-generating article 500. The support elements 521 , 522 may be made of any suitable material, such as cellulose acetate.

[0095] The aerosol-generating article 500 may optionally include a capsule 550 embedded in the substrate element 510. The capsule 550 may include an aerosol-forming agent. The user may rupture the capsule 550 before using the aerosol-generating article 500 to release the aerosol-forming agent and impregnate the absorbent carrier 512 with the aerosol-forming agent.

[0096] The aerosol-generating article 500 may include an aerosol-cooling element 530. The aerosol-cooling element 530 may be located downstream of the substrate element 510 and the optional support element 522. In use, volatile materials released from the substrate element 510 pass through the aerosol-cooling element 530 toward the mouth end 551 of the aerosol-generating article 500. The volatile materials may cool within the aerosol-cooling element 530 to form an aerosol that may be inhaled by a user.

[0097] The aerosol-cooling element 530 may be made of any suitable material, such as a rolled and gathered sheet material that provides a plurality of longitudinal channels extending along the length of the aerosol-cooling element 530. One example of a suitable material for the aerosol-cooling element 530 is a polylactic acid sheet. The polylactic acid sheet may be rolled.

[0098] The aerosol-generating article 500 may further comprise a mouthpiece 540 located immediately downstream of and adjacent the aerosol-cooling element 530. The mouthpiece 540 may comprise a filter. One example of a suitable filter is a conventional cellulose acetate tow filter.

[0099] The elements of the aerosol-generating article 500 may be surrounded by an outer wrapper, wall or sleeve 560 to hold the elements in place.

[0100] The aerosol generating article 500 has a proximal end, a downstream end or an oral end 551 for insertion into the mouth of a user, and an upstream end or a distal end 552 located at the opposite end of the oral end 551. The aerosol generating article 500 and each of its elements can be generally cylindrical, each having approximately the same diameter. For example, the aerosol generating article 500, the support elements 521, 522, the substrate element 510, the cooling element 530 and the mouthpiece 540 can be generally cylindrical and can each have approximately the same diameter. These elements can be arranged sequentially to form a cylindrical rod. These elements can be surrounded by an outer wrapper 560.

[0101] To assemble the aerosol-generating article 500, the components are aligned and tightly packed in an outer wrapper. The outer wrapper may be conventional cigarette paper. Once assembled, the aerosol-generating article 500 may have an overall length of about 40 mm to about 60 mm, or about 45 mm to about 53 mm, and a diameter of about 6.5 mm to about 8 mm, or about 7.2 mm.

[0102] Reference now Figure 2 , the aerosol-generating article 500 may be inserted into the aerosol-generating device 600. The aerosol-generating article 500 and the aerosol-generating device 600 together may form the aerosol-generating system 400.

[0103] Figure 2 The aerosol generating device 600 shown in FIG. 1 is configured to receive Figure 1 The aerosol generating device 600 includes a housing 601 and a container 610 formed in the housing 601. The container 610 is configured to receive the aerosol generating article 500. The size and shape of the container 610 can be designed so that when the aerosol generating article 500 is inserted into the container 610, at least a portion of the aerosol generating article 500 (e.g., the mouthpiece 540) remains outside the container 610.

[0104] The aerosol generating system 400 includes a heating element. Figure 2 As shown, the heating element may be an external heating element 622. The external heating element 622 may be a part of the aerosol generating article 500, or may be mounted along the inner wall of the container 610 of the aerosol generating device 600. In use, when the user inserts the aerosol generating article 500 into the container 610 of the aerosol generating device 600, the heating element 622 at least partially surrounds the aerosol-forming substrate 511 of the aerosol generating article 500, as shown in FIG. Figure 2 shown.

[0105] Reference now Figure 3 , an aerosol generating article 500 configured for use with an internal heating element is shown. The aerosol generating article 500 shown includes a plurality of coaxial elements. However, many of the elements are optional or preferred, and the aerosol generating article 500 can be manufactured with or without them. The aerosol generating article 500 includes at least one substrate element 510, the at least one substrate element including an aerosol-forming substrate 511, an absorptive carrier 512, and an aerosol-forming agent impregnated or impregnable in the absorptive carrier 512. In the embodiment shown, the absorptive carrier 512 forms a core that is disposed in the center of the substrate element 510 and is surrounded by the aerosol-forming substrate 511. The absorptive carrier 512 can form a slot configured to receive the internal heating element.

[0106] The aerosol-generating article 500 may further comprise one or more support elements 521, 522 disposed adjacent the substrate element 510. A first support element 521 may be located at the distal-most or upstream end 552 of the aerosol-generating article. A second support element 522 may be located on the opposite side and immediately downstream of the substrate element 510. The support elements 521, 522 may be used to help maintain the aerosol-forming substrate 511 in a desired position within the substrate element 510. The support elements 521, 522 may be air permeable or may include an air path 526 through the tubular element 524 to allow airflow through the aerosol-generating article 500. The support elements 521, 522 may be made of any suitable material, such as cellulose acetate.

[0107] The aerosol generating article 500 may include a Figure 1 The aerosol-cooling element 530, the mouthpiece 540 and the outer wrapper, wall or sleeve 560 are shown. The aerosol-generating article 500 may be similar to Figure 1 The aerosol generating article 500 may have a Figure 1 The aerosol-generating article 500 has a generally cylindrical shape similar to that of the aerosol-generating article 500 .

[0108] Figure 4 The invention shows an aerosol generating device 600 and Figure 3 An exemplary aerosol generating system 400 of an aerosol generating article 500 is provided. Figure 4 The illustrated aerosol generating device 600 comprises a housing 601 and a receptacle 610 formed in the housing 601. The receptacle 610 is configured to receive the aerosol generating article 500. The size and shape of the receptacle 610 may be designed such that when the aerosol generating article 500 is inserted into the receptacle 610, at least a portion of the aerosol generating article 500 (e.g., the mouthpiece 540) remains outside the receptacle 610.

[0109] Figure 4 The aerosol generating system 400 of the invention comprises an internal heating element 621. The internal heating element 621 may be part of the aerosol generating article 500, or may be mounted within the receptacle 610 of the aerosol generating device 600. In use, a user inserts the aerosol generating article 500 into the receptacle 610 of the aerosol generating device 600, such that the internal heating element 621 is inside the aerosol-forming substrate 511 of the aerosol generating article 500, as shown in FIG. Figure 4 As shown. Figure 4 In the embodiment shown, the internal heating element 621 is a heater blade.

[0110] If the internal heating element 621 is mounted within the receptacle 610, inserting the aerosol-generating article 500 into the receptacle 610 may cause the aerosol-generating article 500 to experience a certain amount of penetration force during insertion. During insertion of the internal heating element 621 of the aerosol-generating device 600 into the aerosol-forming substrate 511, the second support element 522 of the aerosol-generating article 500 resists the penetration force of the internal heating element 621, thereby resisting downstream movement of the aerosol-forming substrate 511 within the aerosol-generating article 500.

[0111] Figure 5 An aerosol generating device 600 is shown comprising both an internal heating element 621 and an external heating element 622 .

[0112] like Figure 2 , Figure 4 and Figure 5 The aerosol generating device 600 shown comprises a power source 651 and electronics 652, 653 that allow the heating elements 621, 622 to be actuated. Such actuation may be manually operated or may occur automatically in response to a user taking a puff on an aerosol generating article 500 inserted into an aerosol generating article receptacle 610 of the aerosol generating device 600. One or more openings may be provided in the aerosol generating device 600 to allow air to flow to the aerosol generating article 500.

[0113] The electronic device may include a controller 652 and a user interface 653. The controller 652 may be operably connected to the heating elements 621, 622, the power source 651, and the user interface 653. The user interface 653 may include, for example, buttons, a display, or both. The controller 652 controls the power supplied to the heating elements 621, 622 to adjust their temperature. The power source 651 may be an electrical energy supply, such as a rechargeable lithium-ion battery. The electronic device may also include a temperature controller.

[0114] Preferably, in various embodiments, the absorptive carrier 512 impregnated or impregnable with an aerosol-forming agent is disposed between the heating elements 621, 622 and the aerosol-forming substrate 511. Initially, once the aerosol-generating article 500 is inserted into the container 610 and the heating elements 621, 622 are actuated, the temperature of the substrate element 510 begins to rise. Because the absorptive carrier is closest to the heating element (e.g., disposed between the heating element and the substrate), the aerosol-forming agent impregnated in the absorptive carrier 512 reaches its volatilization temperature first before the aerosol-forming substrate. At this temperature, the volatile compounds are released from the aerosol-forming agent. The temperature of the aerosol-forming substrate continues to rise until a target temperature is reached, such as a temperature of about 375 degrees Celsius. The aerosol-forming substrate also begins to release vapor when it reaches a temperature above the evaporation temperature of the volatile compounds in the aerosol-forming substrate. When the user draws on the mouth end 70 of the aerosol-generating article 500, volatile compounds emitted from the aerosol-forming agent impregnated in the absorbent carrier 512 are drawn downstream through the aerosol-generating article 500 and condense to form an aerosol that is drawn into the user's mouth through the mouthpiece 50 of the aerosol-generating article 500. After a short time (e.g., after the first few puffs), the aerosol-forming substrate 511 also heats to a sufficient temperature to also release an aerosol from the aerosol-forming substrate 511 itself.

[0115] As the aerosol passes downstream through the aerosol-cooling element 530, the temperature of the aerosol is reduced due to the transfer of heat energy from the aerosol to the aerosol-cooling element 530. When the aerosol enters the aerosol-cooling element 530, its temperature is about 60 degrees Celsius. Due to cooling within the aerosol-cooling element 530, the temperature of the aerosol when it leaves the aerosol-cooling element is about 40 degrees Celsius.

[0116] FIG. 6A to FIG. 6E Various embodiments of a substrate element 510 are shown, which includes an aerosol-forming substrate 511, an absorptive carrier 512, and an aerosol-forming agent impregnated or impregnable in the absorptive carrier 512. FIG. 6A to FIG. 6E The substrate element 510 may be combined with any suitable aerosol generating device (including but not limited to Figure 2 , Figure 4 , Figure 5 and Figure 8 shown). Fig. 6A In the first embodiment shown, the substrate element 510 comprises a core of an aerosol-forming substrate 511 surrounded by an absorbent carrier 512 impregnated with an aerosol-forming agent. The first embodiment is particularly suitable for use with an external heating element at least partially surrounding the substrate element 510.

[0117] exist Figure 6BIn the second embodiment shown, the substrate element 510 includes an aerosol-forming substrate 511 and, at the center of the aerosol-forming substrate 511, an absorbent carrier 512 impregnated with an aerosol-forming agent. The second embodiment is particularly suitable for use with an internal heating element that penetrates the substrate element 510. The absorbent carrier 512 may form a slot configured to receive the internal heating element. The substrate element 510 may also include a susceptor. Figure 6B , an optional susceptor is shown as a susceptor blade 514 disposed adjacent to an absorbent carrier 512.

[0118] exist Figure 6C In the third embodiment shown, the substrate element 510 comprises a spiral of a plurality of alternating layers of an absorbent carrier 512 impregnated with an aerosol-forming agent and an aerosol-forming substrate 511 . Figure 6C The substrate element 510 may be, for example, Figure 5 For use with an aerosol generating device 600.

[0119] exist Fig.6D In the fourth embodiment shown, the substrate element 510 comprises alternating layers of an aerosol-forming substrate 511 and an absorbent carrier 512 impregnated with an aerosol-forming agent, and a spiral of susceptor material layers 516. The susceptor material layers 516 may be laminated with or to the layers of the absorbent carrier 512. Fig.6D The substrate element 510 may be, for example, Figure 5 For use with an aerosol generating device 600.

[0120] exist Fig. 6E In the fifth embodiment shown, the substrate element 510 comprises a core of an aerosol-forming substrate 511 surrounded by an absorbent carrier 512 which may be impregnated with an aerosol-forming agent. The aerosol-forming agent is contained in a capsule 550 embedded in the substrate element 510. The user may rupture the capsule 550 prior to using the aerosol-generating article 500 to release the aerosol-forming agent and impregnate the absorbent carrier 512 with the aerosol-forming agent.

[0121] The substrate element 510 may also include a combination of the five embodiments shown in the figure. For example, the substrate element 510 may include Fig. 6A and Figure 6B or Fig. 6A and Figure 6C , Fig. 6A and Fig.6D , Fig. 6A and Fig. 6E or Figure 6B and Figure 6C , Figure 6B and Fig.6D , Figure 6B and Fig. 6E or Figure 6C and Fig. 6E or Fig.6D and Fig. 6E A combination of features, or in fact FIG. 6A to FIG. 6E Any combination of two, three or four of the following.

[0122] refer to Fig. 7A and Figure 7B , the aerosol generating article 500 may be configured as a cartridge. For example, FIG. 6A to FIG. 6E The substrate element shown in the figure can be provided with the main body of the tube. The tube 200 has a main body 210 defining a cavity 218, in which an aerosol-forming substrate 511 and an absorption carrier 512 impregnated with an aerosol-forming agent can be provided. The main body 210 includes a top 215, a bottom 213 and a sidewall 212. The main body 210 can be formed by one or more parts. For example, the top 215 or the bottom 213 can be removably attached from the sidewall 212 to allow the aerosol-forming substrate 511 and the absorption carrier 512 to be arranged in the cavity 218. The absorption carrier 512 can be arranged along the sidewall 212 of the cavity 218 or the sidewall 212 and the bottom 213. The absorption carrier 512 can also be arranged along the top 215, or arranged along any combination of the bottom 213, the top 215 or the sidewall 212, or can partially cover any of these surfaces. In the example shown, the absorbent carrier 512 has pleated sides that surround the periphery of the aerosol-forming substrate 511 .

[0123] Figure 7C A cross-sectional view of a cartridge 200 is shown in which an aerosol-forming substrate 511 and an absorbent carrier 512 form a spiral cylindrical shape comprising a plurality of alternating layers of absorbent carrier 512 and aerosol-forming substrate 511. The rolled cylindrical shape is provided inside a body 210 of the cartridge 200.

[0124] The cartridge 200 has a heatable surface area inside the cavity 218 which is a surface capable of transferring heat applied to the exterior of the body to the absorptive carrier 512 and aerosol-forming substrate 511 in the cavity 218, for example by a heating element of an aerosol generating device.

[0125] The top 215 and bottom 213 of the body may have a plurality of openings to allow air to flow through the cartridge when the cartridge 200 is in use. The cartridge 200 may also or alternatively include openings along the sidewall 212. The absorbent carrier 512 may be arranged along the bottom 213, the top 215, the sidewall 212, or a combination thereof, covering some or all of the openings. When the cartridge is stored prior to use, the openings may be further closed by a peelable seal or cover.

[0126] In some embodiments, the aerosol-generating article 500 configured as a cartridge is configured for use in a hookah device. Figure 81 is a schematic cross-sectional view of an example of an aerosol generating system including a hookah device 100. The hookah device 100 includes a vessel 17 defining an internal volume configured to contain a liquid 19 and defining a headspace outlet 15 above the level of the liquid 19. The liquid 19 preferably comprises water, which may optionally be infused with one or more colorants, one or more flavorants, or one or more colorants and one or more flavorants. For example, the water may be infused with one or both of a botanical infusion or an herbal infusion.

[0127] The device 100 also includes an aerosol generating element 130. The aerosol generating element 130 includes a container 140 configured to receive an aerosol generating article arranged as a cartridge 200, the aerosol generating article comprising an aerosol forming substrate and an absorbent carrier forming a sheet and impregnated with an aerosol forming agent. The aerosol generating element 130 also includes a heating element 160, which forms at least one surface of the container 140. In the illustrated embodiment, the heating element 160 defines the top surface and the side surface of the container 140. The aerosol generating element 130 also includes a fresh air inlet channel 170, which draws fresh air into the device 100. In some embodiments, a portion of the fresh air inlet channel 170 is formed by the heating element 160 to heat the air before the air enters the container 140. The preheated air then enters the cartridge 200 (which is also heated by the heating element 160) to carry the aerosol generated by the aerosol forming agent and the aerosol forming substrate. The air exits the outlet of the aerosol generating element 130 and enters the conduit 190 .

[0128] The conduit 190 carries air and aerosol into the vessel 17 below the level of the liquid 19. The air and aerosol may bubble through the liquid 19 and then exit the headspace outlet 15 of the vessel 17. A hose 20 may be attached to the headspace outlet 15 to carry the aerosol to the user's mouth. A mouthpiece 25 may be attached to the hose 20 or formed as part of the hose.

[0129] In use, an exemplary air flow path of the device is Figure 8 Indicated by thick arrows.

[0130] The mouthpiece 25 may include an activation element 27. The activation element 27 may be a switch, a button, etc., or may be a suction sensor, etc. The activation element 27 may be placed in any other suitable location of the device 100. The activation element 27 may wirelessly communicate with the control electronics 30 to place the device 100 in a state of use or to cause the control electronics to activate the heating element 160; for example, by causing the power supply 35 to power the heating element 140.

[0131] The control electronics 30 and power source 35 may be located at any suitable location on the aerosol generating element 130, rather than at a location such as Figure 8The bottom of element 130 is shown.

[0132] The specific embodiments described above are intended to illustrate the invention. However, other embodiments may be prepared without departing from the scope of the invention as defined in the claims, and it is to be understood that the specific embodiments described above are not intended to be limiting.

[0133] As used herein, the singular forms "a", "an", and "the" encompass embodiments having plural referents unless the content clearly dictates otherwise.

[0134] As used herein, "or" is generally employed in its sense including "and / or" unless the content clearly dictates otherwise. The term "and / or" means one or all of the listed elements or a combination of any two or more of the listed elements.

[0135] As used herein, "having", "including", "comprising", etc. are used in their open sense and generally mean "including (but not limited to)". It should be understood that "consisting essentially of", "consisting of", etc. are included in "comprising", etc.

[0136] The words "preferred" and "preferably" refer to embodiments of the invention that may provide certain benefits under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. In addition, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure (including the claims).

[0137] As used herein, the term "substantially" has the same meaning as "quite", and can be understood to modify the subsequent term by at least about 90%, at least about 95%, or at least about 98%. As used herein, the term "substantially not" has the same meaning as "not quite", and can be understood to have the opposite meaning of "substantially", that is, modifying the subsequent term by no more than 10%, no more than 5%, or no more than 2%.

[0138] Any directions mentioned herein such as "top", "bottom", "left", "right", "upper", "lower", and other directions or orientations described herein for the sake of clarity and brevity are not intended to limit the actual device or system. The devices and systems described herein can be used in multiple directions and orientations.

[0139] Thus, an aerosol generating article for use with an aerosol generating device is described. Various modifications and variations of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in conjunction with specific preferred embodiments, it will be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which would be apparent to those skilled in the mechanical arts, chemical arts, and aerosol generating article manufacturing or related arts are intended to be within the scope of the following claims.

Claims

1. An aerosol generating system comprising: An aerosol-generating article, the aerosol-generating article comprising: an aerosol-forming substrate; an absorptive carrier forming a sheet, the sheet comprising a heating element contact surface, wherein the absorptive carrier at least partially surrounds the aerosol-forming substrate; and an aerosol former for being impregnated into the absorption carrier; an aerosol-generating device for receiving the aerosol-generating article; and a heating element for heating the aerosol-forming substrate of the aerosol-generating article, the heating element comprising an external heating element at least partially surrounding the aerosol-generating article when the aerosol-generating article is received in the aerosol-generating device, wherein the system is configured such that when the article is received by the aerosol generating device, the absorbent carrier is disposed between the aerosol-forming substrate and the heating element, and the heating element contact surface contacts the external heating element.

2. An aerosol generating system according to claim 1, wherein the aerosol generating article further comprises the external heating element, or wherein the aerosol generating device comprises the external heating element.

3. An aerosol generating system according to claim 1 or 2, wherein the heating element comprises a susceptor, and wherein the aerosol generating device comprises an induction coil, the induction coil being configured to heat the susceptor when the article is received in the device.

4. An aerosol-generating system according to claim 1, wherein the aerosol-generating article is inserted into a receptacle of the aerosol-generating device and the absorbent carrier is disposed between the aerosol-forming substrate and the heating element.

5. An aerosol generating system according to claim 1 or 2, further comprising an internal heating element.

6. An aerosol-generating article for use in an aerosol-generating system according to any preceding claim, the aerosol-generating article comprising: an aerosol-forming substrate; an absorptive carrier forming a sheet, the sheet comprising a heating element contact surface, wherein the absorptive carrier at least partially surrounds the aerosol-forming substrate; as well as an aerosol former for being impregnated into the absorption carrier; wherein the aerosol-generating article is configured such that when the article is received by the aerosol-generating device, the absorbent carrier is disposed between the aerosol-forming substrate and the heating element, and the heating element contact surface contacts the external heating element.

7. An aerosol-generating article according to claim 6, wherein the aerosol-generating article comprises a frangible membrane containing the aerosol-forming agent, and wherein the frangible membrane is arranged to release the aerosol-forming agent into the absorbent carrier when the frangible membrane is ruptured.

8. An aerosol-generating article according to claim 6, wherein the aerosol-forming substrate comprises a solid, a paste, a gel, a slurry, a liquid or a combination thereof.

9. An aerosol-generating article according to claim 6, wherein the aerosol-forming substrate comprises a solid.

10. An aerosol-generating article according to claim 6, wherein the aerosol-forming substrate forms a core, and wherein the absorbent carrier comprises a cylindrical portion at least partially surrounding at least a portion of the core.

11. An aerosol-generating article according to claim 6, wherein the aerosol-forming substrate forms a layer applied to the absorbent carrier, and wherein the absorbent carrier and the aerosol-forming substrate form a spiral of alternating layers of absorbent carrier and aerosol-forming substrate.

12. An aerosol-generating article according to claim 6, wherein the absorbent carrier is lined with a thermally conductive or inductive material.

13. An aerosol-generating article according to claim 6, wherein the absorbent carrier comprises paper.

14. An aerosol-generating article according to claim 6, wherein the article comprises a cartridge housing, and the aerosol-forming substrate and the absorbent carrier are disposed within the cartridge housing.

15. An aerosol-generating article according to claim 6, wherein the article comprises a susceptor.

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