Electrically operated aerosol-generating system

Abstract

This application relates to an electrically operated aerosol generation system, comprising an aerosol generation apparatus, a removable aerosol forming cylinder, and a removable heater, the cylinder and heater being disposed separately from each other. The cylinder includes at least one aerosol forming matrix, and the heater includes at least one electric heater element and a first electrical contact connected to the at least one electric heater element. The aerosol generation apparatus includes: a body defining a main cavity and at least one opening for receiving the cylinder and heater into the main cavity; a power source; and a second electrical contact connected to the power source. The first electrical contact contacts the second electrical contact when both the cylinder and heater are received within the main cavity, and the heater is arranged to heat the aerosol forming matrix. The cylinder and heater are substantially flat, and the main cavity, cylinder, and heater are arranged such that when received together in the main cavity, the cylinder and heater are substantially parallel and adjacent to each other.

Description

[0001] This application is a divisional application of the invention patent application entitled "Aerosol Generation System Including Removable Heater", with an international filing date of July 10, 2015, international application number PCT / EP2015 / 065912, and national application number 201580033317.8. Technical Field

[0002] This invention relates to an aerosol generation system including a removable heater. The invention has a specific application in aerosol generation system for heating a nicotine-containing aerosol forming matrix. Background Technology

[0003] One type of aerosol generation system is an electrically operated fumigation system. Handheld electrically operated fumigation systems are known, consisting of an electric heater, an aerosol generation device including a battery and control electronics, and an aerosol forming cylinder. In some instances, the electric heater forms part of the aerosol generation device. However, the electric heater can become contaminated with materials from the aerosol forming matrix during use, and the electric heater within the device can be difficult to clean. In some cases, if the heater cannot be adequately cleaned, the entire device needs to be disposed of. Other examples attempt to overcome this problem by incorporating the electric heater into the aerosol forming cylinder, allowing the heater to be disposed of along with the cylinder after use. However, while this eliminates the need to clean the heater, the cost of manufacturing the system increases significantly because the heater needs to be incorporated into each cylinder.

[0004] Therefore, it is desirable to develop an electrically operated aerosol generation system that solves the problem of heater contamination while minimizing the cost of manufacturing equipment and cylinders. Summary of the Invention

[0005] According to the present invention, an electrically operated aerosol generation system is provided, comprising an aerosol generation device, a removable aerosol forming cylinder, and a removable heater, wherein the removable aerosol forming cylinder and the removable heater are disposed separately from each other. The aerosol forming cylinder includes at least one aerosol forming matrix, and the heater includes at least one electric heater element and a first electrical contact connected to the at least one electric heater element. The aerosol generation device includes a body defining a main cavity and at least one opening for receiving the aerosol forming cylinder and the heater within the main cavity. The aerosol generation device also includes a power source and a second electrical contact connected to the power source. When both the aerosol forming cylinder and the heater are received within the main cavity, the first electrical contact contacts the second electrical contact, and the heater is arranged to heat the aerosol forming matrix. The aerosol forming cylinder and the heater are substantially flat, and the main cavity, the aerosol forming cylinder, and the heater are arranged such that the aerosol forming cylinder and the heater are substantially parallel to each other and adjacent to each other when received together in the main cavity.

[0006] As used herein, the term "aerosol generation system" refers to a combination of an aerosol generation apparatus, an aerosol forming cylinder, and a heater, as further described and illustrated herein. In this system, the apparatus, cylinder, and heater cooperate to generate aerosols.

[0007] As used herein, the term "aerosol generating apparatus" refers to an apparatus that interacts with an aerosol forming cylinder and a heater to generate aerosols. An aerosol generating apparatus includes a heater powered by an electric source to heat the aerosol forming cylinder.

[0008] As used herein, the term "tube" refers to a consumable configured to be connected to an aerosol generating device and assembled as a single unit that can be connected and disconnected as a single unit.

[0009] As used herein, the term "aerosol forming cartridge" refers to a cartridge comprising at least one aerosol forming matrix capable of releasing volatile compounds that can form aerosols. For example, an aerosol forming cartridge may be a smoking article that generates aerosols.

[0010] As used herein, the term 'aerosol forming matrix' is used to describe a matrix capable of releasing and forming aerosols. Aerosols generated from the aerosol forming matrix of the aerosol forming cylinder according to the invention may be visible or invisible and may include vapors (e.g., fine particulate matter in a gaseous state, which are typically liquid or solid at room temperature) as well as droplets of gas and condensed vapors.

[0011] As used herein, the term "substantially flat" means that a component has a thickness-to-width ratio of at least 1:2. Preferably, the thickness-to-width ratio is less than about 1:20 to minimize the risk of the component bending or breaking.

[0012] Advantageously, providing a substantially flat heater and a substantially flat cylinder facilitates the insertion of the heater and cylinder into the device. Furthermore, flat components can be easily handled during manufacturing. Additionally, it has been found that the release of aerosols from the aerosol forming matrix is ​​improved when the aerosol forming matrix is ​​substantially flat and when arranged such that the gas flow is drawn through the width, length, or both of the aerosol forming matrix.

[0013] Arranging the main chamber, heater, and cylinder such that they are substantially parallel and adjacent to each other when received together in the main chamber advantageously ensures optimal contact between the heater and cylinder, and thus maximizes heat transfer from the heater to the cylinder. This arrangement also minimizes the size of the chamber, and therefore the overall size of the aerosol generation system.

[0014] By configuring the heater as a separate and removable element from both the aerosol generating device and the aerosol forming cylinder, the system according to the invention also facilitates cleaning the heater in the event of contamination from materials from the aerosol generating device and the aerosol forming cylinder. Furthermore, the heater can be used with multiple aerosol forming cylinders, thus making the system more cost-effective compared to known systems where each disposable cylinder includes a heater element. Additionally, if needed, the heater in the system according to the invention can be replaced by the user without requiring replacement of the aerosol generating device. Therefore, multiple different heaters can also be used to heat multiple different aerosol-formed articles using only a single aerosol generating device.

[0015] In a preferred embodiment, the heater can be used to heat at least 5 aerosol forming cylinders, more preferably at least 10 aerosol forming cylinders, more preferably at least 15 aerosol forming cylinders, and most preferably at least 20 aerosol forming cylinders. Alternatively, the heater can be used to heat no more than 30 aerosol forming cylinders, preferably no more than 25 aerosol forming cylinders, and most preferably no more than 20 aerosol forming cylinders. In some embodiments, the aerosol generating apparatus is configured to monitor the number of aerosol-formed articles heated by a particular heater. In these embodiments, the apparatus may be configured to prompt the user to clean or replace the heater after a predetermined number of heating cycles. Alternatively, the apparatus may be configured to prevent further operation of the apparatus until the heater has been removed for cleaning or replacement. The heater may include a data storage device such that the aerosol generating apparatus can retain a record of the number of times a particular heater has been used for heating, even if the heater is removed from the apparatus and reinserted. The record may be stored on the heater's data storage device. Alternatively, the data storage device on the heater may include a unique dataset that can be used by the aerosol generating device to identify and distinguish different heaters, and the aerosol generating device may include a second data storage device for recording the number of heating cycles for each heater used with the device. According to some embodiments, the removable heater includes a data storage medium arranged to communicate with the aerosol generating device when the removable heater is inserted into the main chamber. According to some embodiments, the aerosol generating device and the data storage medium are configured to store data on the data storage medium indicating the number of heating cycles used by the removable heater.

[0016] In any of the above embodiments, the heater and aerosol forming cylinder can be configured to be detachably connected to each other to form an aerosol forming heater assembly. In these embodiments, the main cavity and at least one opening are configured to receive the aerosol forming heater assembly. This arrangement of the heater and aerosol forming cylinder combined before insertion into the device is particularly advantageous in embodiments where at least one of the heater and aerosol forming cylinder is relatively thin. Specifically, because the combination of the heater and aerosol forming cylinder has a greater thickness compared to each individual component, inserting both the heater and cylinder as a single component into the device reduces the risk of bending or otherwise damaging at least one of the heater and cylinder.

[0017] In these embodiments, the heater and aerosol forming cylinder can be removably connected to each other to form an aerosol forming heater assembly. The heater may include a heating chamber for removably receiving the aerosol forming cylinder, such that when the aerosol forming element and the heater are detachably connected to each other, the aerosol forming element is at least partially located within the heating chamber. Using a heating chamber into which the cylinder is inserted facilitates a robust connection between the cylinder and the heater. Using a heating chamber also optimizes heat transfer from the heater to the aerosol forming substrate during system operation.

[0018] Additionally, the heating chamber can also form an airflow chamber, within which the aerosol-forming matrix is ​​positioned when the cylinder is connected to the heater. The airflow chamber can form an airflow channel between an air inlet and an air outlet, wherein the airflow channel is configured to control the airflow through the aerosol generation system. For example, the inner wall surface of the airflow channel may include one or more flow disturbance devices configured to generate turbulent boundary layer airflow when air is drawn through the airflow channel.

[0019] In any of the above embodiments, which include a heater and an aerosol forming cavity that can be detachably connected to each other to form an aerosol forming heater assembly, at least one opening may be a single opening, wherein the opening and at least one of the main cavity include at least one of a guide groove, recess, track, or protrusion for guiding the aerosol forming heater assembly to its correct position within the main cavity.

[0020] As an alternative to a heater and aerosol forming cylinder being removably connected to each other to form an aerosol forming heater assembly, at least one opening and main cavity can be configured to receive the heater and aerosol forming assembly separately. That is, the device can receive both the heater and the cylinder simultaneously, but each of the heater and cylinder can be independently inserted into and removed from the device. Advantageously, this arrangement eliminates the need to remove and reinsert the heater each time the aerosol forming cylinder is replaced. Instead, the heater can remain in the device for use with multiple aerosol forming cylinders until it needs to be removed for cleaning or replacement.

[0021] In those embodiments where the heater and aerosol forming cylinder can be independently inserted into and removed from the aerosol generating apparatus, at least one of the main cavity and at least one opening preferably includes at least one of a guide groove, recess, track, or protrusion for guiding each of the aerosol forming cylinder and heater into the correct position within the main cavity.

[0022] Alternatively, at least one opening may include a first slot for receiving the aerosol forming cylinder and a second slot for receiving the heater. In these embodiments, preferably, the dimensions of the first and second slots, the heater, and the aerosol forming cylinder are configured such that the aerosol forming cylinder can only be inserted into the first slot, and the heater can only be inserted into the second slot. This arrangement will therefore prevent a user from inserting one or both of the aerosol forming cylinder and the heater into incorrect slots on the device, which could potentially damage at least one of the device, the heater, and the aerosol forming cylinder. For example, the first slot and the aerosol forming cylinder may each include a maximum width and a maximum height, while the second slot and the heater may each include a maximum width greater than the maximum width of the first slot and the aerosol forming cylinder, and both the second slot and the heater may include a maximum height less than the maximum height of the first slot and the aerosol forming element.

[0023] Furthermore, the aerosol generation system may include electronic devices for determining whether the heater and cylinder have been inserted into the correct slots on the equipment. For example, the device may be configured to measure the electrical load on components inserted into the first and second slots, respectively. Based on the measured electrical load, the device can determine whether the heater and cylinder have been inserted into the correct slots. If the heater and cylinder are inserted into the incorrect slots, the device is preferably configured to prevent activation. Preferably, the device includes an indicator for notifying the user that the heater and cylinder have been inserted into the incorrect slots.

[0024] In any of the above embodiments, at least one of the aerosol forming chamber, heater, and aerosol generating apparatus may further include an additional heater arranged to heat at least a portion of the aerosol forming matrix when both the aerosol forming chamber and the heater are received within the main chamber. In these embodiments, the additional heater may be connected to a third electrical contact, wherein the aerosol generating apparatus further includes a fourth electrical contact connected to a power source, the third and fourth electrical contacts being in contact with each other when both the aerosol forming chamber and the heater are received within the main chamber.

[0025] In some embodiments, the heater may form a main heater, while the auxiliary heater may form a secondary or booster heater. That is, the main heater heats the aerosol-forming matrix to a first temperature, while the auxiliary heater provides selective additional heat input to selectively raise the aerosol-forming matrix to a higher second temperature. For example, the aerosol generation apparatus may be configured for two or more different types of aerosol-forming cartridges, each comprising a different aerosol-forming matrix requiring different heating profiles. In these embodiments, the auxiliary heater may be configured to heat the aerosol-forming matrix to the higher second temperature only when certain types of aerosol-forming cartridges are inserted into the apparatus. Alternatively, the auxiliary heater may be selectively activated by the user during operation of the apparatus to provide a temporary increase in the amount of aerosol delivered to the user.

[0026] Alternatively, at least one aerosol forming matrix on each aerosol forming cylinder may include two or more aerosol forming matrices, wherein the heater and additional heater are arranged as sequential heaters to sequentially heat the different aerosol forming matrices to provide consistent aerosol delivery throughout the entire operating duration of the system.

[0027] In some embodiments, at least one electric heater element includes a first electric heater element connected to a first electrical contact, and an auxiliary heater includes a second electric heater element disposed within the heater and connected to a third electrical contact, wherein the first and second electric heater elements are arranged to heat different portions of the aerosol forming cylinder when both the aerosol forming cylinder and the heater are received within the main cavity. This arrangement is particularly suitable for aerosol forming cylinders comprising two or more aerosol forming matrices, as described above.

[0028] In any of the above embodiments, the heater may include an electrically insulating substrate, wherein at least one electric heater element includes one or more substantially flat heater elements disposed on the electrically insulating substrate. The substrate may be flexible. The substrate may be polymeric. The substrate may be a multilayer polymer material. The heating element(s) may extend across one or more holes in the substrate.

[0029] In use, the heater can be arranged to heat the aerosol forming matrix by one or more of conduction, convection, and radiation. The heater can heat the aerosol forming matrix by conduction and can be at least partially in contact with the aerosol forming matrix. Alternatively or additionally, heat from the heater can be conducted to the aerosol forming matrix by means of an intermediate heat conduction element. Alternatively or additionally, the heater can transfer heat to ambient air drawn through the cylinder during use, which in turn heats the aerosol forming matrix sequentially by convection.

[0030] The heater may include an internal electric heating element for at least partial insertion into the aerosol forming matrix. An "internal heating element" is an element adapted for insertion into the aerosol forming material. Optionally or additionally, the electric heater may include an external heating element. The term "external heating element" refers to a heating element that at least partially surrounds the aerosol forming cylinder. The heater may include one or more internal heating elements and one or more external heating elements. The heater may include a single heating element. Alternatively, the heater may include more than one heating element.

[0031] At least one heating element may comprise a resistive material. Suitable resistive materials include, but are not limited to: semiconductors such as doped ceramics, electrically “conductive” ceramics (such as molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made of ceramic and metallic materials. Such composites may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, alloys containing nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, and iron, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, and iron-manganese-aluminum alloys. In composites, the resistive material may optionally be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the energy transfer kinetics and desired external physicochemical properties. Alternatively, the heater may comprise an infrared heating element, a photon source, or an induction heating element.

[0032] The heater can take any suitable form. For example, it can take the form of heating blades. Alternatively, it can take the form of a sleeve or matrix with different conductive portions, or a resistive metal tube. Furthermore, the heater may include one or more heating needles or rods penetrating the center of the aerosol-forming matrix. Alternatively, the heater may be a disc (end) heater or a combination of a disc heater and heating needles or rods. The heater may include one or more stamped parts of a resistive material, such as stainless steel. Other alternatives include heating wire or filament, such as Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire, or a heating plate.

[0033] In some preferred embodiments, the heater comprises multiple conductive filaments. The conductive filaments may form a mesh or array of filaments or may comprise interwoven or non-interwoven fabrics.

[0034] The conductive filaments define gaps between the filaments, and these gaps can have widths between 10 μm and 100 μm. Preferably, the filaments induce capillary action in the gaps, such that when the heater is placed to form a matrix with a liquid-containing aerosol, the liquid to be evaporated is drawn into the gaps, thereby increasing the contact area between the heater assembly and the liquid. The conductive filaments can form a mesh with a size between 160 and 600 meshes per inch (+ / - 10%). The gap width is preferably between 25 μm and 75 μm. The percentage of the open area of ​​the mesh, which is the ratio of the area of ​​the gaps to the total area of ​​the mesh, is preferably between 25% and 56%. The mesh can be formed using different types of braids or lattice structures. The mesh, array, or fabric of the conductive filaments can also be characterized by its ability to retain liquid, which is well known in the art. The conductive filament may have a diameter between 10 μm and 100 μm, preferably between 8 μm and 50 μm, and more preferably between 8 μm and 39 μm. The filament may have a circular cross-section or a flat cross-section. The heater filament may be formed by etching a sheet of material such as foil. This can be particularly advantageous when the heater comprises an array of parallel filaments. If the heater comprises a mesh or fabric of filaments, then the filaments may be formed individually and knitted together. The conductive filaments may be provided as a mesh, array, or fabric. The area of ​​the mesh, array, or fabric of conductive filaments may be small, preferably less than or equal to 25 mm², allowing it to be incorporated into a handheld system. The mesh, array, or fabric of conductive filaments may, for example, be rectangular and have dimensions of 5 mm by 2 mm. Preferably, the mesh or array of conductive filaments covers an area between 10% and 50% of the heater area. More preferably, the mesh or array of conductive filaments covers an area between 15% and 25% of the heater area.

[0035] In one embodiment, electrical energy is supplied to the electric heater until the heating element or element of the electric heater reaches a temperature of approximately 180°C to approximately 310°C. Any suitable temperature sensor and control circuitry can be used to control the heating of one or more heating elements to achieve the desired temperature. This is in contrast to conventional cigarettes: the combustion of tobacco and cigarette packaging can reach 800°C.

[0036] Preferably, the minimum distance between the electric heater and at least one aerosol forming matrix is ​​less than 50 micrometers, and preferably, the cylinder comprises one or more layers of capillary fibers in the space between the electric heater and the aerosol forming matrix.

[0037] The heater may include one or more heating elements located above at least one aerosol-forming matrix. Alternatively, the heater may include one or more heating elements located below at least one aerosol-forming matrix. With this arrangement, heating of the aerosol-forming matrix and aerosol release occur on opposite sides of at least one aerosol-forming matrix. This has been found to be particularly effective for aerosol-forming matrices containing tobacco-containing materials. In some embodiments, the heater includes one or more heating elements located near opposite sides of the aerosol-forming matrix. Preferably, the heater includes a plurality of heating elements arranged to heat different portions of the aerosol-forming matrix. In some preferred embodiments, at least one aerosol-forming matrix comprises a plurality of aerosol-forming matrices separately arranged on a base layer, and the heater includes a plurality of heating elements, each arranged to heat a different one of the plurality of aerosol-forming matrices.

[0038] In any of the above embodiments, at least one aerosol-forming matrix may include nicotine. For example, at least one aerosol-forming matrix may include a tobacco-containing material comprising volatile tobacco flavor compounds, which are released from the aerosol-forming matrix when heated.

[0039] Preferably, at least one aerosol-forming matrix includes an aerosol-forming agent, i.e., a substance that generates an aerosol upon heating. The aerosol-forming agent can be, for example, a polyol aerosol-forming agent or a non-polyol aerosol-forming agent. It can be solid or liquid at room temperature, but is preferably liquid at room temperature. Suitable polyols include sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol. Suitable non-polyols include monohydric alcohols such as menthol, high-boiling hydrocarbons, acids such as lactic acid, and esters such as glyceryl diacetate, glyceryl triacetate, triethyl citrate, or isopropyl myristate. Aliphatic carboxylic acid esters, such as methyl stearate, dimethyl dodecanoate, and dimethyl tetradecanoate, can also be used as aerosol-forming agents. Combinations of aerosol-forming agents can be used in equal or different proportions. Polyethylene glycol and glycerol can be particularly preferred, while glyceryl triacetate is more difficult to stabilize and may require encapsulation to prevent its migration within the product. At least one aerosol forming matrix may include one or more flavoring agents, such as cocoa, licorice, organic acids, or menthol.

[0040] At least one aerosol-forming matrix may include a solid matrix. The solid matrix may comprise one or more of the following: powders, granules, pellets, fragments, tubes, strips, or sheets comprising one or more of the following: herbaceous leaves, tobacco leaves, tobacco rib fragments, regenerated tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco. Optionally, the solid matrix may contain additional tobacco or non-tobacco volatile flavor compounds to be released upon heating of the matrix. Optionally, the solid matrix may also contain capsules, for example, comprising additional tobacco or non-tobacco volatile flavor compounds. Such capsules may melt during heating of the solid aerosol-forming matrix. Alternatively or additionally, such capsules may be crushed before, during, or after heating of the solid aerosol-forming matrix.

[0041] In cases where at least one aerosol-forming matrix comprises a solid matrix containing homogeneous tobacco material, the homogeneous tobacco material can be formed by agglomerating particulate tobacco. The homogeneous tobacco material may be in sheet form. The homogeneous tobacco material may contain an aerosol forming agent at a dry weight content exceeding 5%. The homogeneous tobacco material may also have an aerosol forming agent at a dry weight content between about 5% and about 30%. Homogenized tobacco material sheets can be formed by agglomerating particulate tobacco obtained by grinding or otherwise pulverizing one or both of tobacco leaves and tobacco stems; alternatively or additionally, homogeneous tobacco material sheets may include one or more of tobacco powder, fine tobacco powder, and other particulate tobacco byproducts formed during, for example, tobacco processing, handling, and transportation. Homogenized tobacco material sheets may include one or more inherent binders as endogenous tobacco binders, one or more exogenous binders as exogenous tobacco binders, or combinations thereof, to facilitate the agglomeration of particulate tobacco. Alternatively or additionally, homogeneous tobacco material sheets may include other additives, including but not limited to tobacco fibers and non-tobacco fibers, aerosol forming agents, humectants, plasticizers, flavorings, fillers, aqueous solvents and anhydrous solvents, and combinations thereof. Homogeneous tobacco material sheets are preferably manufactured by a casting process in which a slurry comprising particulate tobacco and one or more binders is cast onto a conveyor belt or other supporting surface, the slurry is dried to form a homogeneous tobacco material sheet, and the homogeneous tobacco material sheet is removed from the supporting surface.

[0042] Optionally, the solid matrix may be provided on or embedded in a heat-stable carrier. The carrier may take the form of powder, granules, microspheres, fragments, tubes, strips, or sheets. Alternatively, the carrier may be a tubular carrier having a thin layer of solid matrix deposited on its inner surface, such as those disclosed in US-A-5 505 214, US-A-5 591 368, and US-A-5 388 594, or a tubular carrier having a thin layer of solid matrix deposited on its outer surface, or a tubular carrier having thin layers of solid matrix deposited on both its inner and outer surfaces. Such tubular carriers may be formed from, for example, paper or paper-like materials, nonwoven carbon fiber pads, low-quality open-mesh wire mesh, or perforated metal foil, or any other heat-stable polymer matrix. The solid matrix may be deposited on the surface of the carrier in the form of, for example, sheets, foams, gels, or slurries. The solid matrix may be deposited on the entire surface of the carrier, or alternatively, may be patterned to provide predetermined or non-uniform fragrance delivery during use. Alternatively, the carrier may be a nonwoven fabric or fiber bundle in which tobacco components have been incorporated, such as that described in EP-A-0857431. The nonwoven fabric or fiber bundle may comprise, for example, carbon fibers, natural cellulose fibers, or cellulose derivative fibers.

[0043] As an alternative form of solid tobacco-based aerosol-forming matrix, at least one aerosol-forming matrix may include a liquid matrix, and the cartridge may include means for holding the liquid matrix, such as one or more containers. Alternatively or additionally, the cartridge may include a porous carrier material into which the liquid matrix can be absorbed, as described in WO-A-2007 / 024130, WO-A-2007 / 066374, EP-A-1736062, WO-A-2007 / 131449 and WO-A-2007 / 131450.

[0044] The liquid matrix is ​​preferably a nicotine source, which may include one or more of nicotine, nicotine base, nicotine salt (e.g., nicotine hydrochloride, nicotine hydrogen tartrate or nicotine ditartrate) or nicotine derivatives.

[0045] Nicotine sources can include natural nicotine or synthetic nicotine.

[0046] Nicotine sources may include pure nicotine, nicotine solutions in aqueous or non-aqueous solvents, or liquid tobacco extracts.

[0047] Nicotine sources may also include electrolyte-forming compounds. These compounds may be selected from alkali metal hydroxides, alkali metal oxides, alkali metal salts, alkaline earth metal oxides, alkaline earth metal hydroxides, and combinations thereof.

[0048] For example, the nicotine source may contain an electrolyte-forming compound selected from the following: potassium hydroxide, sodium hydroxide, lithium oxide, barium oxide, potassium chloride, sodium chloride, sodium carbonate, sodium citrate, ammonium sulfate, and combinations thereof.

[0049] In some embodiments, the nicotine source may include an aqueous solution of nicotine, nicotine base, nicotine salt, or nicotine derivative and an electrolyte forming a compound.

[0050] Alternatively or additionally, nicotine sources may also include other components, including but not limited to natural flavorings, artificial flavorings, and antioxidants.

[0051] In addition to a nicotine-containing aerosol-forming matrix, the aerosol-forming cartridge may also include a source of volatile delivery-enhancing compounds that react with gaseous nicotine to help deliver nicotine to the user.

[0052] Volatile delivery-enhancing compounds may include a single compound. Alternatively, volatile delivery-enhancing compounds may include two or more different compounds.

[0053] Preferably, the volatile delivery-enhancing compound is a volatile liquid.

[0054] Volatility delivery-enhancing compounds may include aqueous solutions of one or more compounds. Alternatively, volatile delivery-enhancing compounds may include non-aqueous solutions of one or more compounds.

[0055] Volatile delivery-enhancing compounds may include two or more different volatile compounds. For example, volatile delivery-enhancing compounds may include a mixture of two or more different volatile liquid compounds.

[0056] Alternatively, the volatile delivery-enhancing compound may include one or more non-volatile compounds and one or more volatile compounds. For example, the volatile delivery-enhancing compound may include a solution of one or more non-volatile compounds in a volatile solvent, or a mixture of one or more non-volatile liquid compounds and one or more volatile liquid compounds.

[0057] In one embodiment, the volatile delivery-enhancing compound comprises an acid. The volatile delivery-enhancing compound may comprise an organic acid or an inorganic acid. Preferably, the volatile delivery-enhancing compound comprises an organic acid, more preferably a carboxylic acid, and most preferably an α-keto acid or a 2-oxoacid.

[0058] In a preferred embodiment, the volatile delivery-enhancing compound comprises an acid selected from 3-methyl-2-oxovalerate, pyruvate, 2-oxovalerate, 4-methyl-2-oxovalerate, 3-methyl-2-oxobutyric acid, 2-oxooctanoic acid, and combinations thereof. In a particularly preferred embodiment, the volatile delivery-enhancing compound comprises pyruvate.

[0059] As a solid or liquid aerosol forming matrix, the at least one aerosol forming matrix may alternatively be any other kind of matrix, such as a gaseous matrix, a gel matrix, or any combination of various types of matrices.

[0060] In any of the above embodiments, at least one aerosol-forming matrix may comprise a single aerosol-forming matrix. Alternatively, the at least one aerosol-forming matrix may be multiple aerosol-forming matrices. The aerosol-forming matrices may have substantially the same composition. Alternatively, multiple aerosol-forming matrices may comprise two or more aerosol-forming matrices having substantially different compositions. Multiple aerosol-forming matrices may be stored together on a substrate. Alternatively, multiple aerosol-forming matrices may be stored separately. By storing two or more different portions of the aerosol-forming matrix separately, two incompatible substances can be stored in the same container. Advantageously, storing two or more different portions of the aerosol-forming matrix separately can extend the container's lifespan. It also allows two incompatible substances to be stored in the same container. Furthermore, it allows the aerosol-forming matrix to be aerosolized individually, for example, by heating each aerosol-forming matrix separately. Thus, aerosol-forming matrices with different heating profile requirements can be heated differently to improve aerosol formation. Since more volatile substances can be separated from less volatile substances and to a lower degree, more efficient energy use can also be achieved. Individual aerosol-forming matrices can also be aerosolized in a predetermined order, for example, by heating a different aerosol-forming matrix among multiple aerosol-forming matrices each time the cartridge is used, ensuring that the aerosol-forming matrix is ​​aerosolized "fresh" each time the cartridge is used. In embodiments that include a liquid nicotine aerosol-forming matrix and a volatile delivery-enhancing compound aerosol-forming matrix, nicotine and the volatile delivery-enhancing compound are advantageously stored separately and reacted together in the gas phase only when the system is running.

[0061] Preferably, at least one aerosol-forming matrix is ​​substantially flat. The at least one aerosol-forming matrix can have any suitable cross-sectional shape. Preferably, the at least one aerosol-forming matrix has a non-circular cross-sectional shape. In some preferred embodiments, the at least one aerosol-forming matrix has a substantially rectangular cross-sectional shape. In some embodiments, the at least one aerosol-forming matrix has an elongated substantially rectangular parallelepiped shape.

[0062] In some preferred embodiments, the evaporation temperature of at least one aerosol-forming matrix is ​​from about 60°C to about 320°C, preferably from about 70°C to about 230°C, and more preferably from about 90°C to about 180°C. As used herein, the term "evaporation temperature" refers to a temperature such that:

[0063] The aerosol forming cylinder can have any suitable size. Preferably, the cylinder has a size suitable for use with a handheld aerosol generating device. In some embodiments, the cylinder has a length of about 5 mm to about 200 mm, preferably about 10 mm to about 100 mm, more preferably about 20 mm to about 35 mm. In some embodiments, the cylinder has a width of about 5 mm to about 12 mm, preferably about 7 mm to about 10 mm. In some embodiments, the cylinder has a height between about 2 mm and about 10 mm, preferably between about 5 mm and about 8 mm.

[0064] In use, at least one of the aerosol forming cylinder and the aerosol generating device can be connected to a separate suction port section through which a user can draw airflow through or adjacent to the cylinder by sucking at the downstream end of the suction port section. In such embodiments, preferably, the cylinder is arranged such that the suction resistance at the downstream end of the suction port section is about 50 mmWG (mm water column) to about 130 mmWG, more preferably about 80 mmWG to about 120 mmWG, more preferably about 90 mmWG to about 110 mmWG, and most preferably about 95 mmWG to about 105 mmWG. The term "suction resistance" as used herein refers to the pressure required to force air through the entire length of the test object at a rate of 17.5 ml / s at 22°C and 101 kPa (760 Torr). Suction resistance is measured according to ISO 6565:2011 and is typically expressed in mm, water column (mmWG).

[0065] The heater includes at least a first electrical contact arranged to supply power to the heater from a power source in the aerosol generator. Additionally, the first electrical contact may be arranged to transmit data to or from the heater, or to both the heater and the heater. The electrical contacts disposed on the heater are accessible from the outside of the heater. The electrical contacts may be positioned along one or more edges of the heater. In some embodiments, the electrical contacts may be positioned along the lateral edge of the heater. For example, the electrical contacts may be positioned along the upstream edge of the heater. Alternatively or additionally, the electrical contacts may be positioned along a single longitudinal edge of the heater.

[0066] In addition, the aerosol forming assembly may include one or more electrical contacts. The electrical contacts disposed on the aerosol forming cylinder are accessible from the outside of the cylinder. The electrical contacts may be positioned along one or more edges of the cylinder. In some embodiments, the electrical contacts may be positioned along the lateral edge of the cylinder. For example, the electrical contacts may be positioned along the upstream edge of the cylinder. Alternatively or additionally, the electrical contacts may be positioned along a single longitudinal edge of the cylinder. The electrical contacts on the cylinder may include data contacts for transmitting data to or from the cylinder, or transmitting data to and from both the cylinder and the cylinder.

[0067] Any of the above-described electrical contacts can have any suitable form. The electrical contacts can be substantially flat. Advantageously, substantially flat electrical contacts have been found to be more reliable for establishing electrical connections and easier to manufacture. Preferably, the electrical contacts include components of standardized electrical connections, including but not limited to USB-A, USB-B, USB-mini, USB-micro, SD, miniSD, or microSD type connections. Preferably, the electrical contacts include common components of standardized electrical connections, including but not limited to USB-A, USB-B, USB-mini, USB-micro, SD, miniSD, or microSD type connections. As used herein, the term "standardized electrical connection" refers to an electrical connection defined by an industry standard.

[0068] In any of the above embodiments, the cylinder may include a capping layer that is fixed to the substrate and covers at least a portion of at least one aerosol-forming matrix. Advantageously, the capping layer may fix at least one aerosol-forming matrix in a suitable location on the substrate. The capping layer may be fixed directly to the substrate or indirectly via one or more intermediate layers or components. Aerosols released by the aerosol-forming matrix may pass through one or more openings in the capping layer, the substrate, or both. The capping layer may have at least one gas-permeable window to allow aerosols released by the aerosol-forming matrix to pass through the capping layer. The gas-permeable window may be substantially open. Alternatively, the gas-permeable window may comprise a perforated membrane or a grid extending through openings in the capping layer. The grid may be of any suitable form, such as a transverse grid, a longitudinal grid, or a mesh grid. The capping layer may form a seal with the substrate. The capping layer may form an hermetically tight seal with the substrate. The capping layer may include a polymer coating that covers at least one area for the capping layer to be fixed to the substrate, the polymer coating forming a seal between the capping layer and the substrate.

[0069] The aerosol forming cartridge may include a protective foil positioned on at least a portion of at least one aerosol forming matrix. The protective foil may be airtight. The protective foil may be arranged to hermetically seal the aerosol forming matrix within the cartridge. As used herein, the term "hermetically sealed" means that the weight of volatile compounds in the aerosol forming matrix changes by less than 2% over two weeks, preferably over two months, and more preferably over two years.

[0070] The substrate may include at least one cavity for holding an aerosol-forming matrix therein. In these embodiments, a protective foil may be arranged to close one or more cavities. The protective foil may be at least partially removable to expose at least one aerosol-forming matrix. Preferably, the protective foil is removable. Where the substrate includes multiple cavities for containing multiple aerosol-forming matrices, the protective foil may be stagedly removable to selectively open one or more aerosol-forming matrices. For example, the protective foil may include one or more removable portions, each arranged to expose one or more cavities when removed from the remainder of the protective foil. Alternatively or additionally, the protective foil may be attached such that the required removal force varies between stages of removal as an instruction to the user. For example, the required removal force may increase between adjacent stages, requiring the user to intentionally pull the protective foil more forcefully to continue removing it. This can be achieved by any suitable means. For example, the pulling force may be varied by changing the type, number, or shape of the adhesive layers, or by changing the shape or number of solder lines to which the protective foil is attached.

[0071] The protective foil can be removably attached to the base layer, directly or indirectly, via one or more intermediate components. When the cylinder includes a cover layer as described above, the protective foil can be removably attached to the cover layer. When the cover layer has one or more vents, the protective foil can extend through and close one or more vents. The protective foil can be removably attached by any suitable method, such as using an adhesive. The protective foil can be removably attached by ultrasonic welding. The protective foil can be removably attached by ultrasonic welding along a weld line. The weld line can be continuous. The weld line can include two or more continuous weld lines arranged side-by-side. With this arrangement, a seal can be maintained as long as at least one of the continuous weld lines remains intact.

[0072] The protective foil can be a flexible film. The protective foil can include any suitable material or multiple materials. For example, the protective foil can include a polymer foil, such as polypropylene (PP) or polyethylene (PE). The protective foil can include multilayer polymer foils.

[0073] The aerosol generating apparatus may include a controller configured to control the power supply to the heater.

[0074] The power source can be a DC voltage source. In a preferred embodiment, the power source is a battery. For example, the power source can be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, such as a lithium cobalt, lithium iron phosphate, or lithium polymer battery. Alternatively, the power source can be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows sufficient energy storage for the aerosol generating device and one or more aerosol generating articles.

[0075] The aerosol generation apparatus may include one or more temperature sensors configured to sense the temperature of at least one of a heater and one or more aerosol-forming matrices. In these embodiments, a controller (if present) may be configured to control the power supply to the heater based on the sensed temperature.

[0076] In those embodiments, the heater includes at least one resistance heating element, which can be formed using a metal having a defined relationship between temperature and resistivity. In such embodiments, the metal can be formed as a track between two suitable insulating materials. A heater element formed in this way can serve as both a heater and a temperature sensor.

[0077] In any of the above embodiments, the aerosol generating apparatus may include an external plug or socket that allows the aerosol generating apparatus to connect to another electrical device. For example, the aerosol generating apparatus may include a USB plug or USB socket to allow the aerosol generating apparatus to connect to another USB-enabled device. For example, the USB plug or socket may allow the aerosol generating apparatus to connect to a USB charging device to charge a rechargeable power source within the aerosol generating apparatus. Alternatively or additionally, the USB plug or socket may support data transfer to or from the aerosol generating apparatus or to and from the aerosol generating apparatus. For example, the apparatus may connect to a computer to download data from the apparatus, such as usage data. Alternatively or additionally, the apparatus may connect to a computer to transfer data to the apparatus, such as a new heating profile for a new or updated aerosol forming cylinder, wherein the heating profile is stored in a data storage device within the aerosol generating apparatus.

[0078] In embodiments where the device includes a USB plug or socket, the device may also include a removable cover that covers the USB plug or socket when not in use. In embodiments where the USB plug or socket is a USB plug, the USB plug may additionally or alternatively be retractable in the device. Attached Figure Description

[0079] The invention will now be further described by way of example only with reference to the accompanying drawings, in which:

[0080] Figure 1 A partial exploded view of a heater according to an embodiment of the present invention is shown;

[0081] Figure 2 The fully assembled structure is shown. Figure 1 The heater shown;

[0082] Figure 3 An aerosol forming cylinder according to an embodiment of the present invention is shown;

[0083] Figure 4The insertion was shown Figure 2 In the heater Figure 3 The aerosol forming cylinder is used to form an aerosol forming heater assembly; and

[0084] Figure 5 An embodiment of the present invention is shown. Figure 4 An aerosol forming heater assembly is inserted into an aerosol generating device to form an aerosol generating system. Detailed Implementation

[0085] Figure 1 and Figure 2 A heater 10 according to an embodiment of the present invention is shown. The heater 10 includes an electrically insulating substrate layer 12 on which a plurality of electric heater elements 14 are disposed. A plurality of electrical contacts 16 are also disposed on the electrically insulating substrate layer 12 at the upstream end of the heater 10. When the heater 10 is connected to an aerosol generating apparatus, the electrical contacts 16 provide power to the electric heater elements 14.

[0086] The heater 10 also includes a set of guide rails 18 extending along the longitudinal edge of the heater 10 and end stops 20 extending through the upstream transverse edge of the heater. The inner edge of each guide rail 18 extending along the longitudinal edge is spaced apart from the insulating substrate layer 12 to form a longitudinal groove 19 for receiving the aerosol forming cylinder. The end stops 20 are spaced apart from the electrical contacts 16 to form a groove 22 in which a corresponding electrical contact on the aerosol generating device is received.

[0087] Figure 3 An aerosol forming cylinder 30 according to an embodiment of the present invention is shown. The cylinder 30 includes a base layer 32 and a cover layer 34, the cover layer 34 covering a plurality of aerosol forming matrices sandwiched between the base layer 32 and the cover layer 34. The cover layer 34 includes a mesh grid 36 covering the aerosol forming matrices to allow aerosol particles to escape from the aerosol forming cylinder 30 during heating. A removable polymer film 38 covers the mesh grid 36 to prevent volatile components from prematurely escaping from the aerosol forming matrices. The polymer film 38 is removed before use of the cylinder 30.

[0088] Figure 4 An embodiment of the present invention is shown. Figure 3 Aerosol forming cylinder 30 inserted Figure 2 The heater assembly 40 in the heater 10 shown is formed by forming an aerosol. A removable polymer film 38 is removed from a cylinder 30, which is inserted into a longitudinal groove 19 between the guide rail 18 and the insulating substrate layer 12 of the heater 10. Figure 4 The cylinder 30 is shown partially inserted into the heater 10. When the cylinder 30 is fully inserted into the heater 10, the cylinder 30 abuts against the end stop 20.

[0089] Figure 5 An embodiment of the present invention is shown. Figure 4 An aerosol forming heater assembly 40 is inserted into an aerosol generating device 50 to form an aerosol generating system 70. The aerosol generating device 50 includes a body 51 defining a main cavity for receiving the heater assembly 40 and an opening at a downstream end of the device 50 through which the heater assembly 40 is inserted into the main cavity. Fully inserting the heater assembly 40 into the device 50 causes a plurality of electrical contacts 16 on the heater 10 to contact a plurality of electrical contacts within the main cavity of the device 50. The electrical contacts conduct power from a rechargeable battery within the device 50 to the heater element 14. A removable suction port 52 is provided at the upstream end of the device 50, wherein the suction port 52 is removed from the device 50 to allow the heater assembly 40 to be inserted into the device 50, and then reattached to the device 50 after the heater assembly 40 is fully inserted. When the device 50 is not in use, a removable suction port cover 54 covers the suction port 52.

[0090] USB plug 56 is located at the downstream end of device 50 for insertion into a suitable USB socket. USB plug 56 can be used to charge the rechargeable battery within device 50 and to exchange data with device 50. For example, the USB plug can be used to download usage data from device 50 and to upload new data to device 50, such as new heating profiles. When USB plug 56 is not in use, a removable cover 58 covers USB plug 56.

Claims

1. An electrically operated aerosol generation system, comprising an aerosol generation device, a removable aerosol forming cylinder, and a removable heater, the removable aerosol forming cylinder and the removable heater being disposed separately from each other, the aerosol forming cylinder including at least one aerosol forming matrix, the heater including at least one electric heater element and a first electrical contact connected to the at least one electric heater element, and the aerosol generation device comprising: A main body defining a main cavity and at least one opening for receiving the aerosol forming cylinder and the heater into the main cavity; power supply; as well as A second electrical contact located in the main cavity and connected to the power supply; When the aerosol forming cylinder and the heater are both received in the main cavity, the first electrical contact contacts the second electrical contact, and the heater is arranged to heat the aerosol forming matrix. The aerosol forming cylinder and the heater are substantially flat, and the main cavity, the aerosol forming cylinder, and the heater are arranged such that when received together in the main cavity, the aerosol forming cylinder and the heater are substantially parallel to each other and adjacent to each other; and The at least one opening and the main cavity are configured to receive the heater and the aerosol forming cylinder separately.

2. The electrically operated aerosol generation system according to claim 1, wherein at least one of the main cavity and the at least one opening includes at least one of a guide groove, a recess, a track, or a protrusion for guiding the aerosol forming cylinder and the heater into the correct position within the main cavity.

3. The electrically operated aerosol generation system according to claim 1, wherein the at least one opening comprises a first slot for receiving the aerosol forming cylinder and a second slot for receiving the heater.

4. The electrically operated aerosol generation system according to claim 3, wherein the dimensions of the first tank and the second tank, the heater and the aerosol forming cylinder are set such that the aerosol forming cylinder can only be inserted into the first tank and the heater can only be inserted into the second tank.

5. The electrically operated aerosol generation system of claim 1, wherein at least one of the aerosol forming cylinder, the heater, and the aerosol generating device further comprises an additional heater arranged to heat at least a portion of the aerosol forming matrix when both the aerosol forming cylinder and the heater are received within the main cavity.

6. The electrically operated aerosol generation system of claim 5, wherein the additional heater is connected to a third electrical contact, and wherein the aerosol generation device further comprises a fourth electrical contact connected to a power source, wherein the third and fourth electrical contacts are in contact with each other when the aerosol forming cylinder and the heater are both received within the main cavity.

7. The electrically operated aerosol generation system of claim 6, wherein the at least one electric heater element includes a first electric heater element connected to the first electric contact, and the additional heater includes a second electric heater element disposed in the heater and connected to the third electric contact, wherein the first and second electric heater elements are arranged to heat different portions of the aerosol forming cylinder when both the aerosol forming cylinder and the heater are received within the main cavity.

8. The electrically operated aerosol generation system of claim 1, wherein the heater comprises an electrically insulating substrate, and wherein the at least one electric heater element comprises one or more substantially flat heater elements disposed on the electrically insulating substrate.

9. The electrically operated aerosol generating system of claim 1, wherein the removable heater includes a data storage medium arranged to communicate with the aerosol generating apparatus when the removable heater is inserted into the main cavity.

10. The electrically operated aerosol generation system of claim 9, wherein the aerosol generation device and the data storage medium are configured to store data on the data storage medium, the data indicating the number of heating cycles used by the removable heater.

11. The electrically operated aerosol generation system of claim 1, wherein the aerosol forming matrix comprises nicotine.

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