Inductively heated aerosol generating system with nicotine tape

Abstract

An aerosol generating system including an induction heating element in an aerosol generating device that receives a replaceable aerosol generating article, the replaceable aerosol generating article including an aerosol generating substrate on a tape, and a plurality of ferritic stainless steel beads disposed within the aerosol generating substrate or within the tape.

Description

[Technical field]

[0001] The present disclosure relates to an aerosol generation system having a nicotine tape, the aerosol generation system configured to generate an aerosol via inductive heating of the nicotine tape. [Background technology]

[0002] The sensory medium in commercially available electronic cigarettes is generally a liquid (so-called e-liquid). These e-liquids are typically contained in aerosol generating articles or "pods" that are replaceable within the electronic cigarette. These pods contain a heater in contact with a porous material or wick. The porous material or wick transports the e-liquid by capillary action to the heater for vaporization into the inhalation airstream of the electronic cigarette.

[0003] A well-known problem with commercial e-cigarettes is e-liquid leakage, which typically occurs when there is too much e-liquid, or when the retention capacity of the porous material does not prevent the e-liquid from overflowing, especially in the case of full-tank commercial e-cigarettes, or when changes in environmental pressure occur during storage or transportation, or when temperature changes affect the viscosity of the e-liquid or the retention capacity of the porous material.

[0004] In addition, heaters in current commercially available e-cigarette systems are typically integrated into replaceable cartridges or "pods" that contain the e-liquid. The inclusion of a heater in a replaceable aerosol-generating article or "pod" increases the cost, complexity, and disposal costs of these replaceable aerosol-generating articles or "pods."

[0005] There is a need for an aerosol generating system that is stable and does not leak liquid.There is a need for a replaceable aerosol generating article that does not include a heating element.

[0006] It is desirable to provide an aerosol generating system that utilizes a stable aerosol-generating substrate in a replaceable aerosol-generating article. It is desirable to provide the aerosol-generating substrate on a tape. The tape may have multiple layers. It is desirable to provide an aerosol generating system including an induction heater (or induction heating element) in an aerosol generating device that receives the replaceable aerosol-generating article. The induction heater may be a work coil that generates an alternating magnetic field when an alternating current flows through the coil. This alternating magnetic field induces eddy currents in a susceptor material that is positioned within the generated magnetic field. The eddy currents cause the susceptor material to heat. The heated susceptor material provides heat to the aerosol-generating substrate. When the aerosol-generating substrate is heated, the aerosol-generating substrate releases volatile compounds from the aerosol-generating substrate to form an aerosol. When the aerosol is entrained in the flow of air moving along the airflow channel, the aerosol is delivered to an air outlet for inhalation by a user. The susceptor material is in "magnetic contact" or "magnetically coupled" with the induction heater when it is within the generated magnetic field.

[0007] It is desirable to provide an aerosol generating system that includes an induction heater magnetically coupled to ferritic stainless steel beads dispersed within an aerosol-generating substrate. Summary of the Invention

[0008] The present disclosure is directed to an aerosol generating system that includes an induction heating element in an aerosol generating device that receives a replaceable aerosol generating article. The replaceable aerosol generating article includes a tape having an aerosol-generating substrate thereon. A susceptor, e.g., ferritic stainless steel beads, is dispersed within the aerosol-generating substrate or within the tape.

[0009] According to one aspect of the present invention, an aerosol generating system is provided that includes an aerosol generating device and a replaceable cartridge. The aerosol generating device includes a housing having an air outlet and an air inlet, and an airflow channel fluidly connecting the air outlet with the air inlet. The aerosol generating device includes an induction heating element coupled to the housing and along the airflow channel, and a cartridge receiving cavity defined within the housing and configured to receive a cartridge including a tape containing an aerosol-generating substrate. The aerosol generating system has a cartridge received within the cartridge receiving cavity. When the cartridge is received within the cavity, the induction heating element is in magnetic contact with the tape. When the induction heating element is in magnetic contact with the tape, the induction heating element has the ability to induce heat in a susceptor element in or on the tape. That is, the tape may have multiple layers, and the susceptor element may be between the layers of the tape. Alternatively, the susceptor element may be in or on the aerosol-generating substrate. The cartridge includes a tape extending from a first end to a second end, a rotatable supply reel secured within the cartridge, and a rotatable take-up reel secured within the cartridge, with the first end of the tape secured to the take-up reel and the second end of the tape secured to the supply reel. An aerosol-generating substrate is disposed on the tape. The aerosol-generating substrate includes nicotine and glycerol. The susceptor element comprises a plurality of ferritic stainless steel beads disposed within the aerosol-generating substrate or within the tape.

[0010] According to another aspect of the invention, a method of using the aerosol-generating system described herein includes rotating a take-up reel to move the tape forward and to align the induction heating element with the aerosol-generating substrate, and heating the aerosol-generating substrate by creating a magnetic field induced by the induction heating element to heat a susceptor (such as a plurality of ferritic stainless steel beads), thereby heating the aerosol-generating substrate to form an aerosol in the inhalation airstream.

[0011] According to another aspect of the invention, the aerosol-generating substrate may be a solid at 25°C.

[0012] Advantageously, the aerosol-generating substrate does not liquefy or create an aerosol until the heating step, and is therefore stable and does not leak liquid during transportation or storage of the aerosol-generating substrate. In addition, the replaceable cartridge does not include an induction heating element, and is therefore less complicated and less costly to manufacture. Instead, the induction heating element is within the aerosol generating device and is reusable in multiple replaceable cartridges. In addition, each replaceable cartridge provides a metered dose of aerosol-generating substrate per inhale or puff as the tape is gradually rotated past the heating element by the user.

[0013] All values ​​reported as percentages are assumed to be weight percent based on total weight.

[0014] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are intended to facilitate understanding of certain terms used frequently herein.

[0015] As used herein, the singular forms "a," "an," and "the" include embodiments having plural referents unless the content clearly dictates otherwise.

[0016] As used herein, "or" is generally employed in its inclusive sense, unless the context clearly dictates otherwise. The term "and / or" refers to one or all of the listed elements or a combination of any two or more of the listed elements.

[0017] As used herein, the words "have," "having," "include," "including," "comprise," "comprising," and the like are used in their open-ended sense and generally mean "including, but not limited to." It should be understood that "consisting essentially of," "consisting of," and the like are encompassed by "comprising" and the like.

[0018] The words "preferred" and "preferably" refer to embodiments of the invention that may offer certain advantages, under particular circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, 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 present disclosure, including the claims.

[0019] The term "substantially" as used herein can be understood to have the same meaning as "significantly" and to modify the associated term by at least about 90%, at least about 95%, or at least about 98%. The term "not substantially" as used herein can be understood to have the same meaning as "not significantly" and to have the opposite meaning of "substantially", i.e., modifying the associated term by no more than 10%, no more than 5%, or no more than 2%.

[0020] The terms "upstream" and "downstream" refer to the relative positions of elements of the inhaler device and inhaler system described with respect to the direction of the inhalation airflow as it is drawn through the body of the inhaler device and inhaler system.

[0021] The term "solid" refers to a fundamental state of matter that does not expand to fill space or flow at a temperature of 25 degrees Celsius and one atmosphere of pressure.

[0022] The term "nicotine" refers to nicotine and nicotine derivatives, such as free base nicotine, nicotine salts, and the like.

[0023] As used herein, the terms "control electronics," "controller," and "processor" refer to any device or apparatus capable of providing suitable or configurable computing and control capabilities to implement the methods, processes, and techniques described herein, such as, for example, a microprocessor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), equivalent discrete or integrated logic circuitry, or any combination thereof, and capable of providing suitable data storage capabilities, including any medium (e.g., volatile or non-volatile memory, or magnetic recording media such as disks or tapes, etc.) containing digital bits (e.g., digital bits coded in binary, ternary, etc.) that may be readable and writable.

[0024] The term "aerosol" is used herein to refer to a suspension of solid particles or liquid droplets, or a combination of solid particles and liquid droplets in a gas. The gas may be air. The solid particles or droplets may include one or more volatile flavor compounds. The aerosol may be visible or invisible. The aerosol may include a vapor of a substance that is normally a liquid or solid at room temperature. The aerosol may include a vapor of a substance that is normally a liquid or solid at room temperature, in combination with solid particles, or in combination with liquid droplets, or in combination with both solid particles and droplets. Preferably, the aerosol includes nicotine.

[0025] The term "aerosol-generating substrate" is used herein to refer to a material capable of releasing one or more volatile compounds capable of forming an aerosol. In some embodiments, the aerosol-generating substrate may be heated to volatilize one or more components of the aerosol-generating substrate to form an aerosol. In some cases, the volatile compounds may be released by a chemical reaction. The aerosol-generating substrate may be solid or liquid, or may include both solid and liquid components, such as a gel. The aerosol-generating substrate may be adsorbed, coated, impregnated or otherwise loaded onto a carrier or support. The aerosol-generating substrate preferably comprises nicotine. The aerosol-generating substrate may comprise a plant-derived material. The aerosol-generating substrate may comprise tobacco. The aerosol-generating substrate may comprise a tobacco-containing material that contains volatile tobacco flavor compounds that are released from the aerosol-generating substrate upon heating. The aerosol-generating substrate may alternatively comprise a non-tobacco-containing material. The aerosol-generating substrate may comprise a homogenized plant-derived material. The aerosol-generating substrate may comprise a homogenized tobacco material. The aerosol-generating substrate may comprise at least one aerosol former. The aerosol-generating substrate may include other additives and ingredients (such as flavourants). The aerosol-generating substrate may include an active ingredient. The aerosol-generating substrate may be provided as part of an aerosol-generating article. The aerosol-generating substrate may be provided within an aerosol-generating article.

[0026] The term "aerosol-generating article" is used herein to refer to a disposable product that can include (e.g., hold, contain, have or store) an aerosol-generating substrate. The aerosol-generating article may have the ability to removably connect or dock with an aerosol-generating device. This allows the aerosol-generating device to generate an aerosol from the aerosol-generating substrate of the aerosol-generating article. An "aerosol-generating cartridge" or "cartridge" is an example of an "aerosol-generating article".

[0027] The term "aerosol-generating device" is used herein to refer to any device configured to be used or utilized with an aerosol-forming substrate that emits a volatile compound to form an aerosol that can be inhaled by a user. The aerosol-generating device may be coupled to an aerosol-generating article that includes the aerosol-generating substrate.

[0028] The terms "induction heating element" or "induction heater" (these terms are used interchangeably) are used herein to refer to a work coil or induction coil (which can take many forms, as described below) that generates an alternating magnetic field when an alternating current is passed through the coil. This alternating magnetic field induces eddy currents in a susceptor material that is positioned within the generated magnetic field.

[0029] The terms "susceptor" or "susceptor element" (the terms are used interchangeably) are used herein to refer to a metallic or magnetic material that heats when exposed to an alternating magnetic field generated by an induction heating element.

[0030] The terms "magnetically coupled" or "magnetically in contact" are used herein to refer to the placement of a susceptor(s) within a magnetic field generated by an induction heating element or induction heater. When a susceptor is magnetically coupled with an induction heating element, the susceptor will heat. When a susceptor is in magnetic contact with an induction heating element, the susceptor will heat. The susceptor heats as a result of eddy currents induced in the susceptor as a result of exposure to the magnetic field created by the induction heating element.

[0031] The aerosol generating system includes an induction heating element in an aerosol generating device that receives a replaceable aerosol generating article. The replaceable aerosol generating article includes a tape having an aerosol generating substrate thereon. The aerosol generating substrate may be solid at room temperature. The solid aerosol generating substrate remains solid until heated. A susceptor element is provided in or on the tape. Alternatively or additionally, a susceptor element is provided in or on the aerosol generating substrate. In an embodiment, the susceptor element is a plurality of ferritic stainless steel beads disposed in or on the solid aerosol generating substrate or in or on the tape. The induction heating element magnetically contacts the susceptor element and inductively heats the susceptor element. The susceptor element heats the aerosol generating substrate to a temperature sufficient to vaporize the solid aerosol generating substrate, preferably in the range of about 200 degrees Celsius to about 450 degrees Celsius. The susceptor heats the aerosol-generating substrate in the range of 200 degrees Celsius to 350 degrees Celsius. The susceptor heats the aerosol-generating substrate in the range of 200 degrees Celsius to 300 degrees Celsius. The vaporized aerosol-generating substrate forms an aerosol that is carried in an airflow towards an air outlet of the mouthpiece of the aerosol generating device.

[0032] The aerosol generating system includes an aerosol generating device and a replaceable cartridge. The aerosol generating device includes a housing having a mouthpiece or air outlet. The aerosol generating device includes an intake air inlet. The aerosol generating device includes an airflow channel fluidly connecting the air outlet with the air inlet. The aerosol generating device includes an induction heating element coupled to the housing and along the airflow channel. The aerosol generating device includes a cartridge receiving cavity defined within the housing and configured to receive a cartridge including a tape having an aerosol-generating substrate. The cartridge is received within the cartridge receiving cavity such that the induction heating element creates a magnetic field in or on the tape, or in or on the aerosol-generating substrate disposed on the tape, in sufficient proximity to the susceptor(s) to create eddy currents in the susceptor(s) and heat the susceptor(s). That is, the susceptor(s) are in magnetic contact with the induction heating element.

[0033] The cartridge includes a rotatable supply reel secured within the cartridge, a rotatable take-up reel secured within the cartridge, and a tape disposed on the supply reel and on the take-up reel. The tape extends from a first end to a second end. The first end of the tape is secured to the take-up reel and the second end of the tape is secured to the supply reel. The tape includes an aerosol-generating substrate disposed on the tape. The solid aerosol-generating substrate includes nicotine and glycerol. The aerosol-generating substrate may be a solid at room temperature.

[0034] The susceptor element is disposed on or within an aerosol-generating substrate. The aerosol-generating substrate may be a solid at room temperature. The susceptor element is disposed on the tape. The susceptor element is a metallic or magnetic material that heats when exposed to an alternating magnetic field generated by an induction heating element.

[0035] Examples of susceptor materials may include conductive carbon, such as graphite, aluminum, stainless steel, copper, bronze, or any combination thereof. Preferably, the susceptor material is a magnetic stainless steel material.

[0036] The susceptors may be beads, continuous fibers, broken fibers, particles, or any combination thereof. The susceptors may be multiple elements that are not in conductive relationship with each other to reduce undesired conductive heating of adjacent non-target susceptors. The susceptors may be interleaved in a pattern to delineate the target area to be inductively heated. The susceptor material is preferably beads or spherical particles.

[0037] The susceptor element may be a plurality of ferritic stainless steel beads. The plurality of ferritic stainless steel beads may be disposed within the aerosol-generating substrate. The plurality of ferritic stainless steel beads may be disposed adjacent to the aerosol-generating substrate. The plurality of ferritic stainless steel beads may be disposed on the tape. The plurality of ferritic stainless steel beads may be disposed within the tape or between layers of the tape. The plurality of ferritic stainless steel beads may be disposed on the tape. The plurality of ferritic stainless steel beads may be disposed on both the solid aerosol-generating substrate and the tape, or within both the solid aerosol-generating substrate and the tape.

[0038] The induction heating element includes one or more induction coils. The induction heating element generates heat by inductively heating a susceptor element. For example, the induction heating element generates heat by generating an alternating magnetic field and induces eddy currents in a susceptor, such as a ferritic stainless steel bead, when the ferritic stainless steel bead is disposed within the alternating magnetic field. The susceptor, such as a ferritic stainless steel bead, may be disposed within or on a tape. The susceptor, such as a ferritic stainless steel bead, may be disposed within or on an aerosol-generating substrate. Inductive heating of the susceptor, such as a ferritic stainless steel bead, vaporizes the aerosol-generating substrate in proximity to or in contact with the susceptor, such as a ferritic stainless steel bead. The induction heating element is electrically coupled to a power source of the aerosol-generating device.

[0039] The induction heating element is, for example, about 20 mm 2 ~ approx. 100mm 2 , or about 40 mm 2 ~about 80mm 2 The induction heating element may have a surface area in the range of 0.1 - 0.5 MHz. The induction heating element may operate at a frequency in the range of 5 MHz - 30 Mhz. The induction heating element may operate at a frequency in the range of 6 MHz - 15 Mhz. The induction heating element may operate at a frequency in the range of 6 MHz - 7 Mhz. The induction heating element may operate at a frequency in the range of 13 MHz - 14 Mhz. The induction heating element may operate at a frequency in the range of 26 MHz - 27 Mhz.

[0040] The induction heating element may be a planar coil. The induction heating element may be a single planar coil that provides an alternating magnetic field to the susceptor elements in the tape or aerosol-generating substrate. The induction heating element may be a single planar coil that provides an alternating magnetic field to the susceptor elements in the tape or aerosol-generating substrate. The induction heating element may be two or more planar coils that are continuous along a single side of the tape and that provide an alternating magnetic field to the susceptor elements in the tape or aerosol-generating substrate. The susceptor elements are preferably a plurality of ferritic stainless steel beads disposed within the solid aerosol-generating substrate or tape.

[0041] The induction heating element may be two or more planar coils continuous along a single side of the tape and providing an alternating magnetic field to a susceptor element in the tape or aerosol-generating substrate. The induction heating element may be a single planar coil providing an alternating magnetic field to a susceptor element in the tape or aerosol-generating substrate. The susceptor elements are preferably a plurality of ferritic stainless steel beads disposed within the solid aerosol-generating substrate or tape.

[0042] The induction heating element may be a U-shaped coil that partially surrounds the tape and provides an alternating magnetic field to a susceptor element in the tape or aerosol-generating substrate. The induction heating element may be a U-shaped coil that partially surrounds the tape and provides an alternating magnetic field to a susceptor element on the tape or aerosol-generating substrate. The susceptor elements are preferably a plurality of ferritic stainless steel beads disposed within the solid aerosol-generating substrate or within the tape.

[0043] The induction heating element may be two or more planar coils along either side of the tape (where tape separates the opposing planar magnetic coils) and providing an alternating magnetic field to the susceptor elements on the tape or the aerosol-generating substrate. The induction heating element may be two or more planar coils along either side of the tape (where tape separates the opposing planar magnetic coils) and providing an alternating magnetic field to the susceptor elements in the tape or the aerosol-generating substrate. Alternatively, the induction heating element may be a coil surrounding the tape. The susceptor elements are preferably a plurality of ferritic stainless steel beads disposed within the solid aerosol-generating substrate or within the tape.

[0044] The induction heating element may be separated from the tape. For example, a plastic spacer may separate the coil(s) from the tape. The plastic spacer may have a thickness in the range of, for example, 100 to 500 micrometers, or 250 to 350 micrometers. If present, the spacer should be sized to allow the magnetic field generated by the induction heating element to reach the susceptor element(s) to cause heating of the susceptor element and the aerosol-generating substrate. The coil(s) and susceptor element may be separated by a distance of 100 to 1000 micrometers, or 500 to 1000 micrometers. The tape may be in contact with the induction heating element. The induction heating element may be in contact with the tape. The induction heating element may warp the tape.

[0045] The induction heating element may be a solenoid coil. The induction heating element may be a single solenoid coil that provides a magnetic field to a plurality of ferritic stainless steel beads in the tape. The induction heating element may be a single solenoid coil that provides a magnetic field to a plurality of ferritic stainless steel beads on the tape. The induction heating element may be a single solenoid coil that provides a magnetic field to a plurality of ferritic stainless steel beads in the aerosol-generating substrate. The induction heating element may be a single solenoid coil that provides a magnetic field to a plurality of ferritic stainless steel beads on the aerosol-generating substrate.

[0046] The induction heating element may be two or more solenoid coils that are continuous along a single side of the tape and provide an alternating magnetic field to the susceptor elements in or on the tape. The induction heating element may be two or more solenoid coils that are continuous along a single side of the tape and provide an alternating magnetic field to the susceptor elements in or on the tape. The induction heating element may be two or more solenoid coils that are continuous along a single side of the tape and provide an alternating magnetic field to the susceptor elements in or on the aerosol-generating substrate. The induction heating element may be two or more solenoid coils that are continuous along a single side of the tape and provide an alternating magnetic field to the susceptor elements in or on the aerosol-generating substrate.

[0047] A plastic spacer may separate the solenoid coil(s) from the tape. If present, the spacer should be sized to allow the magnetic field generated by the induction heating element to reach the susceptor element to cause heating of the susceptor element and the aerosol-generating substrate. The plastic spacer may have a thickness in the range of, for example, 100 to 500 micrometers, or 250 to 350 micrometers. The solenoid coil(s) and the susceptor element may be separated by a distance of 100 to 1000 micrometers, or 500 to 1000 micrometers. The tape may be in contact with the induction heating element. The induction heating element may contact the tape, causing the tape to warp. The tape may contact a portion of the circumference of the induction heating element. The tape may contact about 25% to about 50% of the circumference of the induction heating element.

[0048] The susceptor is preferably a plurality of ferritic stainless steel beads having a number average diameter in the range of 5 micrometers to 50 micrometers, or 10 micrometers to 40 micrometers, or 20 micrometers to 35 micrometers. The ferritic stainless steel beads generally define a spherical shape. The ferritic stainless steel beads are magnetic. The ferritic stainless steel beads are formed of iron and 16% to 18% chromium by weight. These magnetic ferritic stainless steel beads have been found to be particularly useful as susceptor elements. The plurality of ferritic stainless steel beads is preferably formed of AISI 430 stainless steel.

[0049] The aerosol-generating substrate may contain ferritic stainless steel beads. The plurality of ferritic stainless steel beads may be uniformly distributed within or on the aerosol-generating substrate. The aerosol-generating substrate may contain 1% to 30% by volume, or 5% to 20% by volume, or 5% to 15% by volume of ferritic stainless steel beads. The plurality of ferritic stainless steel beads may be present within the aerosol-generating substrate. The plurality of ferritic stainless steel beads may be present on the aerosol-generating substrate.

[0050] The tape may contain ferritic stainless steel beads. The plurality of ferritic stainless steel beads may be uniformly distributed within or on the tape. The tape may contain 1% to 30% by volume, or 5% to 20% by volume, or 5% to 15% by volume of ferritic stainless steel beads. The plurality of ferritic stainless steel beads may be present within the tape. The plurality of ferritic stainless steel beads may be present on the tape.

[0051] Alternatively, the plurality of ferritic stainless steel beads may be uniformly distributed in or on the tape and on or within the solid aerosol-generating substrate. The tape and solid aerosol-generating substrate may contain 1% to 30% by volume, or 5% to 20% by volume, or 5% to 15% by volume of the ferritic stainless steel beads.

[0052] The tape may have multiple layers, and the plurality of ferritic stainless steel beads may be uniformly distributed among the layers of the tape, or alternatively, the tape may be a unitary body formed of a single layer, and the plurality of ferritic stainless steel beads may be uniformly distributed within the tape layer.

[0053] As the tape advances from the supply reel to the take-up reel, it passes an induction heating element which advances the tape to an area of ​​a solid aerosol-generating substrate on the tape. The induction heating element activates and inductively heats ferritic stainless steel beads in or on the tape or aerosol-generating substrate to heat the aerosol-generating substrate and form an aerosol in the intake air flowing along the airflow channel from the air inlet to the air outlet.

[0054] Rotation of the supply reel or take-up reel, or both, may be accomplished by a drive mechanism. The drive mechanism may be coupled to the supply reel, the take-up reel, or the heating element, or a combination thereof. The drive mechanism may be coupled to the take-up reel to rotate the take-up reel and the supply reel.

[0055] The actuation mechanism may be a force applied by a user, such as a trigger or lever element. The actuation mechanism may be a force applied by a stored energy element. The actuation mechanism may be a force applied by a stored energy element that is a bent spring.

[0056] The drive mechanism may be electrically coupled to a power source. The drive mechanism may be a force applied by a linear actuator. The drive mechanism may be a force applied by a motor. The drive mechanism may be a force applied by a linear actuator or a motor electrically coupled to a power source.

[0057] The drive mechanism may be electrically coupled to the control electronics. The control electronics may be electrically coupled to the induction heating element. The control electronics may be electrically coupled to the induction heating element and the drive mechanism. Activation of the drive mechanism may activate the induction heating element.

[0058] The aerosol generating device may include a controller or control electronics with one or more processors (e.g., microprocessors). The one or more processors may operate with processing programs or routines and associated data storage or memory to access one or more types of data that may be used to perform the exemplary methods. For example, the processing programs or routines stored in the data storage may include programs or routines for controlling or sensing the heating elements and drive mechanisms, individually controlling the heating elements and drive mechanisms, executing programs or schemes that use one or more of the heating elements and drive mechanisms, and the like.

[0059] The control electronics may comprise a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated circuit chip (ASIC), or other electronic circuitry capable of providing control. The control electronics may comprise further electronic components. The control electronics may be configured to regulate the amount of power supplied to the heating element, the drive mechanism, and the like. Power may be supplied to the heating element continuously after activation of the system, or may be supplied intermittently, such as after every puff. Power may be supplied to the heating element in the form of pulses of power.

[0060] The aerosol generating device includes a power source for the heating element and the drive mechanism. The power source may be a battery (such as a lithium iron phosphate battery) within the device. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows for storage of sufficient energy for one or more smoking experiences. For example, the power source may have a capacity sufficient to allow continuous generation of aerosol for approximately 6 minutes, or a multiple of 6 minutes, corresponding to the typical time it takes to smoke one conventional cigarette. In another embodiment, the power source may have a capacity sufficient to allow a predetermined number of puffs, or discontinuous activation of the heating element.

[0061] The computer program product used to implement the processes described herein may be provided using any programmable language, such as a high-level procedural or object-oriented programming language suitable for communicating with a computer system. Any such program product may be stored on any suitable device (e.g., a storage medium) that can be read by, for example, a general-purpose or application-specific program, a controller device to configure and operate a computer when read by a suitable device to perform the procedures described herein. In other words, in at least one embodiment, the aerosol generating device may be implemented using a non-transitory computer-readable storage medium configured with a computer program, the storage medium configured in such a way that the computer operates in a specific and predetermined manner to perform the functions described herein.

[0062] The exact configuration of the controller of the aerosol generating device is not limited, and essentially any device capable of providing suitable computational and control capabilities to perform the method may be used. In view of the above, it will be readily apparent that the functions may be implemented in any manner as would be known to one of ordinary skill in the art. Thus, the computer language, controller, or any other software / hardware used to perform the processes described herein is not limited in scope to the systems, processes, or programs described herein (e.g., the functionality provided by such processes or programs). The methods and processes (including those resulting from the systems) or various components described herein may be implemented at least in part in hardware, software, firmware, or any combination thereof. For example, various embodiments of the present technology may be implemented in one or more processors, including one or more microprocessors, DSPs, ASICs, FPGAs, CPLDs, microcontrollers, or any other equivalent integrated or discrete logic circuits, as well as any combination of such components. When implemented in software, the functionality of the systems, apparatus, and methods described in this disclosure may be embodied as instructions on a computer-readable medium, such as a RAM, a ROM, a NVRAM, an EEPROM, a flash memory, a magnetic data storage medium, an optical data storage medium, or the like. The instructions may be executed by one or more processors to support one or more embodiments of the functionality.

[0063] The induction heating element is configured to heat the aerosol-generating substrate to at least 200 degrees Celsius within 300 milliseconds. The induction heating element may be configured to heat the aerosol-generating substrate to at least 250 degrees Celsius within 200 milliseconds, or within 100 milliseconds, or within 50 milliseconds, or within 25 milliseconds.

[0064] The cartridge includes a rotatable supply reel secured within the cartridge, a rotatable take-up reel secured within the cartridge, and a tape disposed on the supply reel. The tape extends from a first end to a second end. The first end is secured to the take-up reel and the second end is secured to the supply reel. The tape includes an aerosol-generating substrate disposed on the tape. The aerosol-generating substrate includes nicotine and glycerol.

[0065] The tape may be made of a material that does not decompose or ignite at the heating temperature. The tape may be made of metal. The tape may be made of carbon fiber.

[0066] The tape has a thickness ranging from about 25 micrometers to about 1000 micrometers, or from about 50 micrometers to about 750 micrometers, or from about 100 micrometers to about 500 micrometers, or about 300 micrometers.

[0067] The aerosol-generating substrate is a layer, preferably a solid layer (at room temperature), disposed on the tape. The aerosol-generating substrate may have a thickness in the range of from 100 micrometers to 750 micrometers, or from 200 micrometers to 500 micrometers.

[0068] The aerosol-generating substrate may define a continuous layer disposed on the tape.

[0069] The aerosol-generating substrate may define discrete areas on the tape. Each discrete area of ​​the aerosol-generating substrate may be, for example, about 20 mm 2 ~ approx. 100mm 2 , or about 40 mm 2 ~about 80mm 2 The area may be in the range of

[0070] The aerosol-generating substrate may be a tape. An aerosol-generating substrate that is a tape may incorporate susceptor elements. The susceptor elements may be continuous fibers. The susceptor elements may be broken fibers. The susceptor elements may be particles. The susceptor elements may be wires. The fibers or wires may be round or flat in cross section. The susceptor elements may be a combination of beads, particles, fibers, or wires. The susceptor elements may be arranged in a pattern to delineate a target area to be inductively heated.

[0071] Each individual region of the aerosol-generating substrate may be separated from the others by a distance sufficient to prevent vaporization of adjacent individual regions of the aerosol-generating substrate during the heating step, for example each individual region of the aerosol-generating substrate may be separated from the others by from about 1 mm to about 5 mm, or from 2 mm to about 5 mm.

[0072] A method of using the aerosol generating system described herein includes rotating a take-up reel to align an inductively heated surface with a solid aerosol-generating substrate, and inductively heating the solid aerosol-generating substrate with an inductive heating element and ferritic stainless steel beads to form an aerosol in the inhalation airstream.

[0073] The user may then advance the tape one increment past the induction heating element to align another dose of aerosol-generating substrate with the induction heating element such that the aerosol is introduced along the airflow channel of the aerosol-generating device and into the inhalation airstream. The rotating step advances the tape one increment from the supply reel, past the induction heating element to the take-up reel to generate a subsequent "puff" of aerosol into the inhalation airstream.

[0074] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0075] Example 1 An aerosol generating system includes an aerosol generating device and a replaceable cartridge. The aerosol generating device includes a housing having an air outlet and an air inlet, and an airflow channel fluidly connecting the air outlet with the air inlet, an induction heating element coupled to the housing and along the airflow channel, a cartridge receiving cavity defined within the housing and configured to receive a cartridge including a tape containing an aerosol-generating substrate, the cartridge being received within the cartridge receiving cavity, and the induction heating element being in magnetic contact with the tape. The cartridge includes a tape extending from a first end to a second end, a rotatable supply reel secured within the cartridge, and a rotatable take-up reel secured within the cartridge, the first end of the tape being secured to the take-up reel and the second end of the tape being secured to the supply reel. The aerosol-generating substrate is disposed on the tape. The aerosol-generating substrate includes nicotine and glycerol. A plurality of ferritic stainless steel beads are disposed within the aerosol-generating substrate or within the tape.

[0076] Example 2 An aerosol-generating system as described in Example 1, wherein the aerosol-generating substrate is a solid at 25°C.

[0077] Example 3 An aerosol generating system as described in Example 1 or Example 2, wherein the plurality of ferritic stainless steel beads have a number average diameter in the range of 5 micrometers to 50 micrometers, or 10 micrometers to 40 micrometers, or 20 micrometers to 35 micrometers.

[0078] Example 4 The aerosol generating system of any of Examples 1-3, wherein the plurality of ferritic stainless steel beads are formed from AISI 430 stainless steel.

[0079] Example 5 An aerosol-generating system as described in any of Examples 1 to 4, wherein the aerosol-generating substrate contains ferritic stainless steel beads.

[0080] Example 6 An aerosol-generating system as described in any of Examples 1 to 5, wherein the aerosol-generating substrate contains 1 vol.% to 30 vol.%, or 5 vol.% to 20 vol.%, or 5 vol.% to 15 vol.% of ferritic stainless steel beads.

[0081] Example 7 An aerosol generating system as described in any of Examples 1-6, wherein the tape contains ferritic stainless steel beads.

[0082] Example 8 An aerosol generating system as described in any of Examples 1 to 7, wherein the tape contains 1 vol% to 30 vol%, or 5 vol% to 20 vol%, or 5 vol% to 15 vol% ferritic stainless steel beads.

[0083] Example 9 An aerosol generating system according to any of Examples 1 to 8, wherein the induction heating element comprises a planar coil.

[0084] Example 10 The aerosol generating system of any of Examples 1 to 9, wherein the induction heating element comprises a solenoid coil.

[0085] Example 11 An aerosol generating system according to any one of Examples 1 to 10, wherein the induction heating element is in contact with the tape.

[0086] Example 12 An aerosol generating system according to any one of Examples 1 to 11, wherein the induction heating element contacts the tape to warp the tape.

[0087] Example 13 An aerosol generation system according to any one of Examples 1 to 12, wherein the aerosol generation device comprises a drive actuator coupled to the take-up reel.

[0088] Example 14 An aerosol generating system according to any of Examples 1 to 13, wherein the induction heating element operates at a frequency in the range of 5 MHz to 30 MHz, or 6 MHz to 15 MHz, or 6 MHz to 7 Mhz.

[0089] Example 15 An aerosol generating system according to any one of Examples 1 to 14, wherein the aerosol generating device comprises a power source electrically coupled to the induction heating element.

[0090] Example 16 An aerosol generating system as described in any of Examples 1-15, wherein the induction heating element and ferritic stainless steel beads are configured to heat the aerosol-generating substrate to 200° C. within 300 milliseconds.

[0091] Example 17 An aerosol generating system as described in any of Examples 1 to 16, wherein the tape has a thickness in the range of about 25 micrometers to about 1000 micrometers, or about 50 micrometers to about 750 micrometers, or about 100 micrometers to about 500 micrometers, or about 300 micrometers.

[0092] Example 18 An aerosol-generating system as described in any of Examples 1 to 17, wherein the aerosol-generating substrate has a thickness in the range of 100 micrometers to 750 micrometers, or 200 micrometers to 500 micrometers.

[0093] Example 19. A method of using the aerosol generating system of any of Examples 1-18, comprising rotating a take-up reel to rotate the heating element and to align the induction heating element with the aerosol-generating substrate, and heating the aerosol-generating substrate with the induction heating element and ferritic stainless steel beads to form an aerosol in the inhalation airstream.

[0094] The embodiments will now be further described with reference to the following figures: [Brief description of the drawings]

[0095] [Figure 1] FIG. 1 is a schematic cross-sectional view of an exemplary aerosol generation system. [Diagram 2] FIG. 2 is a perspective view of an exemplary aerosol generation system with a cartridge being inserted into the aerosol generation device. [Diagram 3] FIG. 3 is a perspective schematic diagram of a tape and planar coil induction heating element. [Figure 4A] FIG. 4A is a schematic top view of a tape and solenoid induction heating element. [Figure 4B] FIG. 4B is a perspective view of the tape and solenoid induction heating element of FIG. 4A. [Diagram 5] FIG. 5 is a schematic top view of another tape and solenoid induction heating element.

[0096] The schematic diagrams are not necessarily to scale and are presented for purposes of illustration, not limitation. The drawings illustrate one or more aspects described in the present disclosure. However, it will be understood that other aspects not shown in the drawings fall within the scope and spirit of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0097] Figure 1 is a schematic cross-sectional view of an exemplary aerosol generation system 100. Figure 2 is a perspective view of the exemplary aerosol generation system 100 with a cartridge 110 inserted into an aerosol generation device 120. Figure 3 is a schematic perspective view of the tape 113 and the planar coil induction heating element 125.

[0098] The aerosol generating system 100 includes an aerosol generating device 120 and a replaceable cartridge 110. The aerosol generating device 120 includes a housing 121 having an air outlet 122 and an intake air inlet 123, and an airflow channel 124 fluidly connecting the air outlet 122 with the air inlet 123. An induction heating element 125 is coupled to the housing 121 and is located along or within the airflow channel 124. A cartridge receiving cavity 126 is defined within the housing 121 and configured to receive a cartridge 110 including a tape 113 containing an aerosol-generating substrate 116. The cartridge 110 is received within the cartridge receiving cavity 126, with the heating element 125 in magnetic contact with the tape 113. The cartridge 110 includes a rotatable supply reel 111 secured within the cartridge 110, a rotatable take-up reel 112 secured within the cartridge 110, and a tape 113 disposed on the supply reel 111. The tape 113 extends from a first end to a second end. The first end is secured to the take-up reel 112 and the second end is secured to the supply reel 111. The tape 113 includes an aerosol-generating substrate 116 disposed on the tape 113. The aerosol-generating substrate 116 includes nicotine and glycerol. A susceptor including a plurality of ferritic stainless steel beads 118 is disposed on or within the aerosol-generating substrate 116 or within or on the tape 113.

[0099] The aerosol-generating substrate 116 may contain ferritic stainless steel beads 118. The plurality of ferritic stainless steel beads 118 may be uniformly distributed within the solid aerosol-generating substrate 116. The tape 113 may contain ferritic stainless steel beads 118. The plurality of ferritic stainless steel beads 118 may be uniformly distributed within the tape 113. The plurality of ferritic stainless steel beads 118 may be uniformly distributed within the tape 113 or the solid aerosol-generating substrate 116, or both.

[0100] A drive mechanism 127 , a power supply 128 , and control electronics 129 are disposed within a housing 121 of the aerosol generation device 120 .

[0101] 2 is a perspective view of an exemplary aerosol generation system 100 with a cartridge 110 being inserted into a cartridge-receiving cavity 126 of an aerosol generation device 120. A device lid 140 can be opened to insert the cartridge 110, after which the lid 140 may be closed once the cartridge 110 is placed within the cartridge-receiving cavity 126 of the aerosol generation device 120.

[0102] The induction heating element 125 includes one or more induction coils configured to inductively heat a plurality of ferritic stainless steel beads 118 disposed within the solid aerosol-generating substrate 116 or within the tape 113. The plurality of ferritic stainless steel beads 118 generate heat through induction heating, heating the solid aerosol-generating substrate 116 and vaporizing the aerosol-generating substrate 116 to form an aerosol in the inhaled air 101 that flows along the airflow channel 124 from the air inlet 123 to the mouthpiece or air outlet 122, and the inhaled air 102 flows through the air outlet.

[0103] The induction heating element 125 is coupled to the supply reel 111 or the take-up reel 112. Rotation of the supply reel 111 or the take-up reel 112 may be accomplished by a drive mechanism 127. The drive mechanism 127 may be coupled to the supply reel 111 or the take-up reel 112. The drive mechanism 127 may be coupled to the take-up reel 112 to rotate the supply reel 111 and the take-up reel 112. Rotating the take-up reel 112 and the supply reel 111 advances the tape forward to be heated by the induction heating element 125 and provide the solid aerosol generation substrate 116 for vaporization.

[0104] Figure 4A is a schematic top view of tape 113 and solenoid induction heating element 125. Figure 4B is a perspective view of tape 113 and solenoid induction heating element 125 of Figure 4A. Figure 5 is a schematic top view of another tape 113 and solenoid induction heating element 125.

[0105] 4A and 4B illustrate tape 113 being unwound from supply reel 111, wound onto take-up reel 112, and contacting circular solenoid induction heating element 125. Tape 113 is deflected by solenoid induction heating element 125 and passes over guide elements on either side of solenoid induction heating element 125. Tape 113 contacts approximately 50% of the circumference of circular solenoid induction heating element 125. Tape 113 contacts circular solenoid induction heating element 125.

[0106] 5 illustrates tape 113 being unwound from supply reel 111, wound onto take-up reel 112, and contacting a diamond-shaped (or square) solenoidal induction heating element 125. The tape 113 is deflected by the solenoidal induction heating element 125 and passes over guide elements on either side of the solenoidal induction heating element 125. The tape 113 contacts approximately 50% of the circumference of the diamond-shaped solenoidal induction heating element 125. The tape 113 contacts a circular solenoidal induction heating element 125.

[0107] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like, should be understood in all cases as modified by the term "about." Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A±2%. Within this context, the number A may be considered to include a numerical value that is within the general standard error for the measurement of the property that the number A modifies. The number A may deviate by the percentages recited above, in some cases as used in the appended claims, provided that the amount by which A deviates does not materially affect the basic and novel property(ies) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. An aerosol generating device, comprising: a housing having an air inlet and an air outlet; an airflow channel fluidly connecting the air outlet with the air inlet; an induction heating element coupled to the housing and along the airflow channel; an aerosol generating device comprising: a cartridge-receiving cavity defined within the housing and configured to receive a cartridge including a tape containing an aerosol-generating substrate; a cartridge received within the cartridge-receiving cavity, the induction heating element being in magnetic contact with the tape, the cartridge comprising: a tape extending from the first end to the second end; a rotatable supply reel fixed within the cartridge, a rotatable take-up reel fixed within the cartridge, a supply reel and a take-up reel, the first end of the tape being secured to the take-up reel and the second end of the tape being secured to the supply reel; an aerosol-generating substrate disposed on the tape, the aerosol-generating substrate comprising nicotine and glycerol; a cartridge including a susceptor element including a plurality of ferritic stainless steel beads disposed within the aerosol-generating substrate or within the tape.

2. 2. The aerosol-generating system of claim 1, wherein the aerosol-generating substrate is a solid at 25°C.

3. 3. The aerosol generating system of claim 1 or claim 2, wherein the plurality of ferritic stainless steel beads have a number average diameter in the range of 5 micrometers to 50 micrometers, or 10 micrometers to 40 micrometers, or 20 micrometers to 35 micrometers.

4. 3. The aerosol generating system of claim 1 or claim 2, wherein the plurality of ferritic stainless steel beads are formed of AISI 430 stainless steel.

5. 3. The aerosol-generating system according to claim 1, wherein the aerosol-generating substrate comprises the ferritic stainless steel beads.

6. 3. An aerosol-generating system according to claim 1 or claim 2, wherein the aerosol-generating substrate contains from 1% to 30% by volume, or from 5% to 20% by volume, or from 5% to 15% by volume of ferritic stainless steel beads.

7. 3. The aerosol generating system of claim 1 or claim 2, wherein the tape contains the ferritic stainless steel beads.

8. 3. The aerosol generating system of claim 1 or claim 2, wherein the tape contains 1% to 30%, or 5% to 20%, or 5% to 15% by volume of ferritic stainless steel beads.

9. 3. The aerosol generating system of claim 1 or claim 2, wherein the induction heating element comprises a planar coil.

10. 3. The aerosol generating system of claim 1 or claim 2, wherein the induction heating element comprises a solenoid coil.

11. 3. The aerosol generating system of claim 1 or claim 2, wherein the induction heating element contacts the tape to cause the tape to warp.

12. 3. An aerosol generating system according to claim 1 or claim 2, wherein the induction heating element operates at a frequency in the range of 5 MHz to 30 MHz, or 6 MHz to 15 MHz, or 6 MHz to 7 Mhz.

13. 3. The aerosol generating system of claim 1, wherein the aerosol generating device comprises a power source electrically connected to the induction heating element, and the induction heating element and ferritic stainless steel beads are configured to heat the aerosol generating substrate to 200°C within 300 milliseconds.

14. 3. The aerosol-generating system of claim 1, wherein the tape has a thickness in the range of about 25 micrometers to about 1000 micrometers, or about 50 micrometers to about 750 micrometers, or about 100 micrometers to about 500 micrometers, or about 300 micrometers, and the aerosol-generating substrate has a thickness in the range of 100 micrometers to 750 micrometers, or 200 micrometers to 500 micrometers.

15. 3. A method of using the aerosol generating system of claim 1 or claim 2, comprising: rotating the take-up reel to rotate the heating element and to align the induction heating element with the aerosol-generating substrate; heating the aerosol-generating substrate having the ferritic stainless steel beads with the induction heating element to form an aerosol in the inhalation airstream.

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