Aerosol-forming cartridge and system having nicotine gel - Patents.com

Abstract

The aerosol-forming cartridge includes a housing defining a cartridge body and having a housing interior, an aerosol-forming substrate reservoir secured within the housing interior, and a revolver element rotatably secured within the housing interior and having two or more chambers disposed about the revolver element. The aerosol-forming substrate reservoir contains a volume of aerosol-forming substrate. The aerosol-forming substrate is a gel. A biasing element applies a force to the volume of the aerosol-forming substrate. The aerosol-forming substrate reservoir has an exit opening. The two or more chambers of the revolver are sequentially aligned with the exit opening as the revolver element rotates.

Description

[Technical field]

[0001] The present disclosure relates to an aerosol-forming system having a nicotine gel, the aerosol-forming system being configured to generate an aerosol via heating of the nicotine gel. [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 within the electronic cigarette in replaceable aerosol-forming articles or "pods." 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 into the inhalation airstream of the electronic cigarette for vaporization. Summary of the Invention [Problem to be solved by the invention]

[0003] A known problem with commercial e-cigarettes is the leakage of e-liquid. Leaking occurs when there is too much e-liquid. Leaking occurs when the retention capacity of the porous material does not prevent the e-liquid from seeping out, especially when the commercial e-cigarette is full. Leaking occurs upon changes in environmental pressure during storage or transportation. Leaking may also occur with temperature changes that affect the viscosity of the e-liquid and the retention capacity of the porous material.

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

[0005] There is a need for an aerosol-forming cartridge or system that is stable and leak-proof.There is a need for a replaceable aerosol-forming article that does not contain a heating element.There is a need for an aerosol-forming cartridge or system that provides a metered dose of an aerosol-forming substrate during operation.

[0006] It is desirable to provide an aerosol-forming system that utilizes a gel aerosol-forming substrate within a replaceable aerosol-forming article. It is desirable to provide an aerosol-forming system that includes a heating element within an aerosol-forming device that receives a replaceable aerosol-forming article. It is desirable to provide an aerosol-forming article that includes a rotating revolver element having two or more chambers that receive a metered dose of aerosol-forming substrate or gel within each chamber. It is desirable to provide an aerosol-forming article that includes a rotating revolver element having at least three chambers and including a heating position, a cleaning position, and a deposition position. [Means for solving the problem]

[0007] The present disclosure is directed to an aerosol-forming article or cartridge that includes an aerosol-forming substrate reservoir and a rotating revolver element having two or more chambers that receive a metered dose of aerosol-forming substrate or gel in each chamber. The rotating revolver element includes at least a heating position and a deposition position, and optionally a cleaning position.

[0008] According to one aspect of the invention, there is provided an aerosol-forming cartridge including a housing defining a cartridge body and having a housing interior, an aerosol-forming substrate reservoir secured within the housing interior, and a revolver element rotatably secured within the housing interior and having two or more chambers disposed about the revolver element. The aerosol-forming substrate reservoir contains a volume of an aerosol-forming substrate. The aerosol-forming substrate is a gel. A biasing element applies a force to the volume of the aerosol-forming substrate. The aerosol-forming substrate reservoir has an exit opening. The two or more chambers of the revolver are sequentially aligned with the exit opening as the revolver element rotates.

[0009] According to another aspect of the present invention, an aerosol-forming system includes an aerosol-forming device and a replaceable cartridge or aerosol-forming article. The aerosol-forming device includes a device housing defining a device interior and a device exterior surface. The device exterior surface includes a cartridge receiving surface and a heating element secured to the cartridge receiving surface. The replaceable cartridge described herein is configured to mate with the cartridge receiving surface. The device heating element is aligned with the revolver element in a gel heating position.

[0010] According to another aspect of the invention, a method of forming an aerosol includes inserting a replaceable cartridge as described herein onto a cartridge receiving surface of an aerosol forming device as described herein. An aerosol-forming substrate contained within a chamber of a revolver element is then heated to form an aerosol in an inhalation airflow flowing through the cartridge. The aerosol and the inhalation airflow are then passed through a mouthpiece.

[0011] Advantageously, the aerosol-forming substrate in the aerosol-forming cartridge is a gel until the heating stage, and therefore is stable and does not leak liquid during transport or storage or use of the aerosol-forming substrate. Furthermore, the replaceable cartridge does not include a heating element, and is less complicated and less costly to manufacture. In addition, the replaceable cartridge provides a metered dose of aerosol-forming substrate per inhalation or puff as it is incremented forward by the user from a deposition position to a heating position. Advantageously, the revolver element has two or more chamber elements around its periphery, and the revolver element rotates to provide at least a deposition position and a heating position, and optionally a cleaning position between the heating position and the deposition position, to maintain consistent operation of the aerosol-forming system.

[0012] All values ​​reported as percentages are assumed to be weight percent based on total weight.

[0013] 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.

[0014] As used herein, the singular forms "a," "an," and "the" include embodiments having plural referents unless the content clearly dictates otherwise.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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%.

[0019] 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.

[0020] The term "solid" refers to a fundamental state of matter that does not expand or flow to fill space at a temperature of 25 degrees Celsius and one atmosphere of pressure.

[0021] The term "nicotine" refers to nicotine and nicotine derivatives (eg, free base nicotine, nicotine salts, and the like).

[0022] 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 a magnetic recording medium such as a disk or tape, etc.) containing digital bits (e.g., digital bits coded in binary, ternary, etc.) that may be readable and writable.

[0023] 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 liquid droplets. The aerosol preferably includes nicotine.

[0024] The term "aerosol-forming 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-forming substrate may be heated to volatilize one or more components of the aerosol-forming substrate to form an aerosol. In some cases, the volatile compounds may be released by a chemical reaction. The aerosol-forming substrate may be solid or liquid, or may include both solid and liquid components, such as a gel. The aerosol-forming substrate may be adsorbed, coated, impregnated or otherwise loaded onto a carrier or support. The aerosol-forming substrate preferably comprises nicotine. The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco-containing material. The aerosol-forming substrate may comprise a homogenized plant-derived material. The aerosol-forming substrate may comprise a homogenized tobacco material. The aerosol-forming substrate may comprise at least one aerosol former. The aerosol-forming substrate may comprise other additives and ingredients (such as flavourants). The aerosol-forming substrate may comprise an active ingredient. The aerosol-forming substrate may be provided as part of an aerosol-generating article. The aerosol-forming substrate may be provided within an aerosol-generating article.

[0025] 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-forming 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-forming substrate of the aerosol-generating article. An "aerosol-forming cartridge" is one example of an aerosol-generating article.

[0026] 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-forming substrate.

[0027] The term "heating element" is used herein to refer to any device, apparatus, or portion thereof configured to provide heat or thermal energy to an aerosol-generating article to release volatile compounds from the aerosol-generating article and form an aerosol.

[0028] The term "gel" refers to a gelled material. A gelled or gelled material may be solid at room temperature. A gelled or gelled material may substantially maintain its shape and mass at room temperature. Room temperature in this context means 25 degrees Celsius. "Solid" in this context means that the material substantially maintains its shape and mass at room temperature and does not flow.

[0029] The aerosol-forming cartridge includes a housing defining a cartridge body and having a housing interior, an aerosol-forming substrate reservoir secured within the housing interior, and a revolver element rotatably secured within the housing interior and having two or more chambers disposed about the revolver element. The aerosol-forming substrate reservoir contains a volume of aerosol-forming substrate. The aerosol-forming substrate is a gel. A biasing element applies a force to the volume of the aerosol-forming substrate. The aerosol-forming substrate reservoir has an exit opening. The two or more chambers of the revolver are sequentially aligned with the exit opening as the revolver element rotates.

[0030] The aerosol-generating substrate may comprise nicotine. The nicotine may be included in the aerosol-generating substrate in free base form or in salt form. The aerosol-generating substrate may comprise nicotine in a concentration of 1% by weight or more, 1.5% by weight or more, or 2% by weight or more. The aerosol-generating substrate may comprise five concentrations of nicotine: 4% by weight or less, 3% by weight or less, or 2.5% by weight or less. In one embodiment, the aerosol-generating substrate comprises about 2% by weight of nicotine.

[0031] The aerosol-generating substrate is a gel comprising an active ingredient and one or more gelling agents. The active ingredient may comprise nicotine. The nicotine may be included in the gel in free base form or in salt form. The gel may comprise nicotine at a concentration of 1% or more, 1.5% or more, or 2% or more by weight. The gel may comprise nicotine at a concentration of 4% or less, 3% or less, or 2.5% or less by weight. In one embodiment, the gel comprises about 2% nicotine by weight. The one or more gelling agents may comprise a biopolymer. Examples of suitable biopolymers include polysaccharides such as gellan gum (natural, low acyl gellan gum, and high acyl gellan gum), xanthan gum, alginate (alginic acid), agar (a mixture of agarose and agaropectin), agarose, guar gum, wax, etc. The gel may comprise gelling agents at a concentration of 1% or more, 1.5% or more, or 2% or more by weight. The gel may comprise a gelling agent at a concentration of 20% by weight or less, 15% by weight or less, or 10% by weight or less.

[0032] The aerosol-generating substrate may include additional components such as flavorants, aerosol formers, water, and compounds that aid gelling. The aerosol-generating substrate may include one or more flavorants. The one or more flavorants may include tobacco flavors. Examples of suitable tobacco flavors include synthetic and naturally derived tobacco components. Naturally derived tobacco components may include volatile flavors or flavor compounds obtained from tobacco plant materials. Such components may be obtained by any suitable method, such as extraction, drying, grinding, etc. Synthetic tobacco components may include flavor molecules found in tobacco leaves, such as beta-damascenone, alpha- and 3-oxo-alpha-ionone, beta and 4-oxo-beta-ionone, theaspirone, 2-ethyl-3,5-dimethylpyrazine, phenylacetaldehyde, guaiacol, and furaenol. Other suitable flavoring agents include, for example, natural or synthetic menthol, peppermint, spearmint, coffee, tea, spices (such as cinnamon, clove, ginger, or combinations thereof), cocoa, vanilla, fruit flavors, chocolate, eucalyptus, geranium, eugenol, agave, juniper, anethole, linalool, and any combinations thereof.

[0033] The aerosol-generating substrate (e.g., a gel) may comprise glycerol. For example, the aerosol-generating substrate may comprise glycerol at a concentration of 50% by weight or more, 60% by weight or more, or 70% by weight or more. The aerosol-generating substrate may comprise glycerol at a concentration of 95% by weight or less, 90% by weight or less, or 80% by weight or less. The aerosol-generating substrate may comprise glycerol at a concentration in the range 50% to 95% by weight, or in the range 60% to 90% by weight, or in the range 60% to 80% by weight.

[0034] The aerosol-generating substrate may comprise water. For example, the aerosol-generating substrate may comprise water at a concentration of 10% by weight or more, 15% by weight or more, or 20% by weight or more. The aerosol-generating substrate may comprise water at a concentration of 25% by weight or less, 20% by weight or less, or 15% by weight or less. In some embodiments, the aerosol-generating substrate is free of water or substantially free of water.

[0035] The aerosol-generating substrate may include a gel comprising one or more divalent cations. Examples of suitable divalent cations include calcium-containing compounds such as calcium lactate in solution. The divalent cations may be present in the gel at a concentration of 0.1% by weight or more, or 0.5% by weight or more. The divalent cations may be present in the gel at a concentration of 1% by weight or less. In some embodiments, the gel comprises one or more carboxylic acids. The carboxylic acids may include a ketone group. The carboxylic acids may have 10 or fewer carbon atoms. Preferably, the carboxylic acids have 5 carbon atoms. Preferably, the carboxylic acid is levulinic acid.

[0036] One example of a suitable aerosol-generating substrate is a gel comprising nicotine and one or more gelling agents. The gel may comprise 1% to 4% nicotine by weight. The gel may comprise 1% to 7% gelling agent by weight. The gel may comprise 50% to 70% glycerol by weight. The gel may include a flavoring agent, such as a tobacco-derived extract. The gel composition may include a gelling agent forming a solid medium, glycerol dispersed in the solid medium, and nicotine dispersed in the glycerol.

[0037] The housing defines a cartridge body having a housing exterior surface and an interior surface defining a housing interior. The housing may further define at least one air inlet and at least one air outlet. The airflow path extends between the at least one air inlet and the at least one air outlet. The revolver element is disposed along the airflow path and entrains the aerosol formed by the revolver element at the heating position. When the aerosol is inhaled by a consumer of the aerosol forming device, air enters the housing through the at least one air inlet, passes along the airflow path through the housing interior, and exits the housing through the at least one air outlet. The air outlet may form at least a portion of the mouthpiece. The housing or cartridge body may include a mouthpiece formed by the at least one air outlet. The housing or cartridge body may include a mouthpiece in fluid communication with the at least one air outlet.

[0038] The aerosol-forming substrate reservoir is contained within a housing or cartridge body. An interior surface of the housing may surround the aerosol-forming substrate reservoir. The aerosol-forming substrate reservoir contains a volume of aerosol-forming substrate. The aerosol-forming substrate reservoir contains a volume of aerosol-forming substrate sufficient to form 200-300 inhalations or puffs by a consumer. The aerosol-forming substrate reservoir has an exit opening.

[0039] The biasing element applies a force or pressure to the volume of the aerosol-forming substrate. The force or pressure is sufficient to cause the volume of the aerosol-forming substrate to flow towards and through the exit opening. The force or pressure is sufficient to cause the volume of the solid gel to flow towards and through the exit opening. The force of the biasing element may be provided by a spring element pressing against a surface of the volume of the aerosol-forming substrate. The force of the biasing element may be provided by a motor pressing directly or indirectly against a surface of the volume of the aerosol-forming substrate. The force of the biasing element may be provided by directly or indirectly mechanically pressing against a surface of the volume of the aerosol-forming substrate.

[0040] A revolver element is rotatably secured within the housing. The revolver element has two or more chambers disposed about the revolver element. The revolver element may define a flat disk shape having an axis of rotation at a center of the flat disk. The two or more chambers of the revolver element are sequentially aligned with the exit opening as the revolver element rotates. Each of the chambers sequentially receives a defined volume of the aerosol-forming substrate as the aerosol-forming system operates. The revolver element may rotate clockwise or counterclockwise.

[0041] At least one chamber is aligned with the exit opening, and the biasing element is filled with the aerosol-forming substrate by applying a force or pressure to the volume of the aerosol-forming substrate within the aerosol-forming substrate reservoir, and the at least one chamber containing the aerosol-forming substrate is aligned in a heating position. In the heating position, the chamber containing the aerosol-forming substrate is aligned with a heating element that may extend through the housing or may be fixed to the aerosol-forming device when mated with the aerosol-forming device. The chamber may extend through the thickness of the revolver element. The chamber may extend through the entire thickness of the revolver element to form an open opening through the entire thickness of the revolver element. The chamber may extend through only a portion of the thickness of the revolver element to form a cavity having a bottom wall and a side wall that define only a portion of the thickness of the revolver element.

[0042] The revolver element may include three chambers disposed about the periphery of the revolver element. The three chambers may be evenly spaced from one another about the periphery of the revolver element. The three chambers of the revolver element are sequentially aligned with the exit openings as the revolver element rotates. Each of the chambers sequentially receives a defined volume of the aerosol-forming substrate as the aerosol-forming system operates.

[0043] The three-chambered revolver element includes a cleaning position. The chambers aligned in the cleaning position have just rotated away from the heating position and may have residual material remaining in the chambers. In the cleaning position, the residual material is removed by mechanical or thermal cleaning. The residual material may be mechanically removed using a brush element in the housing or cartridge body. The residual material may be thermally removed by a second heating element aligned with the chambers with the residual material in the cleaning position. The chambers with the residual material may be thermally cleaned by pyrolysis to decompose the residual material in the chambers. Thermal cleaning may be accomplished by heating the chambers with the residual material to a temperature in the range of 400 degrees Celsius to 1000 degrees Celsius. The housing interior may define a separate cavity surrounding the cleaning position and a separate cleaning air outlet to prevent hot volatile materials from entering the airflow path to the consumer during consumption.

[0044] The revolver element has three chambers, including a deposition position, a heating position, and a cleaning position, and the three chambers are aligned with each of the three positions and rotate through each of the three positions sequentially as the revolver element rotates one full revolution, or 360 degrees.

[0045] Initially, the first chamber is aligned with the exit opening to receive the aerosol-forming substrate, the second chamber containing the aerosol-forming substrate is aligned in a heating position, and the third chamber containing the residue is aligned in a cleaning position. When the aerosol-forming cartridge is mated with the aerosol-forming device, the consumer can activate the heating element to inhale the aerosol by inhaling a puff. The consumer can then advance the revolver element one increment to move the first chamber containing the aerosol-forming substrate to the heating position, the second chamber with the residue to the cleaning position, and the cleaned third chamber to the deposition position. This method is repeated after every inhalation by the consumer. This provides the consumer with a uniform, metered dose of aerosol with each inhalation.

[0046] The aerosol-forming system includes the above-mentioned cartridge mated with an aerosol-forming device. The aerosol-forming device includes a device housing defining a device interior and a device exterior surface. The device exterior surface includes a cartridge receiving surface. The device housing includes a heating element secured to the cartridge receiving surface. The cartridge is replaceably secured or mated to the cartridge receiving surface. The heating element is aligned with the revolver element in a heating position.

[0047] The cartridge receiving surface, or a surface of the cartridge in contact with the cartridge receiving surface, may include a detent or locking element for holding the cartridge in place on the cartridge receiving surface. The revolver element may include a shaft coupled to a drive element in the aerosol-forming device configured to rotate the revolver element. The shaft is located along an axis of rotation of the revolver element. The cartridge receiving surface may include an opening for receiving the shaft.

[0048] The drive element may include a motor. The drive element may be coupled to the shaft by a gear element. The drive element may be electrically coupled to the control electronics. The drive element may be electrically coupled to a power source.

[0049] The heating element may be a resistive heater or an inductive heater. The heating element may be electrically coupled to the control electronics. The heating element may be electrically coupled to a power source.

[0050] The heating element is configured to heat the aerosol-forming substrate to at least 200 degrees Celsius within 300 milliseconds. The heating element is configured to heat the aerosol-forming substrate to at least 200 degrees Celsius within 200 milliseconds. The heating element is configured to heat the aerosol-forming substrate to at least 250 degrees Celsius within 200 milliseconds, or within 100 milliseconds, or within 50 milliseconds, or within 25 milliseconds.

[0051] 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 the heating element, one or more of the drive elements, and, optionally, for cleaning the second heating element, for individually controlling one or more of the drive elements or heating elements, for implementing a program or scheme using one or more of the drive elements or heating elements, etc.

[0052] 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, for example, on any suitable device, such as a storage medium readable by a general-purpose or application-specific program, a controller device for configuring and operating 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 so configured causing a computer to operate in a specific and predetermined manner to perform the functions described herein.

[0053] 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 described herein, including those resulting from the system, or various components 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 functions 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.

[0054] The aerosol-forming device may include a second heating element positioned on the cartridge receiving surface and aligned with the cleaning position of the revolver element. The second heating element is configured to be heated to a temperature of 400 degrees Celsius and to clean residue from a chamber aligned with the second heating element. The second heating element is configured to be heated to a temperature in a range of 400 degrees Celsius to 600 degrees Celsius and to clean residue from a chamber aligned with the second heating element. The second heating element is configured to be heated to a temperature in a range of 400 degrees Celsius to 1000 degrees Celsius and to clean residue from a chamber aligned with the second heating element.

[0055] The second heating element may be a resistive heater or an inductive heater. The second heating element may be electrically coupled to the control electronics. The second heating element may be electrically coupled to a power source.

[0056] A method of forming an aerosol includes inserting the cartridge described above onto a cartridge receiving surface of the aerosol-forming device described above, heating an aerosol-forming substrate contained within a chamber of a revolver element of the cartridge to form an aerosol in an inhalation airstream flowing through the cartridge, and flowing the aerosol and the inhalation airstream through a mouthpiece.

[0057] The method may further include rotating the revolver element one increment to align the chamber containing the aerosol-forming substrate or gel over the heating element in the heated position and aligning the empty chamber with the exit opening of the aerosol-forming substrate reservoir, and depositing the aerosol-forming substrate or gel into the empty chamber.

[0058] The method may further include rotating the revolver element one increment to align a chamber containing the aerosol-forming substrate or gel over the heating element in a heating position, aligning a chamber containing residue over a cleaning position to mechanically or thermally clean the chamber containing residue, and aligning an empty chamber with the exit opening of the aerosol-forming substrate reservoir to deposit gel into the empty chamber.

[0059] The method may further include replacing the cartridge with a new cartridge when the gel in the cartridge is depleted. A cartridge may provide a consumer with 200-300 inhalations or puffs.

[0060] 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.

[0061] Examples will now be described with reference to the following figures: [Brief description of the drawings]

[0062] [Figure 1] FIG. 1 is a schematic cross-sectional view of an exemplary aerosol-forming cartridge. [Diagram 2] FIG. 2 is a transparent schematic top view of a portion of the aerosol-forming cartridge of FIG. [Diagram 3] FIG. 3 is a transparent schematic perspective view of the aerosol-forming cartridge of FIG. [Figure 4] FIG. 4 is a schematic cross-sectional view of an exemplary aerosol-forming device. [Diagram 5] FIG. 5 is a schematic top view of the aerosol-forming device of FIG. [Figure 6] 6 is a schematic cross-sectional view of an exemplary aerosol-forming system including the aerosol-forming cartridge of FIG. 1 mated with the aerosol-forming device of FIG. [Figure 7] FIG. 7 is a schematic side view of the aerosol formation system of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0063] Example 1. 1. An aerosol-forming cartridge comprising: a housing defining a cartridge body and having a housing interior; an aerosol-forming substrate reservoir secured within the housing interior, the aerosol-forming substrate reservoir containing a volume of the aerosol-forming substrate, the aerosol-forming substrate being a gel, a biasing element applying a force to the volume of the aerosol-forming substrate and having an exit opening; and a revolver element rotatably secured within the housing interior and having two or more chambers disposed about the revolver element, the two or more chambers being sequentially aligned with the exit opening as the revolver element rotates. Example 2. 2. An aerosol-forming cartridge according to example 1, wherein the gel comprises nicotine. Example 3. An aerosol-forming cartridge according to any of Examples 1 and 2, wherein the gel comprises a nicotine salt. Example 4. 4. An aerosol-forming cartridge according to any of Examples 1 to 3, wherein the gel comprises one or more gelling agents comprising a biopolymer. Example 5. An aerosol-forming cartridge according to any of Examples 1 to 4, wherein the gel comprises glycerol. Example 6. 6. An aerosol-forming cartridge according to any of Examples 1 to 5, wherein the gel comprises 50% to 95% by weight of glycerol. Example 7. 7. The aerosol-forming cartridge according to any of Examples 1-6, wherein the revolver element comprises three chambers extending through the thickness of the revolver element. Example 8. An aerosol-forming cartridge according to any of Examples 1-7, wherein the housing includes an airflow path extending from an air inlet through an interior of the housing to an air outlet of the housing, and the revolver is disposed along the airflow path. Example 9. 9. The aerosol-forming cartridge according to example 8, wherein the air outlet forms at least a portion of the mouthpiece. Example 10. The aerosol-forming cartridge according to any of Examples 1-9, wherein the biasing element comprises a spring. Example 11. The aerosol forming cartridge according to any of Examples 1 to 10, wherein the revolver element includes three chambers, a first chamber aligned with the exit opening, a second chamber aligned with a heating position, and a third chamber aligned with a cleaning position. Example 12. The aerosol-forming cartridge according to example 11, wherein the third chamber aligned with the cleaning position is mechanically cleaned or thermally cleaned. Example 13. An aerosol-forming system comprising: an aerosol-forming device having a device housing defining a device interior and a device exterior surface, the device exterior surface including a cartridge receiving surface; and a heating element secured to the cartridge receiving surface; and a cartridge according to any of Examples 1 to 12 configured to mate with the cartridge receiving surface, wherein the heating element is aligned with the revolver element in a gel heating position. Example 14. The aerosol formation system according to example 13, wherein the revolver element comprises a shaft coupled to a drive element in the aerosol formation device configured to rotate the revolver element. Example 15. An aerosol-forming system according to Example 14, wherein the drive element and the heating element are electrically coupled to control electronics within the aerosol-forming device. Example 16. An aerosol-forming system according to Example 14, wherein the driving element and the heating element are electrically coupled to a power source within the aerosol-forming device. Example 17. The aerosol-forming system according to any one of Examples 13 to 16, wherein the heating element is a resistive heating element configured to heat the aerosol-forming substrate to 200 degrees Celsius within 300 milliseconds. Example 18. The aerosol-forming system according to any one of Examples 13-17, wherein the aerosol-forming device comprises a second heating element configured to align with the cleaning position of the revolver element. Example 19. A method of forming an aerosol, comprising: inserting a cartridge according to any one of Examples 1-12 onto a cartridge receiving surface of an aerosol-forming device according to any one of Examples 13-18; then heating an aerosol-forming substrate contained within a chamber of the revolver element to form an aerosol in an inhalation airstream flowing through the cartridge; and flowing the aerosol and the inhalation airstream through a mouthpiece. Example 20. The method of forming an aerosol according to Example 19, further comprising rotating the revolver element one increment to align the chamber containing the gel over the heating element in the heated position and to align the empty chamber with the exit opening of the aerosol-forming substrate reservoir, and depositing the gel into the empty chamber. Example 21. 20. The method of forming an aerosol according to example 19, further comprising replacing the cartridge with a new cartridge when the gel in the cartridge is depleted. Example 22. The method of forming an aerosol according to example 19, further comprising, after forming the aerosol in the inhalation airstream flowing through the cartridge, rotating the revolver element one increment to align the spent chamber with a brush or a second heater to clean the chamber and form a cleaned chamber.

[0064] 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.

[0065] Fig. 1 is a cross-sectional schematic view of an exemplary aerosol-forming cartridge 100. Fig. 2 is a transparent schematic top view of a portion of the aerosol-forming cartridge 100 of Fig. 1. Fig. 3 is a transparent schematic perspective view of the aerosol-forming cartridge 100 of Fig. 1.

[0066] The aerosol-forming cartridge 100 includes a housing 110 having a housing interior 111 defined by an interior surface 113 of the housing 110, defining a cartridge body. An aerosol-forming substrate reservoir 120 is secured within the housing interior 111 to the interior surface 113. A revolver element 130 is rotatably secured to the housing interior 111 to the interior surface 113. The revolver element 130 has three chambers 135 disposed about the revolver element 130. The aerosol-forming substrate reservoir 120 contains a volume of aerosol-forming substrate 125. The aerosol-forming substrate 125 is a gel. A biasing element 128 applies a force to the volume of the aerosol-forming substrate 125. The aerosol-forming substrate reservoir 120 has an exit opening 122. The three chambers 135 of the revolver are sequentially aligned with the exit opening 122 as it rotates.

[0067] The revolver element 130 is a flat disk having a shaft 136 connected to the revolver element 130 at its axis of rotation. The biasing element 128 is shown as a spring member that exerts sufficient force to cause the aerosol-forming substrate 125 to flow toward and out of the exit opening 122 to deposit the aerosol-forming substrate 125 in a chamber 135 aligned with the exit opening 122 at a deposition position P1. The second chamber 135 is located at a heating position P2 and the third chamber 135 is located at a cleaning position P3. The revolver element 130 rotates clockwise through three positions P1, P2 and P3 when viewing the revolver element 130 from above.

[0068] The housing 110 includes an airflow pathway 112 that extends from an air inlet 114 through a housing interior 111 to a housing air outlet 116. A revolver element 130 is disposed along the airflow pathway 112 to provide an aerosol into the inhaled air flowing along the airflow pathway 112.

[0069] The aerosol-forming cartridge 100 includes an aerosol-forming device mating surface 119. A shaft 136 of the revolver element 130 extends through the aerosol-forming device mating surface 119. The revolver element 130 may be parallel to the aerosol-forming device mating surface 119. The aerosol-forming device mating surface 119 may include a heat-conducting element configured to transfer heat from a device heating element to a chamber 135 located at a heating position P2.

[0070] The aerosol-forming cartridge 100 includes a mouthpiece 118. The air outlet 116 forms a portion of the mouthpiece 118.

[0071] The aerosol forming cartridge 100 may include a separation wall 115 separating the cavity at the cleaning position P3 from the airflow path 112, as shown in Figure 2. Thermal cleaning may be accomplished by heating the chamber 135 at the cleaning position P3 to a temperature in the range of 400 degrees Celsius to 1000 degrees Celsius. The separation wall 115 prevents hot volatile materials cleaned from the chamber 135 from entering the airflow path 112 to the consumer during consumption.

[0072] Fig. 4 is a schematic cross-sectional view of an exemplary aerosol-forming device 200. Fig. 5 is a schematic top view of the aerosol-forming device 200 of Fig. 4. Fig. 6 is a schematic cross-sectional view of an exemplary aerosol-forming system 300 including the aerosol-forming cartridge 100 of Fig. 1 fitted to the aerosol-forming device 200 of Fig. 4. Fig. 7 is a schematic side view of the aerosol-forming system 300 of Fig. 6.

[0073] The aerosol-forming device 200 includes a device housing 210 defining a device interior 211 and a device exterior surface 213, the device exterior surface 213 including a cartridge receiving surface 212. A heating element 220 is secured to the cartridge receiving surface. The cartridge 100 mates with the cartridge receiving surface 212. The heating element 220 is aligned with the revolver element 130 at a gel heating position P2.

[0074] The cartridge receiving surface 212 includes a shaft opening 215 configured to receive the shaft 136 of the revolver element 130 when the cartridge 100 is mated with the cartridge receiving surface 212. The shaft 136 is coupled to a drive element 230, such as a motor. The motor 230 includes a motor shaft 235 coupled to one or more gear elements 231 (illustrated here as a single gear for convenience). The drive element 230 is shown coupled to the shaft 136 by the gear elements 231. The drive element 230 rotates the revolver element 130 to provide the aerosol-forming substrate 125 to the heating element 220.

[0075] The control electronics 240 and the power source 250 are disposed within the device housing 210. The drive element 230 is electrically coupled to the control electronics 240. The drive element is electrically coupled to the power source 250.

[0076] The aerosol-forming device 200 is illustrated including a charging port 260 electrically coupled to the power source 250 for recharging the power source 250. The aerosol-forming device 200 is illustrated including a power switch and display unit 270. The power switch and display unit 270 is electrically coupled to the control electronics 240.

[0077] 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. 1. An aerosol-forming cartridge comprising: a housing defining a cartridge body and having a housing interior; an aerosol-forming substrate reservoir fixed within the housing interior, the aerosol-forming substrate reservoir containing a volume of aerosol-forming substrate, the aerosol-forming substrate being a gel, a biasing element applying a force to the volume of aerosol-forming substrate, and the aerosol-forming substrate reservoir having an exit opening; a revolver element rotatably secured within the housing and having two or more chambers arranged around the revolver element, the two or more chambers being sequentially aligned with the outlet opening as the revolver element rotates.

2. 10. The aerosol-forming cartridge of claim 1, wherein the gel comprises nicotine or a nicotine salt.

3. 3. An aerosol-forming cartridge according to claim 1, wherein the gel comprises one or more gelling agents including a biopolymer, preferably glycerol.

4. 10. The aerosol-forming cartridge of claim 1, wherein the gel comprises 50% to 95% by weight of glycerol.

5. 10. The aerosol-forming cartridge of claim 1, wherein the revolver element includes three chambers extending through the thickness of the revolver element.

6. 2. The aerosol-forming cartridge of claim 1, wherein the housing includes an airflow path extending from an air inlet through the interior of the housing to an air outlet of the housing, the revolver is positioned along the airflow path, and the air outlet forms at least a portion of a mouthpiece.

7. the revolver element includes three chambers, a first chamber aligned with the exit opening, a second chamber aligned in a heating position, and a third chamber aligned in a cleaning position; The aerosol-forming cartridge of claim 1 , wherein the third chamber aligned with the cleaning position is mechanically cleaned or thermally cleaned.

8. 1. An aerosol-forming system comprising: An aerosol-forming device, a device housing defining a device interior and a device exterior surface, the device exterior surface including a cartridge receiving surface; and an aerosol-forming device including a heating element fixed to the cartridge receiving surface; a cartridge according to claim 1 configured to mate with the cartridge receiving surface; The aerosol-forming system, wherein the heating element is aligned with the revolver element at a gel-heating position.

9. 9. The aerosol formation system according to claim 8, wherein the revolver element includes a shaft coupled to a drive element within the aerosol formation device configured to rotate the revolver element.

10. The aerosol formation system of claim 9, wherein the driving element and the heating element are electrically coupled to a control electronic circuit within the aerosol formation device, and the driving element and the heating element are electrically coupled to a power source within the aerosol formation device.

11. 9. The aerosol-forming system according to claim 8, wherein the heating element is a resistive heating element configured to heat the aerosol-forming substrate to 200 degrees Celsius within 300 milliseconds.

12. 9. The aerosol-forming system according to claim 8, wherein the aerosol-forming device comprises a second heating element configured to align with a cleaning position of the revolver element.

13. 1. A method of forming an aerosol, comprising: Inserting the cartridge of claim 1 onto the cartridge receiving surface of the aerosol-forming device of claim 10; heating the aerosol-forming substrate contained within a chamber of the revolver element to form an aerosol in an inhalation airstream flowing through the cartridge; and flowing the aerosol and inhaled airflow through a mouthpiece.

14. 14. The method of claim 13, further comprising rotating the revolver element one increment to align a chamber containing the aerosol-forming substrate over the heating element in the heated position and to align an empty chamber with the aerosol-forming substrate outlet opening of the aerosol-forming substrate reservoir, and depositing the aerosol-forming substrate into the empty chamber.

15. 14. The method of claim 13, further comprising, after forming the aerosol in an inhalation airflow flowing through the cartridge, rotating the revolver element one increment to align a chamber having residue with a brush or a second heater to clean the chamber and form a cleaned chamber.

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