Resistively heated aerosol generating system with nicotine tape

Abstract

The aerosol generating system includes a rotating heating element having two or more heating surfaces within an aerosol generating device. The aerosol generating device receives a replaceable aerosol generating article. The replaceable aerosol generating article includes a tape having a solid aerosol-generating substrate thereon. A method of using the aerosol generating system is also described.

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 resistive 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 replaceable aerosol generating articles or "pods" 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, 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, when changes in environmental pressure occur during storage or transportation, or when there are temperature changes that 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 contain 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 a solid aerosol-generating substrate on a tape. The tape may have multiple layers. It is desirable to provide an aerosol generating system that includes a rotatable heating element in an aerosol generating device that receives a replaceable aerosol-generating article. It is desirable to provide an aerosol generating system that includes a rotating heating element having two or more heating surfaces in an aerosol generating device that receives a replaceable aerosol-generating article. It is desirable to provide an aerosol generating system that includes a rotating heating element having two or more heating surfaces and that includes a heating position and a cleaning position. Summary of the Invention

[0007] The present disclosure is directed to an aerosol generating system that includes a rotating heating element having two or more heating surfaces in an aerosol generating device that receives a replaceable aerosol generating article, the replaceable aerosol generating article including a solid aerosol-generating substrate on a tape.

[0008] According to an aspect of the 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 intake air inlet, an airflow channel fluidly connecting the air outlet with the air inlet, a rotatable heating element coupled to the housing and aligned with the airflow channel, and a cartridge receiving cavity defined within the housing and configured to receive a cartridge containing a tape. The cartridge is received within the cartridge receiving cavity, and the rotatable heating element is in magnetic contact with the tape. 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 rotatable supply reel. The tape extends from a first end to a second end. The first end is secured to the rotatable take-up reel and the second end is secured to the rotatable supply reel. The tape includes a solid aerosol-generating substrate disposed on the tape. The solid aerosol-generating substrate includes nicotine and glycerol.

[0009] According to another aspect of the invention, a method of using the aerosol generation system described herein includes rotating a take-up reel to rotate a rotatable heating element to align a heating surface with a solid aerosol-generating substrate, and heating the solid aerosol-generating substrate with the heating surface to form an aerosol in the inhalation airstream.

[0010] Advantageously, the aerosol-generating substrate is solid 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 a heating element and is less complicated and less costly to manufacture. In addition, the replaceable cartridge, when incrementally advanced by the user, provides a metered amount of aerosol-generating substrate per inhale or puff. Advantageously, the heating element has two or more heating surfaces or areas about its periphery, and the heating element rotates to provide at least a cleaning position and a heating position to maintain consistent operation of the aerosol generating system.

[0011] All values ​​reported as percentages are assumed to be weight percent based on total weight.

[0012] 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.

[0013] As used herein, the singular forms "a," "an," and "the" include embodiments having plural referents unless the content clearly dictates otherwise.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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%.

[0018] 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.

[0019] 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.

[0020] The term "nicotine" refers to nicotine and nicotine derivatives, such as free base nicotine, nicotine salts, and the like.

[0021] As used herein, the terms "control electronics," "controller," and "processor" refer to any device or facility 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 containing digital bits (e.g., coded in binary, ternary, etc.) that may be readable and writable (e.g., volatile or non-volatile memory, or magnetic recording media such as disks or tapes, etc.).

[0022] 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.

[0023] 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.

[0024] The term "aerosol-generating article" is used herein to refer to a disposable product that can include an aerosol-generating substrate (e.g., hold, contain, have or store an aerosol-forming substrate). The aerosol-generating article may have the ability to removably attach 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" is an example of an "aerosol-generating article".

[0025] The term "aerosol-generating device" is used herein to refer to any device configured for use or utilization 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.

[0026] 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.

[0027] The aerosol generating system includes a rotating heating element having two or more heating surfaces in an aerosol generating device that receives a replaceable aerosol generating article. The replaceable aerosol generating article includes a tape having a solid aerosol generating substrate thereon. The solid aerosol generating substrate remains solid until heated by the rotating heating element. One of the heating surfaces or regions of the rotatable heating element contacts the solid aerosol generating substrate and 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, or about 200 degrees Celsius to about 350 degrees Celsius. The rotatable heating element is then rotated to a cleaning position to remove any residue from the rotatable heating element surface before contacting the aerosol generating substrate again.

[0028] The 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 intake air inlet, an airflow channel fluidly connecting the air outlet with the air inlet, a rotatable 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 containing a tape. The cartridge is received within the cartridge receiving cavity, with the rotatable heating element being in magnetic contact with the tape. 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 rotatable supply reel. The tape extends from a first end to a second end. The first end is secured to the rotatable take-up reel and the second end is secured to the rotatable supply reel. The tape includes a solid aerosol-generating substrate disposed on the tape. The solid aerosol-generating substrate includes nicotine and glycerol.

[0029] The rotatable heating element includes two or more heating surfaces disposed about the periphery of the rotatable heating element, which generate heat by resistive heating and contact the solid aerosol-generating substrate to heat the aerosol-generating substrate by conduction, and the rotatable heating element or heating surfaces are electrically coupled to a power source of the aerosol-generating device.

[0030] The heating surfaces may be positioned on opposite sides of the rotatable heating element. The heating surfaces may be evenly spaced from one another about the circumference of the rotatable heating element. Each heating surface defines a separate heating area separated from each other by a distance sufficient to prevent heating of one heating surface by an adjacent heating surface by conduction. Each heating surface may be spaced apart from one another by, for example, about 20 mm. 2 ~ approx. 100mm 2 , or about 40 mm 2 ~about 80mm 2 The surface area may be in the range of 0.1 to 100 nm.

[0031] In one embodiment, the rotatable heating element comprises three heating surfaces disposed about the periphery of the rotatable heating element. The three heating surfaces may be evenly spaced from one another about the periphery of the rotatable heating element.

[0032] The rotatable heating element may have a circular perimeter coaxial with the axis of rotation of the heating element. The rotatable heating element may define two or more arcuate sections disposed about the perimeter of the heating element and defining the perimeter of the heating element, each of the heating surfaces rotating coaxially with the axis of rotation of the heating element.

[0033] The heating surfaces may form a straight or flat surface. The heating surfaces may form a curved or arcuate surface. Two heating surfaces may each form a straight or flat surface. Two heating surfaces may each form a curved or arcuate surface. Three heating surfaces may each form a straight or flat surface. Three heating surfaces may each form a curved or arcuate surface.

[0034] The rotatable heating element may be coupled to the movement of a tape contained within a replaceable cartridge such that as the tape advances from a rotatable supply reel to a rotatable take-up reel, the rotatable heating element simultaneously rotates, advancing one of its heating surfaces over the tape to conductively 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.

[0035] The rotatable heating element may be coupled to a rotatable supply reel or a rotatable take-up reel.The rotatable heating element may be coupled to a rotatable supply reel.The rotatable heating element may be coupled to a rotatable take-up reel.

[0036] The rotatable heating element may be mechanically coupled to a rotatable supply reel or a rotatable take-up reel, for example, via one or more gear wheels.

[0037] The rotatable heating element may be electronically coupled to the rotatable supply reel or the rotatable take-up reel, for example, the rotatable heating element may be electronically coupled to the rotatable supply reel or the rotatable take-up reel via control electronics.

[0038] Rotation of the heating element or the supply or take-up reel may be accomplished by a drive mechanism. The drive mechanism may be coupled to the supply reel, take-up reel, or heating element. The drive mechanism may be coupled to the take-up reel to rotate the take-up reel, supply reel, and heating element. The drive mechanism may be coupled to the heating element to rotate the take-up reel and supply reel.

[0039] 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.

[0040] 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.

[0041] The drive mechanism may be electrically coupled to the control electronics. The control electronics may be electrically coupled to the heating element. The control electronics may be electrically coupled to the heating element and the drive mechanism. Activation of the drive mechanism may activate a heating surface in contact with the tape.

[0042] 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 with 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, cleaning elements, preheating elements, and drive mechanisms, individually controlling the heating elements and drive functions, and executing programs or schemes using one or more of the heating elements and drive mechanisms, cleaning elements, preheating elements, and the like.

[0043] 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, the cleaning element, the preheating element, and the like. Power may be supplied to the heating element continuously after start-up 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.

[0044] The aerosol generating device includes a power source for the heating element, the drive mechanism, the cleaning element, or the preheating element, or a combination thereof. The power source may be a battery in the device, such as a lithium iron phosphate battery. 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 about 6 minutes, which corresponds to the typical time it takes to smoke one conventional cigarette, or a multiple of 6 minutes. In another example, the power source may have a capacity sufficient to allow for a predetermined number of puffs, or discontinuous activation of the heating element.

[0045] 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.

[0046] 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.

[0047] The rotatable heating element has two or more positions along a rotational path of the heating element. The rotatable heating element has a heating position and a cleaning position along a rotational path of the heating element.

[0048] In the heating position, the heating surface contacts the tape or aerosol-generating substrate to conductively heat the aerosol-generating substrate. The heating surface may deflect the tape away from the axis of rotation of the heating element. This may help to maintain uniform contact between the heating surface and the tape or aerosol-generating substrate.

[0049] In the cleaning position, the heated surface rotates away from the tape and is spaced from the tape. In the cleaning position, the heated surface is cleaned to remove residues from the heated surface. Cleaning of the heated surface may be achieved, for example, by mechanical cleaning or thermal cleaning. The heated surface may be mechanically cleaned, for example, by brush elements. The heated surface may be thermally cleaned by pyrolysis to break down the residues. Thermal cleaning may be achieved by heating the heated surface to a temperature in the range of 400 degrees Celsius to 1000 degrees Celsius. The heated surface may be activated to achieve the thermal cleaning. Alternatively, or additionally, a separate cleaning element may apply heat to the heated surface to achieve the thermal cleaning.

[0050] The rotatable heating element may have a third position along the rotational path of the heating element. The third position may be a pre-heat position between the cleaning position and the heating position. The heating surface is spaced from the tape at the pre-heat position. At the pre-heat position, the heating surface is heated to a pre-heat temperature. The pre-heat temperature may be equal to the heating temperature. The pre-heat temperature may be in the range of 200 degrees Celsius to 350 degrees Celsius. The pre-heat position may reduce the time required to vaporize the aerosol-generating substrate because the heating surface is already at the heating temperature as soon as the heating surface contacts the tape or aerosol-generating substrate.

[0051] Once the tape has advanced one increment, the rotatable heating element may rotate to its next position. As the heating surface rotates from the heating position to the cleaning position, the tape may curl back towards the axis of rotation of the rotating heating element and then curl away from the axis of rotation of the rotating heating element to introduce the next heating surface back into the heating position.

[0052] The rotatable heating element is configured to heat the aerosol-generating substrate to at least 200 degrees Celsius within 300 milliseconds. The rotatable heating element is 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.

[0053] The cartridge includes a rotatable supply reel secured within the cartridge, a rotatable take-up reel secured within the cartridge, and a tape. The tape extends from a first end to a second end. The first end is secured to the rotatable take-up reel and the second end is secured to the rotatable supply reel. The tape includes a solid aerosol-generating substrate disposed on the tape. The solid aerosol-generating substrate includes nicotine and glycerol.

[0054] The tape may be formed of a material that is heat resistant, e.g., the tape does not decompose, ignite, or melt at heating temperatures. The tape may be formed of a metal. The tape may be formed of carbon fiber.

[0055] The tape has a thickness in the range of about 1 micrometer to about 50 micrometers, or about 1.5 micrometers to about 25 micrometers, or about 5 micrometers to about 15 micrometers, or about 10 micrometers. The tape may have a width in the range of, for example, 1 to 10 mm, or 2 to 7 mm.

[0056] The aerosol-generating substrate is a solid layer disposed on the tape. The aerosol-generating substrate may have a thickness in the range of 100 micrometers to 750 micrometers, or 200 micrometers to 500 micrometers.

[0057] The aerosol-generating substrate may define discrete areas on the tape. Each discrete area of ​​the aerosol-generating substrate may, for example, be about 20 mm 2 ~ approx. 100mm 2 , or about 40 mm 2 ~about 80mm 2The area may be in the range of

[0058] 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. Each individual region of the aerosol-generating substrate may be separated from the others by, for example, from about 1 mm to about 5 mm, or from 2 mm to about 5 mm.

[0059] A method of using the aerosol generation system described herein includes rotating a rotatable take-up reel to rotate a rotatable heating element to align a heating surface of the rotating heating element with a solid aerosol-generating substrate, heating the solid aerosol-generating substrate with the heating surface to provide an aerosol in an inhalation airflow along an airflow channel of the aerosol-forming device, and delivering the aerosol to a user via the airflow outlet.

[0060] The user can then advance the tape and rotatable heating element one increment to align another dose of solid aerosol-forming substrate with the heater to provide another dose of aerosol into the inhalation airflow along the airflow channel of the aerosol-generating device. The rotating step advances the tape one increment from the supply reel to the take-up reel and advances one of the heating surfaces of the heating element into a heating position in contact with the solid aerosol-generating substrate.

[0061] When a cleaning surface is provided on the rotating heating element, the rotating process advances the tape one increment from the supply reel to the take-up reel, advancing one of the heating surfaces of the rotatable heating element from a heating position to a cleaning position.

[0062] When the rotatable heating element includes a pre-heating position, the rotating step advances the tape one increment from the supply reel to the take-up reel and advances one of the heating surfaces of the rotatable heating element from the cleaning position to the pre-heating position. The rotating step advances the tape one increment from the supply reel to the take-up reel and advances one of the heating surfaces of the rotatable heating element from the pre-heating position to the heating position, in contact with a solid aerosol-generating substrate to provide an aerosol into an intake airflow along an airflow channel of the aerosol-forming device and delivers the aerosol to a user via the airflow outlet.

[0063] 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. EXAMPLES

[0064] 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 intake air inlet, an airflow channel fluidly connecting the air outlet with the air inlet, a rotatable heating element coupled to the housing and aligned with the airflow channel, and a cartridge receiving cavity defined within the housing and configured to receive a cartridge containing a tape containing a solid aerosol-generating substrate. The cartridge is received within the cartridge receiving cavity, and the rotatable heating element is in magnetic contact with the tape. 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 rotatable supply reel. The tape extends from a first end to a second end. The first end is secured to the rotatable take-up reel and the second end is secured to the rotatable supply reel. The tape includes a solid aerosol-generating substrate disposed on the tape. The solid aerosol-generating substrate includes nicotine and glycerol.

[0065] Example 2 An aerosol generating system as described in Example 1, wherein the rotatable heating element comprises two or more heating surfaces disposed about the periphery of the rotatable heating element.

[0066] Example 3 An aerosol generating system as described in any of Examples 1-2, wherein the rotatable heating element comprises three or more heating surfaces arranged about the periphery of the rotatable heating element.

[0067] Example 4 An aerosol generation system according to any of Examples 1-3, wherein the rotatable heating element is coupled to a rotatable supply reel or a rotatable take-up reel.

[0068] Example 5 The aerosol generating system of any of Examples 1-4, wherein the rotatable heating element includes a heating position and a cleaning position.

[0069] Example 6 The aerosol generating system of any of Examples 1-5, wherein the rotatable heating element includes a heating position, a cleaning position, and a pre-heating position.

[0070] Example 7 An aerosol generating system as described in any of Examples 1 to 6, wherein the rotatable heating element includes a cleaning position, and in the cleaning position, the aerosol generating device includes a mechanical cleaning element configured to contact and clean one of the heating surfaces of the rotatable heating element.

[0071] Example 8 An aerosol generating system as described in any of Examples 1 to 7, wherein the rotatable heating element includes a cleaning position, and in the cleaning position, the aerosol generating device thermally cleans one of the heating surfaces of the rotatable heating element.

[0072] Example 9 An aerosol generation system according to any of Examples 1 to 8, wherein the aerosol generation device comprises a drive actuator coupled to a rotatable take-up reel.

[0073] Example 10 An aerosol generating system as described in any of Examples 1 to 9, wherein a rotatable heating element contacts and warps the tape.

[0074] Example 11 An aerosol generation system according to any of Examples 1 to 10, wherein the aerosol generation device comprises a power source electrically coupled to the rotatable heating element.

[0075] Example 12 An aerosol-generating system according to any of Examples 1 to 11, wherein the rotatable heating element is configured to heat the aerosol-generating substrate to 200° C. within 300 milliseconds.

[0076] Example 13 An aerosol generating system as described in any of Examples 1 to 12, wherein the tape has a thickness in the range of about 1 micrometer to about 50 micrometers, or about 1.5 micrometers to about 25 micrometers, or about 5 micrometers to about 15 micrometers, or about 10 micrometers.

[0077] Example 14 An aerosol-generating system as described in any of Examples 1 to 13, wherein the aerosol-generating substrate is a solid layer having a thickness in the range of 100 micrometers to 750 micrometers, or 200 micrometers to 500 micrometers.

[0078] Example 15. A method of using the aerosol generating system of any of Examples 1-14, comprising rotating a rotatable take-up reel to rotate a rotatable heating element to align a heating surface with a solid aerosol-generating substrate, and heating the solid aerosol-generating substrate with the heating surface to form an aerosol in the inhalation airstream.

[0079] Example 16. The method of Example 15, wherein the rotating step advances the tape one increment from the rotatable supply reel to the rotatable take-up reel and rotates the rotatable heating element to a heating position where the heater of the rotatable heating element contacts the solid aerosol-generating substrate.

[0080] Example 17. The method of example 16, wherein the rotating step advances the tape one increment from a rotatable supply reel to a rotatable take-up reel and advances one of the heating surfaces of the rotatable heating element from a heating position to a cleaning position.

[0081] Example 18. The method of example 17, wherein the rotating step advances the tape one increment from a rotatable supply reel to a rotatable take-up reel and advances one of the heating surfaces of the rotatable heating element from a cleaning position to a preheating position.

[0082] Example 19. The method of Example 18, wherein the rotating step advances the tape one increment from a rotatable supply reel to a rotatable take-up reel and advances one of the heating surfaces of the rotatable heating element from a preheating position to a heating position in contact with the solid aerosol-generating substrate.

[0083] The embodiments will now be further described with reference to the following figures: [Brief description of the drawings]

[0084] [Figure 1] FIG. 1 is a schematic cross-sectional view of an exemplary aerosol generation system. [Diagram 2] FIG. 2 is a schematic perspective view of a portion of the tape. [Diagram 3] FIG. 3 is a schematic side view of an exemplary aerosol generation system. [Figure 4] FIG. 4 is a schematic cross-sectional view of the aerosol generation system of FIG. [Diagram 5] FIG. 5 is a perspective view of the aerosol generation system of FIG. [Figure 6] FIG. 6 is a schematic top view of a rotating heating element. [Figure 7A] FIG. 7A is a perspective side view of another exemplary aerosol generation system, showing a cartridge being inserted into the aerosol generation device. [Figure 7B] FIG. 7B is a perspective side view of the aerosol generation system of FIG. 7A with the cartridge inserted into the aerosol generation device. [Figure 7C] FIG. 7C is a perspective side view of the aerosol generation system of FIG. 7A with the cartridge fully inserted into the aerosol generation device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0085] 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.

[0086] Figure 1 is a schematic cross-sectional view of an exemplary aerosol generation system 100. Figure 2 is a schematic perspective view of a portion of a tape 113 in which aerosol-generating substrates 116 are spaced apart from one another. Figure 3 is a schematic side view of an exemplary aerosol generation system 100. Figure 4 is a schematic cross-sectional view of the aerosol generation system 100 of Figure 3. Figure 5 is a perspective view of the aerosol generation system 100 of Figure 3 with an open cartridge lid 140. Figure 6 is a schematic top view of a rotating heating element 125.

[0087] 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. Inlet air 101 enters the air inlet 123 and outlet air 102 exits the air outlet 122. A rotatable heating element 125 is coupled to the housing 121 and along the airflow channel 124. A cartridge receiving cavity 126 is defined within the housing 121 and configured to receive a cartridge 110 containing a tape 113. A solid aerosol generating substrate 116 is disposed on the tape 113. The cartridge 110 is received within the cartridge receiving cavity 126, with the rotatable 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 rotatable supply reel 111. The tape 113 extends from a first end to a second end. The first end is secured to the rotatable take-up reel 112 and the second end is secured to the rotatable supply reel 111. The tape 113 includes a solid aerosol-generating substrate 116 disposed on the tape 113. The solid aerosol-generating substrate 116 includes nicotine and glycerol.

[0088] A drive mechanism 127 , power supply 128 , and control electronics 129 are disposed within the aerosol generation device 120 housing 121 .

[0089] The rotatable heating element 125 includes two or more heating surfaces 131, 132, 133 disposed about the periphery of the rotatable heating element 125. The heating surfaces 131, 132, 133 generate heat by resistive heating and are in contact with the solid aerosol-generating substrate 116 to heat the aerosol-generating substrate 116 by conduction.

[0090] The rotatable heating element 125 is coupled to the movement of the tape 113 contained within the replaceable cartridge 110. As the tape 113 advances from the rotatable supply reel 111 to the rotatable take-up reel 112, the rotatable heating element 125 simultaneously rotates, advancing one of the heating surfaces 131, 132, 133 over the tape 113 to conductively heat the aerosol-generating substrate 116 and form an aerosol in the intake air flowing along the airflow channel 124 from the air inlet 123 to the air outlet 122.

[0091] The rotatable heating element 125 is coupled to the rotatable supply reel 111 or the rotatable take-up reel 112. Rotation of the heating element 125 or 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, the take-up reel 112, or the rotatable heating element 125. The drive mechanism 127 may be coupled to the take-up reel 112 to rotate the take-up reel 112, the supply reel 111, and the rotatable heating element 125.

[0092] The rotatable heating element 125 has two or more positions Z1, Z2, Z3 shown in Figure 6 along the rotational path of the heating element 125. The rotatable heating element 125 has a heating position or heating zone Z1 and a cleaning position or cleaning zone Z2 along the rotational path of the heating element 125.

[0093] In the heating position or heating zone Z1, the heating surface 133 contacts the tape 113 or the aerosol-generating substrate 116 to conductively heat the aerosol-generating substrate 116. The heating surface 133 deflects the tape 113 away from the axis of rotation 130 of the heating element 125.

[0094] At the cleaning position or cleaning zone Z2, the heated surface 131 rotates away from and is spaced from the tape 113. At the cleaning position or cleaning zone Z2, the heated surface 131 is cleaned to remove residue from the heated surface 131. Cleaning of the heated surface 131 may be accomplished by mechanical cleaning or thermal cleaning.

[0095] The rotatable heating element 125 may have a third position along the rotational path of the heating element 125. The third position may be a pre-heat position or zone Z3 between the cleaning position or zone Z2 and the heating position or zone Z1. The heating surface 132 is spaced from the tape 113 at the pre-heat position or zone Z3. At the pre-heat position or zone Z3, the heating surface 132 is heated to a pre-heat temperature.

[0096] As the tape 113 is advanced a single increment, the rotatable heating element 125 rotates to the next position. As the heating surface 133 rotates from heating position Z1 to cleaning position Z2, the tape 113 may curl back toward the axis of rotation 130 of the heating element 125 and then curl away from the axis of rotation 130 of the heating element 125 as the next heating surface 132 reaches heating position Z1.

[0097] Figure 7A is a perspective side view of another exemplary aerosol generation system 200 with the lid 240 open and the cartridge 210 being inserted into the aerosol generation device 220. Figure 7B is a perspective side view of the aerosol generation system 200 of Figure 7A with the cartridge 210 inserted into the aerosol generation device 220 and the lid 240 open. Figure 7C is a perspective side view of the aerosol generation system 200 of Figure 7A with the cartridge 210 fully inserted into the aerosol generation device 220 and the lid closed.

[0098] The aerosol generating system 200 includes an aerosol generating device 220 and a replaceable cartridge 210. The aerosol generating device 220 includes a housing 221 having an air outlet 222 and an intake air inlet 223, and an airflow channel fluidly connecting the air outlet 222 with the air inlet 223. A rotatable heating element is coupled to the housing 221 and along the airflow channel, and a cartridge receiving cavity 226 is defined within the housing 221 and configured to receive a cartridge 210 containing a tape 213. A solid aerosol generating substrate is disposed on the tape. The cartridge 210 is received within the cartridge receiving cavity 226, and the rotatable heating element is in magnetic contact with the tape 213. The cartridge 210 includes a rotatable supply reel 211 secured within the cartridge 210, a rotatable take-up reel 212 secured within the cartridge 210, and a tape 213. The tape 213 extends from a first end to a second end. A first end is secured to a rotatable take-up reel 212 and a second end is secured to a rotatable supply reel 211. Tape 213 includes a solid aerosol-generating substrate disposed on the tape. The solid aerosol-generating substrate includes nicotine and glycerol.

[0099] 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 generating system comprising: An aerosol generating device, comprising: a housing having an air outlet and an air inlet; an airflow channel fluidly connecting the air outlet with the air inlet; a rotatable heating element coupled to the housing and aligned with the airflow channel; an aerosol generating device comprising: a cartridge receiving cavity defined within the housing and configured to receive a cartridge containing a tape; a cartridge received within the cartridge-receiving cavity, the heating element contacting the tape, the cartridge comprising: the tape extending from a first end to a second end; a rotatable supply reel fixed within the cartridge; a cartridge comprising a rotatable take-up reel secured within the cartridge; the first end of the tape is secured to the rotatable take-up reel and the second end of the tape is secured to the rotatable supply reel; a solid aerosol-generating substrate disposed on said tape, said solid aerosol-generating substrate comprising nicotine and glycerol;

2. 2. The aerosol generation system of claim 1, wherein the rotatable heating element has two or more heating surfaces arranged around the periphery of the rotatable heating element, or the rotatable heating element has three heating surfaces arranged around the periphery of the rotatable heating element.

3. 3. The aerosol generating system according to claim 1, wherein the rotatable heating element is coupled to the rotatable supply reel or the rotatable take-up reel.

4. 3. The aerosol generating system according to claim 1, wherein the rotatable heating element includes a heating position and a cleaning position.

5. 3. The aerosol generating system according to claim 1, wherein the rotatable heating element includes a heating position, a cleaning position, and a preheating position.

6. 3. The aerosol generating system of claim 2, wherein the rotatable heating element includes a cleaning position, and in the cleaning position, the aerosol generating device includes a mechanical cleaning element configured to contact and clean one of the heating surfaces of the rotatable heating element.

7. 3. The aerosol generating system of claim 2, wherein the rotatable heating element includes a cleaning position, in which the aerosol generating device thermally cleans one of the heating surfaces of the rotatable heating element.

8. 3. The aerosol generating system of claim 1, wherein the rotatable heating element contacts and warps the tape.

9. 3. The aerosol generation system according to claim 1, wherein the aerosol generation device comprises a power source electrically coupled to the rotatable heating element.

10. 3. The aerosol-generating system according to claim 1, wherein the rotatable heating element is configured to heat the aerosol-generating substrate to 200° C. within 300 milliseconds.

11. 3. The aerosol-generating system of claim 1, wherein the tape has a thickness in the range of about 1 micrometer to about 50 micrometers, or about 1.5 micrometers to about 25 micrometers, or about 5 micrometers to about 15 micrometers, or about 10 micrometers, and the aerosol-generating substrate is a solid layer having a thickness in the range of 100 micrometers to 750 micrometers, or 200 micrometers to 500 micrometers.

12. A method of using the aerosol generating system according to any one of claims 1 to 2, comprising: rotating the rotatable take-up reel to rotate the rotatable heating element and align a heating surface with the solid aerosol-generating substrate; heating said solid aerosol-generating substrate with said heated surface to form an aerosol in the inhalation airstream.

13. 13. The method of claim 12, wherein the rotating step advances the tape one increment from the rotatable supply reel to the rotatable take-up reel and rotates the rotatable heating element to a heating position where the heater of the rotatable heating element contacts the solid aerosol-generating substrate.

14. 14. The method of claim 13, wherein the rotating step advances the tape one increment from the rotatable supply reel to the rotatable take-up reel, advances one of the heating surfaces of the rotatable heating element from the heating position to a cleaning position, and advances one of the heating surfaces of the rotatable heating element from the cleaning position to a preheating position.

15. 15. The method of claim 14, wherein the rotating step advances the tape one increment from the rotatable supply reel to the rotatable take-up reel, advancing one of the heating surfaces of the rotatable heating element from the preheating position to the heating position and contacting the solid aerosol-generating substrate.

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