Planar consumables for aerosol generators

Abstract

The present invention relates to a consumable for an aerosol generating device. The consumable comprises a first planar substrate layer of an aerosol-forming substrate. The consumable further comprises a second planar substrate layer of the aerosol-forming substrate. The consumable further comprises a planar porous layer allowing airflow through the porous layer in the direction of extension of the plane of the porous layer. The porous layer is disposed between the first substrate layer and the second substrate layer.

Description

[Technical field]

[0001] The present invention relates to consumables for aerosol generating devices. [Background technology]

[0002] It is known to provide an aerosol-generating device for generating an inhalable vapor. Such a device may heat an aerosol-forming substrate contained in a consumable to a temperature at which one or more components of the aerosol-forming substrate volatilize without combustion. The consumable may be shaped for insertion of the aerosol-generating article into a cavity (such as a heating chamber) of the aerosol-generating device. After the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device, a heating element may be disposed in or around the heating chamber to heat the aerosol-forming substrate. Summary of the Invention [Problem to be solved by the invention]

[0003] It would be desirable to have a consumable for an aerosol-generating device which provides improved airflow through the consumable.It would be desirable to have a consumable for an aerosol-generating device which provides improved heating of an aerosol-forming substrate contained within the consumable.It would be desirable to have a consumable for an aerosol-generating device in which all aerosol-forming substrates contained within the consumable are heated to an optimal temperature. [Means for solving the problem]

[0004] According to one embodiment of the present invention, there is provided a consumable for an aerosol generating device. The consumable may comprise a first planar substrate layer of an aerosol-forming substrate. The consumable may further comprise a second planar substrate layer of an aerosol-forming substrate. The consumable may further comprise a planar porous layer allowing airflow through the porous layer in the direction of extension of the plane of the porous layer. The porous layer may be disposed between the first substrate layer and the second substrate layer.

[0005] According to one embodiment of the present invention, there is provided a consumable for an aerosol generating device. The consumable comprises a first planar substrate layer of an aerosol-forming substrate. The consumable further comprises a second planar substrate layer of the aerosol-forming substrate. The consumable further comprises a planar porous layer allowing airflow through the porous layer in the direction of extension of the plane of the porous layer. The porous layer is disposed between the first substrate layer and the second substrate layer.

[0006] The consumable improves airflow through the consumable, particularly by providing a planar porous layer that allows airflow through the planar porous layer.

[0007] The planar porous layer may be disposed as a central layer within the consumable. Preferably, the porous layer is disposed within the planar extension of the consumable.

[0008] The porous layer preferably allows for lateral airflow through the consumable.

[0009] Heating of the aerosol-forming substrate contained in the consumable is particularly improved by arranging the aerosol-forming substrate in the form of two planar layers. A heating element as described in more detail below may be arranged next to the planar layer of the aerosol-forming substrate, whereby all the aerosol-forming substrates in the planar layer are heated. This prevents uneven heating of the aerosol-forming substrate. Moreover, this prevents the aerosol-forming substrate from being heated to an insufficient temperature, and thus the unused aerosol-forming substrate.

[0010] The length of the consumable is preferably greater than the thickness of the consumable. The ratio of the length to the thickness of the consumable may be greater than 2, preferably greater than 3, more preferably greater than 4, and most preferably greater than 5. The width of the consumable is preferably greater than the thickness of the consumable. The ratio of the width to the thickness of the consumable may be greater than 2, preferably greater than 3, more preferably greater than 4, and most preferably greater than 5.

[0011] The consumable may be flat. Preferably, the consumable is not curved. Preferably, the consumable extends in a plane.

[0012] The length of the consumable may be slightly greater than the width of the consumable. The consumable may have a rectangular cross-sectional shape in a plane of elongation of the consumable. The consumable may further have a rectangular cross-sectional shape in a plane perpendicular to the plane of elongation of the consumable.

[0013] Alternatively, the length of the consumable may be similar or the same as the width of the consumable. In this case, the consumable may have a square cross-sectional shape in a plane of extension of the consumable. The consumable may further have a rectangular cross-sectional shape in a plane perpendicular to the plane of extension of the consumable.

[0014] A first substrate layer may be disposed immediately adjacent to a first surface of the porous layer and a second substrate layer may be disposed immediately adjacent to a second, opposing surface of the porous layer, or in other words, the porous layer may be sandwiched between the first substrate layer and the second substrate layer.

[0015] The surface area of ​​the surface of the first substrate layer facing the porous layer may be the same as the surface area of ​​the surface of the porous layer facing the first substrate layer, and the surface area of ​​the surface of the second substrate layer facing the porous layer may be the same as the surface area of ​​the surface of the porous layer facing the second substrate layer.

[0016] The first substrate layer may have a similar or the same length as the porous layer. The first substrate layer may have a similar or the same width as the porous layer.

[0017] One or both of the first and second substrate layers may have a length of from 10 millimeters to 35 millimeters, preferably from 10 millimeters to 25 millimeters, and most preferably approximately 11 millimeters.

[0018] One or both of the first and second substrate layers may have a thickness of from 0.3 millimeters to 3 millimeters, preferably from 0.4 millimeters to 2 millimeters, and most preferably approximately 0.5 millimeters.

[0019] One or both of the first and second substrate layers has a width of from 2 millimeters to 8 millimeters, preferably from 3 millimeters to 5 millimeters.

[0020] The porous layer may have a length of between 10 millimeters and 35 millimeters, preferably between 10 millimeters and 25 millimeters, and most preferably approximately 11 millimeters.

[0021] The porous layer may have a thickness of from 0.3 millimeters to 3 millimeters, preferably from 0.4 millimeters to 2 millimeters, and most preferably from 0.5 millimeters to 1 millimeter.

[0022] The porous layer may have a width of from 2 millimeters to 8 millimeters, preferably from 3 millimeters to 5 millimeters.

[0023] The second substrate layer may have a similar or the same length as the porous layer. The second substrate layer may have a similar or the same width as the porous layer.

[0024] The first substrate layer may have a similar or the same thickness as the porous layer. The second substrate layer may have a similar or the same thickness as the porous layer. Alternatively, one or both of the first substrate layer and the second substrate layer have a thickness that is less than the thickness of the porous layer.

[0025] The length of one or more of the first substrate layer, the second substrate layer, and the porous layer may be measured in the planar extension direction of the respective layer. The width of one or more of the first substrate layer, the second substrate layer, and the porous layer may be measured in the planar extension direction of the respective layer. The width is measured in a direction perpendicular to the thickness. The thickness of one or more of the first substrate layer, the second substrate layer, and the porous layer may be measured perpendicular to the planar extension direction of the respective layer. The thickness is measured in a direction perpendicular to the length direction and the width direction.

[0026] The ratio between the thickness of the first substrate layer and the thickness of the second substrate layer may be 0.1-10, preferably 0.3-3, more preferably 0.7-1.5, and most preferably approximately 1.

[0027] The ratio between the thickness of one or both of the first and second planar substrate layers and the thickness of the porous layer may be 0.2-10, preferably 0.6-6, more preferably 1-3, and most preferably approximately 2.

[0028] The first substrate layer may have the same cross-sectional shape in the extended plane of the consumable as the porous layer. The first substrate layer may have the same cross-sectional shape in the extended plane of the consumable as the second substrate layer. The second substrate layer may have the same cross-sectional shape in the extended plane of the consumable as the porous layer.

[0029] The first substrate layer may have the same cross-sectional shape as the porous layer in a plane perpendicular to the extended plane of the consumable. The first substrate layer may have the same cross-sectional shape as the second substrate layer in a plane perpendicular to the extended plane of the consumable. The second substrate layer may have the same cross-sectional shape as the porous layer in a plane perpendicular to the extended plane of the consumable.

[0030] The porous layer may include cellulose acetate. The porous layer may consist of cellulose acetate. The porous layer may include a high porosity acetate tow fiber-based compound, or other cellulosic fiber compound. The material of the porous layer may have a cross-sectional porosity.

[0031] The term "porosity" as used herein refers to the proportion of voids in a porous body. More specifically, the term porosity is used herein with respect to the "cross-sectional porosity" of one such body, i.e., the proportion of voids in the cross-sectional area of ​​the porous body, for example in the cross-section of a planar porous layer, or of a first planar substrate layer, or of a second planar substrate layer. The cross-sectional porosity is the area fraction of voids in the cross-sectional cross-sectional area of ​​each layer. The cross-sectional area of ​​each layer is the area of ​​each layer in a plane perpendicular to the longitudinal axis of each layer.

[0032] The porosity of the porous layer in the direction of the extension plane of the consumable may be higher than the porosity of the porous layer in a direction perpendicular to the extension plane of the consumable.

[0033] The porosity of one or both of the first and second substrate layers in the direction of the elongation plane of the consumable may be greater than the porosity of the porous layer in a direction perpendicular to the elongation plane of the consumable.

[0034] The aerosol-forming substrate of one or both of the first and second substrate layers may be a sensory medium. The aerosol-forming substrate may comprise a sensory medium compound, an NCP, an HTP, or herbal or cut filler tobacco.

[0035] The aerosol-forming substrate of the first substrate layer may be different from the aerosol-forming substrate of the second substrate layer. Exemplarily, the first substrate layer may be a nicotine-containing substrate, while the second substrate layer may be a flavour-containing substrate.

[0036] The porous layer may have a higher porosity than the aerosol-forming substrate.

[0037] The porous layer may have a cross-sectional porosity of 0.3 to 0.95, preferably 0.5 to 0.9. The porous layer may have a cross-sectional porosity of at least 0.15, more preferably at least 0.2.

[0038] The first substrate layer may have a cross-sectional porosity of 0.10 to 0.45. The first substrate layer may have a cross-sectional porosity of at least 0.15, more preferably at least 0.2. The first substrate layer may have a cross-sectional porosity of 0.4 or less, more preferably 0.35 or less, and most preferably 0.25 or less. The first substrate layer may have a cross-sectional porosity of 0.15 to 0.40, preferably 0.15 to 0.35, and more preferably 0.15 to 0.25. In other embodiments, the first substrate layer may have a cross-sectional porosity of 0.20 to 0.40, preferably 0.20 to 0.35, and more preferably 0.20 to 0.25.

[0039] The second substrate layer may have a cross-sectional porosity of 0.10 to 0.45. The second substrate layer may have a cross-sectional porosity of at least 0.15, more preferably at least 0.2. The second substrate layer may have a cross-sectional porosity of 0.4 or less, more preferably 0.35 or less, and most preferably 0.25 or less. The second substrate layer may have a cross-sectional porosity of 0.15 to 0.40, preferably 0.15 to 0.35, and more preferably 0.15 to 0.25. In other embodiments, the second substrate layer may have a cross-sectional porosity of 0.20 to 0.40, preferably 0.20 to 0.35, and more preferably 0.20 to 0.25.

[0040] The porous layer may have a cross-sectional porosity of at least 120 percent, preferably at least 130 percent, more preferably at least 140 percent, more preferably at least 150 percent, more preferably at least 175 percent, more preferably at least 200 percent, more preferably at least 250 percent, more preferably at least 300 percent, more preferably at least 400 percent, more preferably at least 500 percent, and more preferably at least 600 percent of the cross-sectional porosity of one or both of the first and second substrate layers.

[0041] The porous layer may have a cross-sectional porosity of 130 percent to 600 percent, preferably 130 percent to 500 percent, more preferably 130 percent to 400 percent, more preferably 130 percent to 300 percent, more preferably 130 percent to 200 percent, more preferably 140 percent to 600 percent, more preferably 140 percent to 500 percent, more preferably 140 percent to 400 percent, more preferably 140 percent to 300 percent, more preferably 140 percent to 200 percent, more preferably 150 percent to 600 percent, more preferably 150 percent to 500 percent, more preferably 150 percent to 400 percent, more preferably 150 percent to 300 percent, and more preferably 150 percent to 200 percent of the cross-sectional porosity of one or both of the first substrate layer and the second substrate layer.

[0042] The porous layer may have a cross-sectional porosity of up to 0.99. The porous layer may have a cross-sectional porosity of less than 0.95, preferably less than 0.90, more preferably less than 0.85. The porous layer may have a cross-sectional porosity of at least 0.3, preferably at least 0.35, more preferably at least 0.4, more preferably at least 0.45. The porous layer may have a cross-sectional porosity of 0.3 to 0.95, preferably 0.35 to 0.95, more preferably 0.4 to 0.95, more preferably 0.5 to 0.95. In other embodiments, the porous layer may have a cross-sectional porosity of 0.3 to 0.90, preferably 0.35 to 0.90, more preferably 0.4 to 0.90, more preferably 0.5 to 0.90. In other embodiments, the porous layer may have a cross-sectional porosity of 0.3 to 0.85, preferably 0.35 to 0.85, more preferably 0.4 to 0.85, more preferably 0.5 to 0.85.

[0043] The cross-sectional porosity is preferably determined by obtaining a digital image of the transverse cross-sectional area of ​​each layer and determining the areal percentage of the transverse voids. Further details regarding the measurement of cross-sectional porosity in porous bodies can be found in the publication of International Patent Application WO 2016 / 023965 in the name of the Applicant.

[0044] The porous layer may have a withdrawal resistance of 10 millimeters H2O to 65 millimeters H2O, preferably 30 millimeters H2O to 60 millimeters H2O.

[0045] The draw resistance of the porous layer may be less than 50%, preferably less than 30%, and more preferably less than 10% of the draw resistance of one or both of the first and second substrate layers.

[0046] The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise an aerosol former. The aerosol-forming substrate may be a solid.

[0047] The aerosol-generating substrate may include an aerosol former. The aerosol-generating substrate preferably includes a homogenized tobacco material, an aerosol former, and water. Providing a homogenized tobacco material may improve aerosol generation and the nicotine content and flavor profile of the aerosol generated during heating of the aerosol-generating article. Specifically, the process of making homogenized tobacco includes grinding tobacco leaves, which allows for more efficient release of nicotine and flavor upon heating.

[0048] The aerosol-generating substrate may further comprise from about 0.1 weight percent to about 10 weight percent of a flavorant, which may be any suitable flavorant known in the art, such as menthol.

[0049] The aerosol former preferably comprises at least one polyhydric alcohol, hi one preferred embodiment, the aerosol former comprises at least one of triethylene glycol, 1,3-butanediol, propylene glycol, and glycerin.

[0050] The consumable may be flat or pouch shaped.

[0051] The consumable product may further comprise an outer layer made of a paper wrapper. In the case of a planar consumable product, the paper wrapper may comprise a first paper wrapper layer and a second paper wrapper layer. The first paper wrapper layer may be disposed on an outer surface of the first substrate layer. The second paper wrapper layer may be disposed on an outer surface of the second substrate layer. The consumable product may comprise a porous layer, a first substrate layer, a second substrate layer, a first paper wrapper layer, and a second paper wrapper layer.

[0052] In the case of a pouch-shaped consumable, a single paper wrapper layer may be disposed to completely surround the consumable, more specifically, a single paper wrapper layer may be provided that covers the large outer surface and at least two sides of the consumable, or that covers the large outer surface and all sides of the consumable.

[0053] The present invention further relates to an aerosol generation system comprising a consumable as described herein and an aerosol generation device. The aerosol generation device may comprise a cavity for receiving the consumable.

[0054] The present invention further relates to an aerosol generation system comprising a consumable as described herein and an aerosol generation device. The aerosol generation device comprises a cavity for receiving the consumable.

[0055] The cavity may have a rectangular cross-section. The cavity may be shaped such that the consumable can be embedded within the cavity. An interior volume of the cavity may correspond to a volume of the consumable.

[0056] The aerosol generating device may comprise a heating element, preferably an induction heating element.

[0057] The heating element may comprise a first planar heater and a second planar heater. The first planar heater may be disposed adjacent a first sidewall of the cavity. The second planar heater may be disposed adjacent a second opposing sidewall of the cavity.

[0058] The first planar heater may at least partially or completely form a first sidewall of the cavity, and the second planar heater may at least partially or completely form a second sidewall of the cavity.

[0059] When the consumable is received in the cavity of the aerosol generating device, a first substrate layer of the consumable may be disposed adjacent to a first planar heater of the heating element, which may then be configured to heat an aerosol-forming substrate of the first substrate layer of the consumable.

[0060] When the consumable is received in the cavity of the aerosol generating device, the second substrate layer of the consumable may be disposed adjacent to a second planar heater of the heating element, which may then be configured to heat the aerosol-forming substrate of the second substrate layer of the consumable.

[0061] The aerosol generating device may include an airflow channel. The airflow channel may be disposed to allow airflow into a base of the cavity. The airflow channel may be disposed against a porous layer of the consumable when the consumable is received in the cavity to allow airflow into the porous layer of the consumable.

[0062] When the consumable is received in the cavity, air may flow centrally through the porous layer, and vaporized substrate from the first substrate layer and the second substrate layer may be entrained in the airflow and delivered towards the user for inhalation.

[0063] Downstream of the cavity, the aerosol generation device may comprise an air outlet. The air outlet may be part of or form the mouthpiece. The mouthpiece may be integrally formed with the aerosol generation device. Alternatively, the mouthpiece may be removably attached to the aerosol generation device.

[0064] One or both of the first planar heater and the second planar heater may be a susceptor.The aerosol generating device may further comprise an induction coil for heating one or both of the first planar heater and the second planar heater.

[0065] The aerosol generating device may comprise an electric circuit. The electric circuit may comprise a microprocessor, which may be a programillimeterable microprocessor. The microprocessor may be part of the controller. The electric circuit may comprise further electronic components. The electric circuit may be configured to regulate the supply of power to one or both of the first and second planar heaters. Power may be supplied continuously to one or both of the first and second planar heaters following activation of the aerosol generating device, or may be supplied intermittently (e.g. after every puff). Power may be supplied to one or both of the first and second planar heaters in the form of current pulses. The electric circuit may be configured to monitor the electrical resistance of one or both of the first and second planar heaters, and may preferably be configured to control the supply of power to one or both of the first and second planar heaters depending on the electrical resistance of one or both of the first and second planar heaters.

[0066] The aerosol generating device may include a power source (typically a battery) within the main body of the aerosol generating device. In one embodiment, the power source is a lithium ion battery. Alternatively, the power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery (e.g., a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer 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 use experiences. For example, the power source may have a capacity sufficient to continuously generate aerosol for about 6 minutes, or a multiple of 6 minutes. In another example, the power source may have a capacity sufficient to provide a predetermined number of puffs, or discontinuous activation of one or both of the first planar heater and the second planar heater.

[0067] The invention further relates to a consumable for an aerosol generating device, the consumable may comprise a first planar substrate layer of an aerosol-forming substrate. The consumable may comprise a second planar substrate layer of an aerosol-forming substrate. The consumable may comprise a first planar porous layer allowing airflow through the first porous layer in the extension direction of the plane of the first porous layer. The consumable may comprise a second planar porous layer allowing airflow through the second porous layer in the extension direction of the plane of the second porous layer and the planar heater. The heater may be disposed between the first substrate layer and the second substrate layer. The heater, the first substrate layer and the second substrate layer may be disposed between the first porous layer and the second porous layer.

[0068] The invention further relates to a consumable for an aerosol generating device, the consumable comprising a first planar substrate layer of an aerosol-forming substrate. The consumable comprising a second planar substrate layer of an aerosol-forming substrate. The consumable comprising a first planar porous layer allowing airflow through the first porous layer in the extension direction of the plane of the first porous layer. The consumable comprising a second planar porous layer allowing airflow through the second porous layer in the extension direction of the plane of the second porous layer and the planar heater. The heater is disposed between the first substrate layer and the second substrate layer. The heater, the first substrate layer and the second substrate layer are disposed between the first porous layer and the second porous layer.

[0069] The first planar substrate layer is preferably different from the second planar substrate layer.The first planar porous layer is preferably different from the second planar porous layer.

[0070] Preferably, one or more of the first planar substrate layer, the second planar substrate layer, the first planar porous layer, and the second planar porous layer have a constant thickness.

[0071] The consumable may not include a single central porous layer. Instead, a planar heater may form the central layer of the consumable. The central planar heater may be sandwiched between a first substrate layer and a second substrate layer. The first and second porous layers may be disposed outside the first and second substrate layers. Thus, the first and second substrate layers may be sandwiched between the first and second porous layers.

[0072] In one embodiment, air may not flow through the center of the consumable, rather, two separate airflows may be created through the first and second porous layers.

[0073] The disclosure herein regarding the dimensions and materials of the first and second substrate layers applies equally to this embodiment. Similarly, the disclosure of the materials and dimensions of the porous layers above applies to the first and second porous layers described for this embodiment with a single difference. In the earlier embodiment, the thickness of the single porous layer is most preferably 1 millimeter. In the current embodiment, the thickness of each of the first and second porous layers is most preferably 0.5 millimeters.

[0074] The heater may be a susceptor. This has the advantage that the heater may be heated by the aerosol generating device without the need for any electrical connection to the consumable. For this purpose the aerosol generating device may comprise an induction coil for generating an alternating magnetic field in the susceptor when the consumable is received in the cavity of the aerosol generating device.

[0075] The consumable may further comprise an outer layer made of a paper wrapper. As in the first described embodiment, the paper wrapper may comprise a first paper wrapper layer and a second paper wrapper layer. The first paper wrapper layer may be disposed on the outside of the first porous layer. The second paper wrapper layer may be disposed on the outside of the second paper wrapper layer. If the consumable is planar, the large outer surface of the consumable may be covered by the first paper wrapper layer and the second paper wrapper layer. Alternatively, the consumable may be a pouch-shaped consumable. In this case, the paper wrapper may completely cover the two large surfaces of the consumable and at least two sides of the consumable, or may completely cover the two large surfaces of the consumable and all sides of the consumable.

[0076] An "aerosol-generating device" as used herein relates to a device which interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate may be part of an aerosol-generating article, such as part of a smoking article. The aerosol-generating device may be a smoking device which interacts with the aerosol-forming substrate of the aerosol-generating article to generate an aerosol which can be inhaled directly into the user's lungs through the user's mouth. The aerosol-generating device may be a holder. The device may be an electrically heated smoking device. The aerosol-generating device may comprise a housing, an electrical circuit, a power source, a heating chamber and a heating element.

[0077] The term "consumable" as used herein refers to an article that includes an aerosol-forming substrate capable of releasing a volatile compound capable of forming an aerosol. For example, the consumable may be a smoking article that generates an aerosol that can be inhaled directly through the user's mouth into the user's lungs. The consumable may be disposable.

[0078] As used herein, the terms "upstream," "downstream," "proximal," "distal," "forward," and "rearward" are used to describe the relative position of a component or portion of a component of an aerosol generating device with respect to the direction in which a user draws on the aerosol generating device when the aerosol generating device is in use.

[0079] The heater may be configured as an induction heater. The induction heater may include an induction coil and a susceptor. Generally, the susceptor is a material that has the ability to generate heat when penetrated by an alternating magnetic field. When placed in the alternating magnetic field. If the susceptor is conductive, typically eddy currents are induced by the alternating magnetic field. If the susceptor is magnetic, typically another effect that contributes to heating is generally called hysteresis loss. Hysteresis loss occurs primarily due to the movement of magnetic domain blocks in the susceptor. This is because their magnetic orientation aligns with the alternating magnetic induction field. Another effect that contributes to hysteresis loss is when magnetic domains expand or contract in the susceptor. Generally, all these changes that occur in the susceptor at nanoscale or below generate heat in the susceptor, and are therefore called "hysteresis loss". Thus, if the susceptor is both magnetic and conductive, both hysteresis loss and the generation of eddy currents will contribute to the heating of the susceptor. If the susceptor is magnetic but not conductive, hysteresis losses are the only means by which the susceptor will heat up when penetrated by the alternating magnetic field. According to the invention, the susceptor may be conductive, or magnetic, or both conductive and magnetic. The alternating magnetic field generated by one or several induction coils heats the susceptor, which then transfers the heat to the aerosol-forming substrate so that the aerosol is formed. The heat transfer may be mainly by thermal conduction. Such heat transfer is best when the susceptor is in intimate thermal contact with the aerosol-forming substrate.

[0080] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. Preferred susceptors may include or consist of ferromagnetic or ferrimagnetic materials (e.g., ferromagnetic alloys, ferritic iron, or ferromagnetic steel or stainless steel). Suitable susceptors may be or include aluminum. Preferred susceptors may be heated to temperatures in excess of 250 degrees Celsius.

[0081] The preferred susceptor is a metal susceptor (e.g., stainless steel). However, the susceptor material may also include or be made of graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloy (austenitic nickel-chromium based superalloy), metal-deposited films, ceramics (e.g., zirconia, etc.), transition metals (e.g., iron, cobalt, nickel, etc.), or semi-metallic components (e.g., boron, carbon, silicon, phosphorus, aluminum, etc.).

[0082] The following provides a non-exhaustive list of non-limiting examples, any one or more of the features of which may be combined with any one or more features of the other examples, embodiments, or aspects described herein.

[0083] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0084] [Figure 1] FIG. 1 shows consumables for an aerosol generating device. [Diagram 2] FIG. 2 shows the consumable of FIG. 1 in a fully assembled state. [Diagram 3] FIG. 3 shows a consumable product in the form of a pouch. [Figure 4] FIG. 4 shows a consumable received within a cavity of an aerosol generating device. [Diagram 5] FIG. 5 shows the consumables and airflow through the cavity. [Figure 6] FIG. 6 illustrates one embodiment of a consumable with an integrated heater. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0085] Example 1: A consumable for an aerosol generating device, comprising: a first planar substrate layer of an aerosol-forming substrate; a second planar substrate layer of the aerosol-forming substrate; a planar porous layer that allows airflow through the porous layer in the direction of extension of the plane of the porous layer; The consumable, wherein the porous layer is disposed between a first substrate layer and a second substrate layer. Example 2: The consumable of Example 1, wherein a first substrate layer is disposed immediately adjacent to a first surface of the porous layer, and a second substrate layer is disposed immediately adjacent to a second, opposing surface of the porous layer. Example 3: The consumable of any of Examples 1-2, wherein the porous layer is sandwiched between a first substrate layer and a second substrate layer. Example 4: A consumable product according to any of Examples 1 to 3, wherein the porous layer comprises cellulose acetate, preferably the porous layer consists of cellulose acetate. Example 5: A consumable product according to any of Examples 1 to 4, wherein the porous layer has a higher porosity than the aerosol-forming substrate. Example 6: A consumable product according to any of Examples 1 to 5, wherein the porous layer has a porosity of 50 percent to 90 percent in the planar extension direction of the porous layer, preferably 60 percent to 80 percent in the planar extension direction of the porous layer, and more preferably 65 percent to 75 percent in the planar extension direction of the porous layer. Example 7: The consumable product of any of Examples 1-6, wherein the porous layer has a withdrawal resistance of 10 millimeters HO to 65 millimeters HO, preferably 30 millimeters HO to 60 millimeters HO. Example 7.1: The consumable of any of Examples 1-7, wherein the pull-out resistance of the porous layer is less than 50%, preferably less than 30%, more preferably less than 10% of the pull-out resistance of one or both of the first substrate layer and the second substrate layer. Example 8: The consumable product of any of Examples 1 to 7.1, wherein the porous layer has a thickness of 0.3 millimeters to 4.0 millimeters, preferably 0.4 millimeters to 3.0 millimeters, and more preferably 0.5 millimeters to 1.0 millimeters. Example 9: A consumable product according to any of Examples 1 to 8, wherein the porous layer has a length of 5 millimeters to 35 millimeters, preferably 7 millimeters to 25 millimeters, more preferably 10 millimeters to 15 millimeters. Example 10: A consumable product according to any one of Examples 1 to 9, wherein the aerosol-forming substrate comprises tobacco. Example 11: The consumable product according to any one of Examples 1 to 10, wherein the aerosol-forming substrate comprises an aerosol-forming body. Example 12: A consumable product according to any of Examples 1 to 11, wherein the aerosol-forming substrate is a solid. Example 13: The consumable product according to any one of Examples 1 to 12, wherein the consumable product is flat or pouch-shaped. Example 14: The consumable product of any of Examples 1 to 13, wherein the consumable product further comprises an outer layer made of a paper wrapper. Example 15: An aerosol generating system comprising the consumable of any one of Examples 1 to 14 and an aerosol generating device, the aerosol generating device comprising a cavity for receiving the consumable. Example 16: An aerosol generating system as described in Example 15, wherein the cavity has a rectangular cross section. Example 17: An aerosol generation system as described in any of Examples 15 and 16, wherein the aerosol generation device comprises a heating element, preferably an induction heating element. Example 18: An aerosol generating system as described in Example 17, wherein the heating element comprises a first planar heater and a second planar heater, the first planar heater being disposed adjacent to a first side wall of the cavity and the second planar heater being disposed adjacent to a second opposite side wall of the cavity. Example 19: An aerosol generation system described in any of Examples 15 to 18, wherein the aerosol generation device has an airflow channel, the airflow channel is arranged to enable airflow into the base of the cavity, and the airflow channel is arranged in abutment against the porous layer of the consumable when the consumable is received in the cavity to enable airflow into the porous layer of the consumable. Example 20: A consumable for an aerosol generating device, comprising: a first planar substrate layer of an aerosol-forming substrate; a second planar substrate layer of the aerosol-forming substrate; a first planar porous layer that allows airflow through the first porous layer in a direction extending in the plane of the first porous layer; a second planar porous layer that allows airflow through the second porous layer in a direction extending in the plane of the second porous layer; A flat heater; A consumable, wherein a heater is disposed between a first substrate layer and a second substrate layer, and the heater, first substrate layer, and second substrate layer are disposed between a first porous layer and a second porous layer. Example 21: The consumable of example 20, wherein the heater is a susceptor. Example 22: The consumable product of any of Examples 1 to 21, wherein the consumable product further comprises an outer layer made of a paper wrapper.

[0086] Features described with respect to one embodiment may be equally applied to other embodiments of the invention.

[0087] A consumable 10 for an aerosol generating device 24 is shown in Figure 1. The consumable 10 comprises a porous layer 12. The porous layer 12 is the central layer of the consumable 10.

[0088] The consumable 10 is planar. The porous layer 12 is planar. The porous layer 12 allows for lateral airflow 34 through the consumable 10. The porous layer 12 has a rectangular cross-sectional shape in the elongated plane of the consumable 10. The consumable 10 as a whole has a rectangular cross-sectional shape in the elongated plane of the consumable 10.

[0089] The consumable 10 further comprises a first substrate layer 14. The first substrate layer 14 comprises an aerosol-forming substrate. The first substrate layer 14 is disposed directly adjacent to the porous layer 12. The first substrate layer 14 has the same cross-sectional shape in the elongated plane of the consumable 10 as the porous layer 12. The first substrate layer 14 has the same length and width as the porous layer 12. The first substrate layer 14 is in direct physical contact with the porous layer 12.

[0090] The consumable 10 further comprises a second substrate layer 16. The second substrate layer 16 comprises an aerosol-forming substrate. The second substrate layer 16 is disposed directly adjacent to the porous layer 12. The second substrate layer 16 has the same cross-sectional shape in the elongated plane of the consumable 10 as the porous layer 12. The second substrate layer 16 has the same length and width as the porous layer 12. The second substrate layer 16 is in direct physical contact with the porous layer 12.

[0091] The aerosol-forming substrate of the first substrate layer 14 may be the same as the aerosol-forming substrate of the second substrate layer 16. Alternatively, the aerosol-forming substrate of the first substrate layer 14 may be different from the aerosol-forming substrate of the second substrate layer 16. Exemplarily, the aerosol-forming substrate of the first substrate layer 14 may be a nicotine-containing substrate and the aerosol-forming substrate of the second substrate layer 16 may be a flavour-containing substrate.

[0092] The porous layer 12 is sandwiched between a first substrate layer 14 and a second substrate layer 16. In other words, the first substrate layer 14 and the second substrate layer 16 cover opposing large surfaces of the porous layer 12.

[0093] The consumable product 10 further comprises a first paper wrapper layer 18 and a second paper wrapper layer 20 .

[0094] The first paper wrapper layer 18 is disposed adjacent to the first substrate layer 14. The first paper wrapper layer 18 is disposed on a large surface of the first substrate layer 14 opposite the porous layer 12. The first paper wrapper layer 18 is the outer layer of the consumable 10. The first paper wrapper layer 18 has the same length and width as the first substrate layer 14.

[0095] A second paper wrapper layer 20 is disposed adjacent to the second substrate layer 16. The second paper wrapper layer 20 is disposed on a large surface of the second substrate layer 16 opposite the porous layer 12. The second paper wrapper layer 20 is the outer layer of the consumable 10. The second paper wrapper layer 20 has the same length and width as the second substrate layer 16.

[0096] First substrate layer 14 and second substrate layer 16 are sandwiched between first paper wrapper layer 18 and second paper wrapper layer 20 .

[0097] Figure 2 shows the consumable 10 of Figure 1 in a fully assembled state. The porous layer 12 forms a central layer. The large surface of the porous layer 12 is covered by a first substrate layer 14 and a second substrate layer 16. The large outer surfaces of the first substrate layer 14 and the second substrate layer 16 are covered by a first paper wrapper layer 18 and a second paper wrapper layer 20. The central porous layer 12 allows airflow 34 through the consumable 10.

[0098] 3 shows a different type of paper wrapper for encasing the consumable product 10. In this embodiment, the paper wrapper also covers all sides of the consumable product 10, thereby configuring the consumable product 10 as a pouch-shaped consumable product 10. Thus, the paper wrapper is configured as a pouch-shaped paper wrapper 22. This may be achieved by providing oversized first and second paper wrapper layers 18 and 20 and gluing the overlapping portions of the layers together.

[0099] Figure 4 shows the consumable 10 of one of Figures 1 and 2 inserted into the cavity of an aerosol generation device 24. Of course, the consumable 10 of Figure 3 can also be inserted into the cavity of the aerosol generation device 24 shown in Figure 4.

[0100] The aerosol generating device 24 includes a first planar heater 26 and a second planar heater 28. The first planar heater 26 is disposed on or forms a side of a cavity into which the consumable 10 is inserted. The second planar heater 28 is disposed on or forms an opposite side of the cavity.

[0101] When the consumable 10 is received in the cavity, the first substrate layer 14 is disposed adjacent to a first planar heater 26. The second substrate layer 16 is disposed adjacent to a second planar heater 28.

[0102] The aerosol generating device 24 further includes an induction coil 30. The induction coil 30 is disposed to at least partially surround the first planar heater 26 and the second planar heater 28. The first planar heater 26 and the second planar heater 28 are each a susceptor. The induction coil 30 is configured to heat the first planar heater 26 and the second planar heater 28.

[0103] FIG. 4 further shows an insulating chamber 32 for insulating the cavity of the aerosol generating device 24 .

[0104] 5 shows the airflow 34 through the consumable 10 and cavity of the aerosol generation device 24 during operation of the aerosol generation device 24. FIG 5 shows a side view of the cavity as opposed to the top view of the cavity shown in FIG 4.

[0105] The airflow 34 comes from the base 36 of the cavity and further flows through the porous layer 12 of the consumable 10. The airflow flows out of the consumable 10 and out of the cavity through the cavity outlet 38. The generated aerosol may then be inhaled by the user.

[0106] 5 further shows contacts 38 for contacting the induction coil 30. A power supply (not shown) and a controller (not shown) are part of the aerosol generation device 24. The controller controls the flow of electrical energy from the power supply to the induction coil 30 during operation of the aerosol generation device 24.

[0107] 6 shows an alternative embodiment of the consumable 10 having an integrated heater. In this embodiment, the central layer is not formed by a single porous layer. Instead, the central layer is formed by a central planar heater 44. The central planar heater 44 is a susceptor.

[0108] As with the previous embodiment, the central layer is sandwiched between first and second substrate layers 14, 16. These substrate layers are the same substrate layers as previously described. These substrate layers are sandwiched between first and second porous layers 40, 42. The first and second porous layers 40, 42 are sandwiched between first and second paper wrapper layers 18, 20. The paper wrapper layers are the same as previously described.

[0109] In this alternative embodiment, it is not necessary to provide a heater in the aerosol generation device 24 since the heater is located within the consumable 10. In this case, the aerosol generation device 24 is equipped only with the induction coil 30 as previously described.

[0110] When the consumable 10 of this embodiment is inserted into the cavity of the aerosol generating device 24, air flows in two separate paths through the first porous layer 40 and the second porous layer 42, which are disposed next to the first substrate layer 14 and the second substrate layer 16, respectively. At the same time, the induction coil 30 of the aerosol generating device 24 will generate an alternating magnetic field, which will heat the central planar heater 44 of the consumable 10. This heat will lead to vaporization of the aerosol-forming substrates of the first substrate layer 14 and the second substrate layer 16. The vaporized aerosol-forming substrates will be entrained in the air flowing through the first porous layer 40 and the second porous layer 42 and delivered to the user for inhalation.

Claims

1. A consumable for an aerosol generating device, a first planar substrate layer of an aerosol-forming substrate; a second planar substrate layer of the aerosol-forming substrate; a planar porous layer that allows airflow therethrough in the direction of extension of the plane of the planar porous layer, the planar porous layer having a draw resistance of 10 mm HO to 65 mm HO, and the porous layer having a thickness of 0.3 mm to 4.0 mm; The consumable article, wherein the porous layer is disposed between the first substrate layer and the second substrate layer.

2. 10. The consumable product of claim 1, wherein the first substrate layer is disposed immediately adjacent to a first surface of the porous layer and the second substrate layer is disposed immediately adjacent to a second, opposite surface of the porous layer.

3. The consumable product of any one of claims 1 to 2, wherein the porous layer is sandwiched between the first substrate layer and the second substrate layer.

4. 10. The consumable product of claim 1, wherein the porous layer comprises cellulose acetate, preferably the porous layer consists of cellulose acetate.

5. The consumable of claim 1 , wherein the porous layer has a higher cross-sectional porosity than the first substrate layer.

6. 2. The consumable of claim 1, wherein the porous layers have a cross-sectional porosity of 0.3 to 0.95, preferably 0.5 to 0.9, the cross-sectional porosity being the area fraction of voids in the cross-sectional area of ​​each of the layers, and the cross-sectional area of ​​each of the layers being the area of ​​each of the layers in a plane perpendicular to the longitudinal axis of each of the layers.

7. 10. The consumable of claim 1, wherein the porous layer has a withdrawal resistance of between 30 millimeters H2O and 60 millimeters H2O.

8. The consumable product of claim 1 , wherein the porous layer has a thickness of 0.4 to 3.0 millimeters, preferably 0.5 to 1.0 millimeters.

9. 2. The consumable product of claim 1, wherein the porous layer has a length of from 5 millimeters to 35 millimeters, preferably from 7 millimeters to 25 millimeters, more preferably from 10 millimeters to 15 millimeters.

10. An aerosol generation system comprising the consumable product of claim 1 and an aerosol generation device, the aerosol generation device comprising a cavity for receiving the consumable product.

11. 11. An aerosol generating system according to claim 9 or claim 10, wherein the aerosol generating device comprises a heating element, preferably an induction heating element.

12. 12. The aerosol generating system of claim 11, wherein the heating element comprises a first planar heater and a second planar heater, the first planar heater being disposed adjacent to a first side wall of the cavity, and the second planar heater being disposed adjacent to a second opposite side wall of the cavity.

13. 10. The aerosol generation system of claim 9, wherein the aerosol generating device comprises an airflow channel, the airflow channel being arranged to allow airflow into the base of the cavity and being arranged in contact with the porous layer of the consumable when the consumable is received in the cavity to allow airflow into the porous layer of the consumable.

14. A consumable for an aerosol generating device, a first planar substrate layer of an aerosol-forming substrate; a second planar substrate layer of the aerosol-forming substrate, wherein the first and second substrate layers are different from each other; a first planar porous layer that allows airflow through the first porous layer in the direction of extension of the plane of the first porous layer; a second planar porous layer that allows airflow through the second porous layer in the direction of extension of the plane of the second porous layer; a flat heater; the heater is disposed between the first substrate layer and the second substrate layer, and the heater, the first substrate layer, and the second substrate layer are disposed between the first porous layer and the second porous layer.

15. The consumable of claim 14 , wherein the heater is a susceptor.

Images