Hybrid aerosol generation system with modular consumables

Abstract

The present invention relates to an aerosol generation system including an aerosol generation device (16) and a consumable (10) for the aerosol generation device. The aerosol generation device may include a cavity (18) for receiving the consumable and a first heating element (20, 22) arranged to at least partially heat the consumable when the consumable is received in the cavity. The aerosol generation device may further include an airflow channel (14). The airflow channel may be arranged to direct air through the device and into the cavity. The consumable may include a tubular wall (12). The tubular wall may extend from a distal opening of the consumable to an opposing proximal opening of the consumable. The consumable may be arranged such that, when the consumable is received in the cavity, air flowing from the airflow channel into the cavity flows into the distal opening of the consumable.

Description

[Technical field]

[0001] The present invention relates to an aerosol generating system. [Background technology]

[0002] It is known to provide an aerosol generating device for generating an inhalable vapor. Such a device may heat the aerosol-forming substrate to a temperature at which one or more components of the aerosol-forming substrate volatilize without burning the aerosol-forming substrate. The aerosol-forming substrate may be provided as part of a consumable, such as an aerosol-generating article. The aerosol-generating article may have a rod shape for insertion of the aerosol-generating article into a cavity (such as a 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 when the aerosol-generating article is inserted into the heating chamber of the aerosol generating device. To further enable the delivery of nicotine or to affect the flavor of the generated aerosol or to improve the quality of the aerosol, the aerosol generating device may comprise a liquid storage portion upstream of the heating chamber. The liquid storage portion may include a liquid aerosol-forming substrate. The liquid aerosol-forming substrate may contain one or more of nicotine and flavoring agents. This conventional aerosol-forming system comprising an aerosol generating device and a consumable may be limited in use when the consumable is received in the heating chamber.

[0003] An aerosol generation system that provides increased flexibility for using the system is desirable. An aerosol generation system that can be used without the need for dedicated consumables is desirable. An aerosol generation system that has the flexibility to enhance or vary the flavor of the generated aerosol is desirable. Summary of the Invention

[0004] According to one embodiment of the present invention, there is provided an aerosol generation system comprising an aerosol generation device and a consumable for the aerosol generation device. The aerosol generation device may comprise a cavity for receiving the consumable and a first heating element arranged to at least partially heat the consumable when the consumable is received in the cavity. The aerosol generation device may further comprise an airflow channel. The airflow channel may be arranged to direct air through the device and into the cavity. The consumable may comprise a tubular wall. The tubular wall may extend from a distal opening of the consumable to a proximal opening of the consumable on the opposite side. The consumable may be arranged such that when the consumable is received in the cavity, air flowing from the airflow channel into the cavity flows into the distal opening of the consumable.

[0005] According to one embodiment of the present invention, there is provided an aerosol generation system comprising an aerosol generation device and a consumable for the aerosol generation device. The aerosol generation device comprises a cavity for receiving the consumable and a first heating element arranged to at least partially heat the consumable when the consumable is received in the cavity. The aerosol generation device further comprises an airflow channel. The airflow channel is arranged to direct air through the device and into the cavity. The consumable includes a tubular wall. The tubular wall extends from a distal opening of the consumable to an opposing proximal opening of the consumable. The consumable is arranged such that air flowing from the airflow channel into the cavity flows into the distal opening of the consumable when the consumable is received in the cavity.

[0006] 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]

[0007] [Figure 1] 1A and 1B show an aerosol generation system including an aerosol generating device and a consumable. [Diagram 2] 2A and 2B show an aerosol generation system that includes an aerosol generating device and a consumable that includes a sensory medium. [Diagram 3]3A and 3B show an aerosol generation system including an aerosol generating device and consumables, the device including a power source. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Providing a consumable with a tubular wall that extends the entire length of the consumable results in a consumable in which air flow is unimpeded.

[0009] The tubular wall is preferably a tubular cellulosic wall.

[0010] Providing the tubular wall as a tubular cellulosic wall results in a consumable that is easy to manufacture.Providing the tubular wall as a tubular cellulosic wall results in a consumable that is low cost.

[0011] The tubular wall may be a tubular metallized paper wall.The tubular wall may be a tubular metal-paper laminate wall.

[0012] The tubular wall may have a thickness of from 3 mm to 7 mm, preferably from 4 mm to 6 mm, more preferably from 3.5 mm to 5.75 mm.

[0013] A tubular wall having such a thickness may provide dimensional stability to the consumable.

[0014] The tubular wall may have a porosity to prevent moisture from forming inside the consumable. The tubular wall may have a porosity to prevent moisture from condensing inside the consumable. The first heating element may heat one or both of the moisture and condensation absorbed in the tubular wall to prevent accumulation of one or both of the moisture and condensation.

[0015] The tubular wall may have a porosity such that, during operation of the aerosol generating device, vapour escapes through the tubular wall, creating a pleasant flavour in the consumable.

[0016] The tubular shape of the tubular wall may form a consumable airflow channel. The consumable airflow channel may be centrally disposed through the consumable. The consumable airflow channel may be surrounded by the tubular wall. The consumable airflow channel may be straight. The consumable airflow channel may have a radius of 2.5 mm to 8.75 mm, more preferably 3 mm to 7 mm.

[0017] The consumable may have an outer diameter of 4.1 mm to 9 mm, preferably 4.5 mm to 7.7 mm. The consumable may have a length of 34 mm to 108 mm, preferably 50 mm to 70 mm.

[0018] The aerosol generating device may further include a liquid reservoir containing a liquid aerosol-forming substrate.

[0019] The aerosol generating device may be configured as a hybrid device: the liquid reservoir containing the liquid aerosol-forming substrate may be configured to generate an inhalable aerosol, and the consumable received within the cavity may be configured to impart a flavor to the generated aerosol.

[0020] Aerosol generated via the liquid aerosol-forming substrate of the liquid storage portion may be generated by an aerosol generator upstream of the cavity. The generated aerosol may flow into the cavity and into a consumable airflow channel of the consumable. In the consumable airflow channel, flavors may be added to the aerosol via the consumable. The aerosol with the selected flavor may then flow out of a proximal opening of the consumable and into the mouth of the user.

[0021] Various types of consumables can be received in the cavity. As a result, a user can select a flavor by selecting various types of consumables. In this way, the aerosol generation of the aerosol generating device can be customized. While the aerosol itself can always be generated via the liquid aerosol-forming substrate of the liquid storage portion, the flavor of the aerosol can change depending on the type of consumable received in the cavity.

[0022] The aerosol generating device may further comprise a second heating element configured to volatilize the liquid aerosol-forming substrate.

[0023] The second heating element may heat the liquid aerosol-forming substrate. The second heating element may function to generate an aerosol upstream of the cavity.

[0024] The volatilized liquid aerosol-forming substrate may be cooled while it passes through the consumable airflow channel. Small liquid droplets may be formed during cooling of the volatilized liquid aerosol-forming substrate, thereby generating an improved inhalable aerosol.

[0025] A second heating element may be disposed to volatilize the liquid aerosol-forming substrate upstream of the cavity.

[0026] This may have the advantage that the heated volatilized liquid aerosol-forming substrate may be cooled while flowing through the consumable airflow channel When the final aerosol reaches the user's mouth, the droplet size of the generated aerosol as well as the temperature of the generated aerosol may be optimal for inhalation.

[0027] The aerosol generating device may further include an air inlet disposed distal to the cavity and proximal to the liquid reservoir.

[0028] The air inlet may be disposed on a housing of the aerosol generating device. The air inlet may be a lateral air inlet. Ambient air may be drawn into the aerosol generating device via the air inlet. Ambient air may be drawn laterally into the aerosol generating device.

[0029] The air inlet can be fluidly connected to the device airflow channel, which can be configured to direct ambient air to one or more of, over, and around the second heating element.

[0030] Thus, ambient air may be entrained around the volatilized aerosol-forming substrate that is heated by the second heating element. The device airflow channel may be further configured to direct the mixture of ambient air and the volatilized aerosol-forming substrate towards the cavity in which the consumable is received. The mixture of the volatilized aerosol-forming substrate and ambient air may be directed through the device airflow channel and into the consumable airflow channel.

[0031] The second heating element can be a resistive heating element.

[0032] The aerosol generating device may further include a wick extending into the liquid reservoir. The second heating element may be a heating coil disposed around the wick.

[0033] The first heating element can be an induction heating element.

[0034] The first heating element may be configured to be heated to a temperature between 190°C and 280°C, more preferably to a temperature between 210°C and 270°C.

[0035] The first heating element may include an induction coil and a tubular susceptor. The tubular susceptor may be disposed to surround a distal portion of the cavity.

[0036] The first heating element may be disposed to heat a distal portion of the consumable when the consumable is received within the cavity. Heating the distal portion of the consumable may release a flavorant in the consumable. The released flavorant may add flavor to an aerosol drawn through the consumable airflow channel.

[0037] The consumable may include a layer of a sensory medium on one or both of the inner surface of the tubular wall and the outer surface of the tubular wall.

[0038] The sensory medium may be a flavoring agent. The sensory medium may be a fragrance compound. The sensory medium may be provided as a gel. The gel may be sufficiently fluid to be applied by spray coating or similar standard manufacturing process. The sensory medium may comprise 0.1-80% by weight menthol, 1-60% by weight gelling agent, and 0.1-50% by weight aerosol former. The gelling agent may comprise alginate and pectin. The ratio of alginate to pectin may be 3:1 to 10:1. The gelling agent may comprise calcium cross-linked alginate, which may comprise α-(1-4)-linked L-guluronic acid (G) units. The aerosol former may comprise a highly volatile material. The aerosol former may include one or more of polyhydric alcohols, such as triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol monotriacetate, glycerol diacetate, or glycerol triacetate, and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate, as well as representative propylene glycol (PG) and vegetable glycerin (VG) as base carriers of the aerosol material, and also aqueous aerosol formers as the main carrier. Water may be used instead of the previous aerosol former material, since the heat for the volatilization of water may be sufficient during the operation of the device. Thus, aqueous carriers may be used as a sustainable solution. Alternatively, as a sensory medium, wax containing flavor molecules may be used as a coating layer having a thickness of about 0.03 to 0.7 mm. Due to the nature of the cellulosic wall, a certain amount of coating material is naturally impregnated or applied onto the fibrous substrate. Between 7% and 41%, preferably between 11% and 38%, of the inner surface of the cellulosic wall may be impregnated with the sensory medium. The inner surface of the cellulosic wall is preferably porous.

[0039] The tubular wall may be made of at least one inner layer of cellulose-based, paper-based, foil, or alternatively, the tubular wall may comprise one or more of cellulose acetate tow and other fiber-based materials, preferably high retention and release materials.

[0040] The sensory medium may be coated on or impregnated within one or both of the inner surface of the tubular wall and the outer surface of the tubular wall.

[0041] The sensory medium may be configured to be released when the sensory medium is heated. The sensory medium may be heated via a first heating element. The sensory medium may be heated by flowing a heated volatile liquid aerosol-forming substrate through the consumable, thereby passing through the sensory medium.

[0042] The sensory medium may be disposed in a distal portion of the consumable that is surrounded by the first heating element when the consumable is received within the cavity.

[0043] Alternatively, the sensory medium may be disposed along the entire length of the consumable, in other words, the sensory medium may be disposed from a proximal opening of the consumable to a distal opening of the consumable. The sensory medium may at least partially, and preferably completely, cover the inner surface of the tubular wall.

[0044] The sensory medium may be configured as a sensory medium layer or a sensory medium film.

[0045] The consumable may include tipping paper surrounding the tubular wall. The tipping paper may be made of a paper-based material.

[0046] The consumable may be comprised of a tubular wall and a layer of sensory medium on the inner surface of the tubular wall, or the consumable may be comprised of a tubular wall and a layer of sensory medium on the inner surface of the tubular wall and tipping paper surrounding the tubular wall. In other words, the consumable does not include any other elements except the tubular wall, and the sensory medium or consumable may not include any other elements except the tubular wall, the sensory medium, and the tipping paper.

[0047] Providing such a simple consumable product can reduce the manufacturing cost of the consumable product. At the same time, a composite aerosol can be generated by combining the simple consumable product with the generation of an aerosol in the device by volatilization of the liquid aerosol-forming substrate in the liquid storage portion by the second heating element.

[0048] In such hybrid devices, the consumable may function to add flavor to the aerosol Additionally or alternatively, the consumable may function to provide a cooling channel for the volatile aerosol-forming substrate to generate an inhalable aerosol.

[0049] The consumables do not have to include tobacco.

[0050] The cavity may be sized to receive a consumable as described herein, or a consumable including tobacco having a larger diameter.

[0051] This embodiment further improves the flexibility of the aerosol generation system: in addition to the simple tobacco-free consumables described herein, more complex consumables that include tobacco may alternatively be received within the cavity.

[0052] The present invention further relates to a consumable for an aerosol generating device, the consumable comprising any of the consumable features described herein.

[0053] In particular, the consumable may include a tubular wall as described herein, preferably extending from a distal opening of the consumable to an opposing proximal opening of the consumable.

[0054] In particular, as described herein, air may flow into a distal opening of the consumable, through the consumable, and out a proximal opening of the consumable.

[0055] In particular, as described herein, the consumable may include a layer of a sensory medium on one or both of the inner surface of the tubular wall and the outer surface of the tubular wall.

[0056] In particular, the sensory medium may be a flavoring agent, which may be coated on or impregnated into one or both of the inner surface of the tubular wall and the outer surface of the tubular wall, as described herein.

[0057] In particular, the consumable may include tipping paper, as described herein, surrounding a tubular wall.

[0058] In particular, as described herein, the consumable may be comprised of a tubular wall and a layer of a sensory medium on the inner surface of the tubular wall, or the consumable may be comprised of a tubular wall and a layer of a sensory medium on the inner surface of the tubular wall, and tipping paper surrounding the tubular wall.

[0059] In particular, as described herein, the consumable product may not include tobacco.

[0060] The cavity of the aerosol generating device may have an open end into which the consumable is inserted. The open end may be a proximal end. The cavity may have a closed end opposite the open end. The closed end may be a base of the cavity. The closed end may be closed except for an air opening disposed in the base. The air opening may be fluidly connected with the device airflow channel. Alternatively, the device airflow channel may be led directly into the cavity through a single opening. The base of the cavity may be flat. The base of the cavity may be circular. The base of the cavity may be disposed upstream of the cavity. The open end may be disposed downstream of the cavity. The cavity may have an elongated extension. The cavity may have a longitudinal central axis. The longitudinal axis may be a direction extending between the open end and the closed end along the longitudinal central axis. The longitudinal central axis of the cavity may be parallel to or aligned with the longitudinal axis of the aerosol generating device.

[0061] The cavity may be configured as a heating chamber. The cavity may have a cylindrical shape. The cavity may have a hollow cylindrical shape. The cavity may have a shape corresponding to the shape of the consumable to be received within the cavity. The cavity may have a circular cross-section. The cavity may have an elliptical or rectangular cross-section. The cavity may have an inner diameter corresponding to the outer diameter of the consumable.

[0062] The capillary material arranged to wick the liquid aerosol-forming substrate in the liquid storage portion to the second heating element may have a fibrous or spongy structure. The capillary material preferably comprises a bundle of capillaries. For example, the capillary material may comprise a plurality of fibers or threads, or other fine tubes. The fibers or threads may be generally aligned to carry the liquid to the second heating element. Alternatively, the capillary material may comprise a spongy or foam-like material. The structure of the capillary material forms a plurality of small holes or tubes through which the liquid can move by capillary action. The capillary material may comprise any suitable material or combination of materials. Examples of suitable materials are spongy or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metal or plastic materials, fibrous materials, such as fibrous materials made of spun or extruded fibers (such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, ethylene or polypropylene fibers, nylon fibers or ceramics). The capillary material may have any suitable capillarity and porosity to be used with different liquid physical properties. The liquid has physical properties including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure that allow the liquid to be moved through the capillary material by capillary action. The capillary material may be configured to carry the aerosol-forming substrate to the second heating element. The capillary material may extend into the gap of the second heating element. Preferably, the second heating element is configured as a resistive heating coil surrounding the capillary material as described herein.

[0063] The capillary material may be arranged to contact a liquid held in the liquid storage portion. The capillary material may extend into the liquid storage portion, whereby in use, liquid may move from the liquid storage portion towards the second heating element by capillary action. The capillary material may have a first end and a second end. The first end may extend into the liquid storage portion to draw a liquid aerosol-forming substrate held within the liquid storage portion to the second heating element. The second end of the capillary material may be surrounded by the second heating element.

[0064] The aerosol generating device may comprise an electric circuit. The electric circuit may comprise a microprocessor, which may be a programmable 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 heating elements. Power may be supplied to one or both of the first and second heating elements continuously following activation of the aerosol generating device or intermittently with each puff. Power may be supplied to one or both of the first and second heating elements 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 heating elements, preferably to control the supply of power to one or both of the first and second heating elements depending on the electrical resistance of one or both of the first and second heating elements.

[0065] 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 six minutes, or a multiple of six 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 and second heating elements.

[0066] At least one air inlet may be provided in the wall of the housing of the aerosol generating device. The air inlet may be a semi-open inlet. The semi-open inlet may be an inlet that allows air or fluid flow in one direction, such as into the device, but at least limits, preferably prohibits, air or fluid flow in the opposite direction. The semi-open inlet preferably allows air to enter the aerosol generating device. Air or liquid may be prevented from leaving the aerosol generating device through the semi-open inlet. The semi-open inlet may for example be a semi-permeable membrane, which is permeable to air only in one direction, but is air-tight and liquid-tight in the opposite direction. The semi-open inlet may also for example be a one-way valve. The semi-open inlet preferably allows air to pass through the inlet only if certain conditions are met, such as for example a minimum pressing of the aerosol generating device or a deposition of air through the valve or membrane.

[0067] As used herein, the term "aerosol-forming substrate" relates to a substrate capable of releasing one or more volatile compounds capable of forming an aerosol. Such volatile compounds can be released by heating the aerosol-forming substrate. The aerosol-forming substrate is preferably provided in liquid form in a liquid reservoir.

[0068] The aerosol-forming substrate is a substrate capable of releasing volatile compounds capable of forming an aerosol. The volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material that contains volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco-containing material. The aerosol-forming substrate may comprise a homogenized plant-derived material.

[0069] The aerosol-forming substrate may include at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the system. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). The aerosol former may be a polyhydric alcohol or a mixture thereof (such as triethylene glycol, 1,3-butanediol, and glycerin). The aerosol former may be propylene glycol. The aerosol former may include both glycerin and propylene glycol.

[0070] The aerosol-forming substrate may be provided in liquid form. The liquid aerosol-forming substrate may include other additives and ingredients, such as flavorants. The liquid aerosol-forming substrate may include water, solvents, ethanol, botanical extracts, and natural or artificial flavors. The liquid aerosol-forming substrate may include nicotine. The liquid aerosol-forming substrate may have a nicotine concentration of about 0.5% to about 10% (e.g., about 2%). The liquid aerosol-forming substrate may be included within a liquid storage portion of the aerosol-generating article, in which case the aerosol-generating article may be labeled as a cartridge.

[0071] Preferably, the liquid aerosol-forming substrate does not include a flavourant. The flavourant is preferably provided by the consumable. In particular, the flavourant is preferably provided by the sensory medium of the consumable, while the liquid aerosol-forming substrate is simply provided for generating the aerosol. In particular, the liquid aerosol-forming substrate is configured to generate an aerosol and preferably includes nicotine, while the consumable is preferably configured to provide a flavour to the aerosol.

[0072] Operation of the aerosol generating device may be triggered by a puff detection system. Alternatively, the aerosol generating device may be triggered by pressing an on-off button and sustained for the duration of the user's puff. The puff detection system may be provided as a sensor, which may be configured as an airflow sensor for measuring airflow velocity. Airflow velocity is a parameter that characterizes the amount of air per time drawn by the user through the airflow channel of the aerosol generating device. The start of a puff may be detected by the airflow sensor when the airflow exceeds a predefined threshold. The start may also be detected after the user activates the button.

[0073] The sensor may be configured as a pressure sensor and may measure the pressure of air within the aerosol generating device that is drawn through the airflow channel of the device by the user during a puff. The sensor may be configured to measure the pressure difference or pressure drop between the pressure of the ambient air outside the aerosol generating device and the pressure of the air drawn through the device by the user. The pressure of the air may be detected at the air inlet, the mouthpiece of the device, the cavity, or any other passage or chamber in the aerosol generating device through which the air flows. When the user inhales on the aerosol generating device, a negative pressure or vacuum is created inside the device, and this negative pressure may be detected by the pressure sensor. The term "negative pressure" is understood as a pressure that is relatively lower than the pressure of the ambient air. In other words, when the user inhales on the device, the air drawn through the device has a lower pressure than the pressure of the ambient air outside the device. The start of a puff may be detected by the pressure sensor when the pressure difference exceeds a predetermined threshold.

[0074] As used herein, the terms "upstream," "downstream," "proximal," and "distal" are used to describe the relative location of components or portions of components of an aerosol generating device with respect to the direction in which a user draws on the aerosol generating device during use.

[0075] The liquid reservoir may be of any suitable shape and size. For example, the liquid reservoir may be substantially cylindrical. The cross section of the liquid reservoir may be, for example, substantially circular, elliptical, square, or rectangular.

[0076] The liquid storage portion may comprise a housing. The housing may include a base and one or more sidewalls extending from the base. The base and one or more sidewalls may be integrally formed. The base and one or more sidewalls may be separate elements attached or fixed to each other. The housing may be a rigid housing. As used herein, the term "rigid housing" is used to mean a self-supporting housing. The rigid housing of the liquid storage portion may provide mechanical support for the aerosol generating means. The liquid storage portion may include one or more flexible walls. The flexible walls may be configured to conform to the volume of the liquid aerosol-forming substrate stored within the liquid storage portion. The housing of the liquid storage portion may comprise any suitable material. The liquid storage portion may comprise a substantially fluid-impermeable material. The housing of the liquid storage portion may include a transparent or translucent portion such that the liquid aerosol-forming substrate stored within the liquid storage portion is visible to the user through the housing. The liquid storage portion may be configured such that the aerosol-forming substrate stored within the liquid storage portion is protected from ambient air. The liquid reservoir may be configured such that the aerosol-forming substrate stored within the liquid reservoir is protected from light, which may reduce the risk of deterioration of the substrate and may also maintain a high level of hygiene.

[0077] The liquid storage portion may be substantially sealed. The liquid storage portion may include one or more outlets for liquid aerosol-forming substrate stored in the liquid storage portion to flow from the liquid storage portion to the aerosol generating device. The liquid storage portion may be permanently disposed within the main body of the aerosol generating device. The liquid storage portion may be refillable. Alternatively, the liquid storage portion may be configured as a replaceable liquid storage portion. The liquid storage portion may be part of or configured as a replaceable cartridge. The aerosol generating device may be configured to receive the cartridge. When the original cartridge is consumed, a new cartridge may be attached to the aerosol generating device.

[0078] As used herein, "aerosol-generating device" refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate is provided in a liquid form in a liquid reservoir. The aerosol-generating device may be a smoking device that interacts with the aerosol-forming substrate to generate an aerosol that is directly inhalable through the user's mouth into the user's lungs. 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.

[0079] As used herein, the term "consumable" refers to an article that preferably includes a sensory medium capable of providing flavor to the aerosol generated by the aerosol generating device. For example, the consumable may be a smoking article. The consumable may be disposable.

[0080] The consumable may be substantially cylindrical in shape. The consumable may be substantially elongated. The consumable may have a length and a circumference substantially perpendicular to the length. The consumable may be substantially rod-like. The sensory medium may be substantially cylindrical in shape. In particular, the consumable is preferably hollow cylindrical in shape. The hollow portion of the cylindrical consumable forms the consumable airflow channel. The sensory medium may also have a hollow cylindrical shape lining the inner wall of the tubular wall of the consumable. The length of the sensory medium is preferably the same as the length of the consumable. The length of the tubular wall is preferably the same as the length of the consumable.

[0081] In any aspect of the present disclosure, the second heating element may include an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, metal alloys, and composites made of ceramic and metal materials. Such composites may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, platinum, gold, and silver. Examples of suitable metal alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, gold-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum-based alloys. In composite materials, the electrically resistive material can optionally be embedded, encapsulated or coated in the insulating material, or vice versa, depending on the required energy transfer kinetics and the external physicochemical properties.

[0082] As noted, in any of the aspects of the present disclosure, the second heating element may be part of the aerosol generating device. Alternatively, the second heating element may be provided as part of a cartridge that includes a liquid reservoir that contains the liquid aerosol-forming substrate. In this case, the capillary material may also be part of the cartridge.

[0083] The second heating element may take the form of one or more flexible heating foils on a dielectric substrate such as polyimide. The flexible heating foils may be shaped to fit the periphery of the substrate receiving cavity. Alternatively, the second heating element may take the form of a metal grid, a flexible printed circuit board, a molded integrated circuit (MID), a ceramic heater, a flexible carbon fiber heater, or may be formed using a coating technique such as plasma deposition on a substrate of suitable shape. Most preferably, however, the second heating element is configured as a helical resistive heating coil surrounding a capillary material. The second heating element may be formed using a metal that has a well-defined relationship between temperature and resistivity. In such an exemplary device, the metal may be formed as a track between two layers of suitable insulating material. A second heating element formed in this manner may be used to both heat the heating element and monitor the temperature of the second heating element during operation.

[0084] The second heating element advantageously heats the liquid aerosol-forming substrate by thermal conduction. The second heating element may be at least partially in contact with the liquid aerosol-forming substrate.

[0085] In operation, the liquid aerosol-forming substrate may be completely contained within the aerosol generating device, in which case the user may puff on the proximal end of the consumable. Alternatively, the aerosol generating device may comprise a mouthpiece utilized by the user for inhalation of the generated aerosol. In this case, the consumable may be covered by the mouthpiece.

[0086] The first heating element may be configured as an induction heating element. The induction heating element 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 located within 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 commonly referred to as hysteresis loss. Hysteresis loss occurs primarily due to the movement of magnetic domain blocks within the susceptor. This is because their magnetic orientation aligns with the alternating induced magnetic field. Another effect that contributes to hysteresis loss is when magnetic domains expand or contract within the susceptor. Generally, all these changes that occur within the susceptor at nanoscale or below generate heat within the susceptor, and are therefore referred to as "hysteresis loss." Thus, if the susceptor is both magnetic and conductive, both hysteresis losses and the generation of eddy currents will contribute to the heating of the susceptor. If the susceptor is magnetic but not conductive, hysteresis losses will be 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 heat to the aerosol-forming substrate, whereby 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.

[0087] 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.

[0088] The preferred susceptor is a metal susceptor, such as 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 deposition film, ceramics, such as zirconia, transition metals, such as iron, cobalt, nickel, or semi-metallic components, such as boron, carbon, silicon, phosphorus, aluminum, etc.

[0089] The first induction heating element may be disposed to at least partially, and preferably completely, surround a distal portion of the cavity. The susceptor element is preferably configured as a cylindrical susceptor that at least partially surrounds or forms a sidewall of the cavity.

[0090] Features described with respect to one embodiment may be equally applied to other embodiments of the invention.

[0091] 1A and 1B show an aerosol generation system that includes an aerosol generation device 16 and a consumable 10. The consumable 10 is shown in FIG.

[0092] The consumable 10 comprises a tubular wall 12 and a consumable airflow channel 14. Additionally (not shown), the consumable 10 may be provided with paper tipping paper as an outer wrapper.

[0093] The tubular wall 12 extends the entire length of the consumable 10. The tubular wall 12 has a hollow cylindrical shape. The tubular wall 12 provides dimensional stability to the consumable 10. Air can flow through the tubular wall 12. The tubular wall 12 forms a consumable airflow channel 14. The consumable airflow channel 14 may be disposed through the center of the consumable 10. The tubular wall 12 is preferably porous to allow at least inhaled flavors to permeate the tubular wall 12 to some extent. This is shown in FIG. 1B near the proximal end 38 of the consumable 10.

[0094] In the embodiment of FIG. 1, the consumable 10 does not include any other components.

[0095] 1B shows that the consumable 10 is received within a cavity 18 of an aerosol generation device 16. The aerosol generation device 16 includes a first heating element for heating a distal portion 40 of the consumable 10. The first heating element includes a susceptor 20 and an induction coil 22.

[0096] In the embodiment shown in FIG. 1B, two induction coils 22 are shown. The two induction coils 22 can heat different portions of the susceptor 20 via induction heating. This can result in the provision of two heating zones within the cavity 18 such that the distal portion 40 of the consumable 10 is received within these two heating zones. Depending on the requirements of the aerosol generation, the first heating element can be controlled to heat one of the heating zones to a different temperature than the other heating zone. Alternatively, only a single induction coil can be provided to heat the susceptor 20 to a uniform temperature.

[0097] 1B further shows an air inlet 24 upstream of the cavity 18. The air inlet 24 is disposed to allow ambient air to be drawn laterally into the aerosol generation device 16.

[0098] 1B further illustrates a liquid storage portion 26 of the aerosol generating device 16. The liquid storage portion 26 may form part of a refillable or replaceable cartridge. A liquid aerosol-forming substrate 28 is held within the liquid storage portion 26. A second heating element is also illustrated in FIG. 1B. The second heating element is configured as a resistive heating coil 30. The heating coil 30 is wound around a capillary material 32. The capillary material 32 contacts the liquid aerosol-forming substrate 28 held within the liquid storage portion 26 and wicks the liquid aerosol-forming substrate 28 towards the heating coil 30.

[0099] During operation, ambient air is drawn into the aerosol-generating device 16 through the air inlet 24. A heating coil 30 is disposed in the center of the aerosol-generating device 16, through which the ambient air is drawn. The heating coil 30 vaporizes the liquid aerosol-forming substrate 28 that is wicked to the heating coil 30 via a capillary material 32. The vaporized liquid aerosol-forming substrate 28 is entrained in the airflow and drawn toward the cavity 18.

[0100] The air is further drawn into the cavity 18 and into the central consumable airflow channel 14. In the consumable airflow channel 14, the air and vaporized aerosol-forming substrate can cool to form an inhalable aerosol. If the liquid aerosol-forming substrate 28 contains a flavorant, the flavor can at least partially permeate the proximal portion of the consumable 10 to create a pleasant odor to the user.

[0101] Figures 2A and 2B show a different embodiment. All elements of this embodiment are identical to those described in relation to Figures 1A and 1B. The only difference is that a sensory medium 34 is provided on the inner surface of the tubular wall 12 of the consumable 10. The sensory medium 34 is coated on the inner surface of the tubular wall 12. The sensory medium 34 includes a flavoring agent. The liquid aerosol-forming substrate 28 held in the liquid storage portion 26 is preferably flavor-free in this embodiment, since the flavor of the generated aerosol may be altered by the used consumable 10. The flavor of the sensory medium 34 may be released, at least primarily, by heating the sensory medium 34 via the first heating element. Alternatively, or additionally, the flavor of the sensory medium 34 may be released at ambient temperature.

[0102] Figures 3A and 3B show further details and alternatives of the aerosol generating device 16. In Figure 3A, the aerosol generating device 16 of Figures 1B and 2B is shown. The aerosol generating device 16 further comprises a body 42 comprising a power source 36 in the form of a battery.

[0103] 3B, one version of the aerosol generating device 16 is shown in which the first heating element is omitted. The consumable 10 in this embodiment is provided with a sensory medium 34 that releases contained flavorants at ambient temperature or at a slightly elevated temperature provided by hot air drawn into the consumable airflow channel 14 and heated by heating coil 30.

Claims

1. An aerosol generation system comprising an aerosol generating device and a consumable for the aerosol generating device, the aerosol generating device comprising: a cavity for receiving said consumable; a first heating element disposed to at least partially heat the consumable when the consumable is received within the cavity; and an airflow channel disposed to direct air through the device and into the cavity; The consumables are a tubular wall extending from a distal opening of the consumable to an opposing proximal opening of the consumable, the tubular wall having a thickness of 3 mm to 7 mm, the consumable including a layer of a sensory medium on one or both of an inner surface of the tubular wall and an outer surface of the tubular wall; An aerosol generating system, wherein the consumable is arranged so that when the consumable is received in the cavity, air flowing from the airflow channel into the cavity flows into the distal opening of the consumable.

2. 10. The aerosol generating system of claim 1, wherein the aerosol generating device further comprises a liquid reservoir containing a liquid aerosol-forming substrate.

3. 3. The aerosol generating system of claim 2, wherein the aerosol generating device further comprises a second heating element configured to volatilize the liquid aerosol-forming substrate.

4. 4. The aerosol generating system of claim 3, wherein the second heating element is disposed to volatilize the liquid aerosol-forming substrate upstream of the cavity.

5. 5. The aerosol generation system of claim 4, wherein the aerosol generation device further comprises an air inlet, the air inlet being disposed distal to the cavity and proximal to the liquid storage portion.

6. 4. The aerosol generating system of claim 3, wherein the second heating element is a resistive heating element, preferably a heating coil arranged to at least partially surround a wick, the wick extending into the liquid storage portion to wick the liquid aerosol-forming substrate toward the heating coil.

7. 7. The aerosol generation system of claim 6, wherein the aerosol generation device further includes a wick extending into the liquid storage portion, and the second heating element is a heating coil disposed around the wick.

8. 2. The aerosol generating system of claim 1, wherein the first heating element is an induction heating element.

9. 9. The aerosol generating system of claim 8, wherein the first heating element comprises an induction coil and a tubular susceptor, the tubular susceptor being disposed to surround a distal portion of the cavity.

10. 2. The aerosol generating system of claim 1, wherein the sensory medium is a flavoring agent coated, applied, or impregnated onto one or both of the inner surface of the tubular wall and the outer surface of the tubular wall.

11. The aerosol generating system of claim 1 , wherein the consumable comprises tipping paper surrounding the tubular wall.

12. 2. The aerosol generating system of claim 1, wherein the consumable comprises the tubular wall and a layer of sensory medium on the inner surface of the tubular wall, or the consumable comprises the tubular wall and a layer of sensory medium on the inner surface of the tubular wall, and tipping paper surrounding the tubular wall.

13. 10. The aerosol generating system of claim 1, wherein the consumables do not include tobacco.

14. 14. An aerosol generation system according to any one of claims 10 to 13, wherein the cavity is dimensioned to receive the consumable or a consumable comprising a cigarette having a larger diameter.

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