Aerosol generation

Abstract

To provide an aerosol generating system.SOLUTION: An aerosol generating system comprises (i) an aerosol generating article comprising a flavorant and (ii) an aerosol generating device comprising an induction heater, wherein during operation the article is inserted into the device, aerosol is generated by using the induction heater to heat the aerosol generating material to at least 150°C, and at least 1 μg of the flavorant is aerosolized from the aerosol generating material under an airflow of at least 1.50 L / m in a two-second period.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a method for generating an aerosol and to an aerosol generating system. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion. An example of such a product is a heating device that releases compounds by heating a material without burning it. This material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Summary of the Invention

[0003] A first aspect of the present invention provides an aerosol-generating system comprising: (i) an aerosol-product article comprising a flavoring; and (ii) an aerosol-generating device comprising an induction heater, wherein in operation, an article is inserted into the device and an aerosol is generated by heating the aerosol-generating material to at least 150°C using the induction heater, and at least 1 μg of flavoring is aerosolized from the aerosol-generating material under an air flow of at least 1.50 L / m for 2 seconds.

[0004] A second aspect of the present invention provides a method of generating an aerosol from an aerosol-forming material comprising a flavorant, the method comprising the step of heating the aerosol-forming material to at least 150°C by use of an induction heater, wherein at least 1 μg of flavorant is aerosolized from the aerosol-forming material under an air flow of at least 1.50 L / m for 2 seconds.

[0005] A further aspect of the invention provides an aerosol comprising at least 1 μg of flavorant obtainable or obtainable by inductive heating of an aerosol-forming material to at least 150° C. under an air flow of at least 1.50 L / m for 2 seconds.

[0006] A further aspect of the present invention provides a method of generating an aerosol from an aerosol-forming material comprising nicotine and an aerosol-forming agent, the method comprising the step of heating the aerosol-forming material to at least 150°C by use of an induction heater, wherein the aerosol generated under an air flow of at least 1.50 L / m for 2 seconds has a weight ratio of flavoring to nicotine of at least approximately 2.5:1, preferably at least 6:1, under an air flow of at least 1.50 L / m for 2 seconds.

[0007] Another further aspect of the present invention provides an aerosol generation system comprising: (i) an aerosol product article comprising an aerosol-forming material comprising nicotine and an aerosol-forming agent; and (ii) an aerosol-generating device comprising an induction heater, wherein in operation an article is inserted into the device and an aerosol is generated by heating the aerosol-generating material to at least 150°C using the induction heater, and wherein the aerosol generated under an air flow of at least 1.50 L / m for 2 seconds has a weight ratio of flavoring to nicotine of at least approximately 2.5:1, preferably at least 6:1.

[0008] A further aspect of the present invention provides an aerosol comprising a flavourant and nicotine, wherein the weight ratio of flavourant to nicotine is at least approximately 2.5:1, preferably at least 6:1, obtainable or obtainable by inductive heating of an aerosol-forming material to at least 150°C under an air flow of at least 1.50 L / m for 2 seconds.

[0009] Features described herein with respect to one aspect of the invention are expressly disclosed in combination with other aspects, to the extent compatible.

[0010] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only and with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a front view of an example of an aerosol generating device. [Figure 2] FIG. 2 is a front view of the aerosol generating device of FIG. 1 with the outer cover removed. [Figure 3] FIG. 2 is a cross-sectional view of the aerosol generating device of FIG. 1. [Figure 4] FIG. 3 is an exploded view of the aerosol generating device of FIG. 2. [Figure 5] Figure 5A is a cross-sectional view of a heating assembly in an aerosol generating device, and Figure 5B is an enlarged view of a portion of the heating assembly of Figure 5A. [Figure 6A] 1 is a cutaway cross-sectional view of an example aerosol product. FIG. [Figure 6B] FIG. 6B is a perspective view of the exemplary aerosol product of FIG. 6A. [Figure 7A] FIG. 1 shows a thermal profile programmed into an example of an aerosol generating device. [Figure 7B] FIG. 1 shows a thermal profile programmed into an example of an aerosol generating device. [Figure 8A] 7B shows the tobacco temperature in the aerosol product heated by the programmed aerosol generating device of FIG. 7A. [Figure 8B] 7C shows the tobacco temperature in the aerosol product heated by the programmed aerosol generating device of FIG. 7B. [Figure 9] FIG. 1 illustrates nicotine release from a heated aerosol product according to one embodiment of the present invention. [Figure 10] FIG. 1 illustrates glycerol release from a heated aerosol product according to one embodiment of the present invention. [Figure 11]FIG. 1 illustrates menthol release from a heated aerosol product in accordance with one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] As used herein, the term "aerosol-generating material" includes materials that volatilize upon heating, typically in the form of an aerosol. Aerosol-generating materials include any tobacco-containing material, such as one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-generating materials also include other non-tobacco products, which may or may not contain nicotine. Aerosol-generating materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-generating materials may also be a combination or blend of materials, for example. Aerosol-generating materials are sometimes known as "smoking materials" or "aerosolizable materials."

[0013] Devices are known that heat aerosol-forming materials to volatilize at least one component of the aerosol-forming materials, typically forming an inhalable aerosol without burning or combusting the aerosol-forming materials. Such devices may be described as "aerosol-generating devices," "aerosol-delivery devices," "non-combustion heating devices," "tobacco heating product devices," "tobacco heating devices," or the like. Similarly, so-called e-cigarette devices exist that vaporize aerosol-forming materials, typically in liquid form (which may or may not contain nicotine). The aerosol-forming materials may be in the form of, or provided as, a part, such as a rod, cartridge, or cassette that can be inserted into the device. The heater that heats and volatilizes the aerosol-forming materials may be a "permanent" part of the device.

[0014] The aerosol-generating device can receive and heat an article containing an aerosol-generating material. In this context, an "article" is a component that, in use, comprises or contains the aerosol-generating material and is heated to volatilize the aerosol-generating material and, optionally, other components in use. A user may insert the article into the aerosol-generating device before the aerosol-generating device is heated to generate an aerosol that the user subsequently inhales. The article may be of a predetermined or specific size, for example, configured to be placed in a heating chamber of a device sized to receive the article.

[0015] The inventors have found that the use of an induction heater allows for more rapid heating and greater control of the thermal profile, which affects the state and composition of the aerosol.

[0016] As noted above, one aspect of the present invention provides a method of generating an aerosol from an aerosol-forming material comprising a flavoring agent, the method comprising the step of heating the aerosol-forming material to at least 150°C using an induction heater, wherein at least 1 μg of flavoring agent is aerosolized from the aerosol-forming material under an air flow of at least 1.50 L / m for 2 seconds.

[0017] Optionally, at least 100 μg, preferably at least 200 μg, or at least 500 μg of flavorant is aerosolized from the aerosol-forming material under an air flow of at least 1.50 L / m for 2 seconds.

[0018] Optionally, less than about 1.5 mg, less than about 1 mg, or less than about 750 μg of flavoring is aerosolized from the aerosol-forming material under an airflow of at least 1.50 L / m for 2 seconds.

[0019] Optionally, at least 10 μg, preferably at least 30 μg, 50 μg, or 100 μg of nicotine is aerosolized from the aerosol-forming material under an airflow of at least 1.50 L / m for 2 seconds. Optionally, less than approximately 200 μg, preferably less than approximately 150 μg, or less than approximately 125 μg of nicotine is aerosolized from the aerosol-forming material under an airflow of at least 1.50 L / m for 2 seconds.

[0020] In each aspect and embodiment of the invention discussed herein, the air flow is preferably at least 1.55 L / m or 1.60 L / m. Optionally, the air flow may be less than approximately 2.00 L / m, 1.90 L / m, 1.80 L / m, or 1.70 L / m. Optionally, the air flow may be approximately 1.65 L / m.

[0021] Optionally, the flavoring comprises (or consists essentially of, or consists of) menthol.

[0022] Optionally, the aerosol-forming material includes nicotine, and the aerosol generated has a weight ratio of flavor to nicotine of at least about 2.5:1, preferably at least 3:1, 3.5:1, 4:1, 5:1, 5.5:1, or 6:1. Optionally, this ratio may be less than about 20:1 or 17:1.

[0023] Optionally, the aerosol-generating material comprises an aerosol-generating agent, which preferably comprises (or consists essentially of, or consists of) glycerol. Optionally, at least 10 μg, preferably at least 100 μg, 300 μg, or 500 μg of the aerosol-generating agent is aerosolized from the aerosol-generating material under an airflow of at least 1.50 L / m for 2 seconds.

[0024] Optionally, the aerosol-forming material is a solid or gel material. That is, the method may be a method of generating an aerosol from a tobacco heating product, also known as a non-combustion heating device. Optionally, the aerosol-forming material comprises tobacco. Optionally, the aerosol-forming material is solid and comprises tobacco.

[0025] In some cases, the aerosol-forming material comprises reconstituted tobacco material. In some cases, the aerosol-forming material comprises or consists of between about 220 mg and about 400 mg. In some cases, the aerosol-forming material comprises between about 220 mg and about 300 mg, preferably between about 240 mg and about 280 mg, and preferably about 260 mg of reconstituted tobacco material. In other cases, the aerosol-forming material comprises between about 320 mg and about 400 mg, preferably between about 320 mg and about 370 mg, and preferably about 340 mg of reconstituted tobacco material.

[0026] Optionally, the aerosol-forming material (which may include tobacco material, preferably the reconstituted tobacco material discussed in the previous paragraph) may have a nicotine content of approximately 5 mg / g to 15 mg / g (dry weight basis), preferably approximately 7 mg / g to 12 mg / g. Optionally, the aerosol-forming material (which may include tobacco material) may have an aerosol-forming agent (preferably glycerol) content of approximately 130 mg / g to 170 mg / g, preferably approximately 145 mg / g to 155 mg / g (all dry weight basis). Optionally, the aerosol-forming material may have a moisture content of approximately 5 to 8 wt% (wet weight basis). Optionally, the aerosol-forming material contains at least approximately 1.5 mg of nicotine, preferably at least approximately 1.7 mg, 1.8 mg, or 1.9 mg of nicotine. Optionally, the aerosol-generating material comprises at least about 25 mg of aerosol-generating agent, preferably at least about 30 mg, 32 mg, 34 mg, or 36 mg of aerosol-generating agent, which optionally comprises or consists of glycerol. Optionally, the aerosol-generating material comprises a weight ratio of aerosol-generating agent to nicotine of at least 10:1, preferably at least 12:1, 14:1, or 16:1.

[0027] Optionally, the aerosol-forming material (which may include tobacco material, preferably reconstituted tobacco material as described above) contains approximately 10 mg / g to 50 mg / g of flavorant (wet weight basis). Suitably, the material may contain approximately 20 mg / g to 40 mg / g, preferably approximately 25 mg / g to 35 mg / g of flavorant. Optionally, the flavorant may include (or consist essentially of, or consist of) menthol.

[0028] Optionally, the density of the aerosol is at least 0.2 μg / cc, 0.3 μg / cc, or 0.4 μg / cc. Optionally, the density of the aerosol is less than approximately 2.5 μg / cc, 2.0 μg / cc, 1.5 μg / cc, or 1.0 μg / cc.

[0029] As defined herein, the term "mean particle or droplet size" refers to the average size of the solid or liquid components of an aerosol (e.g., components suspended in a gas). When an aerosol includes suspended liquid droplets and suspended solid particles, the term refers to the average size of all components together.

[0030] In some cases, the average particle or droplet size of the aerosol produced may be less than about 900 nm, 800 nm, 700 nm, 600 nm, 500 nm, 450 nm, or 400 nm. In some cases, the average particle or droplet size may be greater than about 50 nm or 100 nm.

[0031] Another aspect of the present invention provides an aerosol-generating system comprising: (i) an aerosol-product article comprising a flavoring; and (ii) an aerosol-generating device comprising an induction heater, wherein, during operation, an article is inserted into the device and an aerosol is generated by heating the aerosol-generating material to at least 150°C using the induction heater, and at least 1 μg of flavoring is aerosolized from the aerosol-generating material under an airflow of at least 1.50 L / m for 2 seconds.

[0032] In some cases, the aerosol-forming material is a solid or gel material. That is, the system may be a tobacco heating product, also known as a non-combustion heating device. In some cases, the aerosol-forming material comprises tobacco. In some cases, the aerosol-forming material is solid and comprises tobacco.

[0033] Optionally, during operation, an article is inserted into the device, and an aerosol is generated by using an induction heater to heat the aerosol-forming material to at least 150°C, such that a total amount of flavorant aerosolized from the aerosol-forming material over at least seven 2-second periods under an air flow of at least 1.50 L / m is at least approximately 1.5 mg. Suitably, a total amount of flavorant aerosolized from the aerosol-forming material over at least nine 2-second periods under an air flow of at least 1.50 L / m is at least approximately 2.3 mg, 2.4 mg, 2.5 mg, or 2.6 mg.

[0034] Optionally, during operation, the article is inserted into the device and an aerosol is generated by using an induction heater to heat the aerosol-generating material to at least 150°C, and the aerosol generated in at least seven 2-second periods under an air flow of at least 1.50 L / m has an average aerosol density of at least 0.6 μg / cc, preferably at least 0.8 μg / cc. In other words, the article may generate an aerosol of at least 4.2 μg / cc, preferably at least 5.6 μg / cc, in seven 2-second periods.

[0035] Optionally, during operation, the article is inserted into the device and an aerosol is generated by using an induction heater to heat the aerosol-generating material to at least 150°C, and the aerosol generated under an air flow of at least 1.50 L / m for at least nine two-second periods has an average aerosol density of at least 0.4 μg / cc, preferably at least 0.6 μg / cc. In other words, the article may generate an aerosol of at least 3.6 μg / cc, preferably at least 5.4 μg / cc, for nine two-second periods.

[0036] The heater in the device is an induction heater. The susceptor defines a cylindrical chamber into which the article is inserted during use so that the aerosol-forming material can be heated by the susceptor. The length of the cylindrical chamber may be approximately 40 mm to 60 mm, approximately 40 mm to 50 mm, approximately 40 mm to 45 mm, or approximately 44.5 mm. The diameter of the cylindrical chamber may be approximately 5.0 mm to 6.5 mm, preferably approximately 5.35 mm to 6.0 mm, preferably approximately 5.5 mm to 5.6 mm, or preferably approximately 5.55 mm.

[0037] The aerosol-producing article may include an aerosol-forming material and a wrapping material disposed around the aerosol-forming material. Optionally, the aerosol-forming material includes tobacco. The tobacco may be any suitable solid tobacco, such as a single grade or blend, cut rag or whole leaf, ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, and / or reconstituted tobacco. The tobacco may be of any variety, including Virginia, Burley, and / or Oriental tobacco.

[0038] The aerosol-generating material may be a rod of aerosol-generating material. The wrapper may form a tube disposed around the rod of aerosol-generating material. As used herein, the term "rod" generally refers to an elongated body that may have any suitable shape for use in an aerosol-generating device. In some cases, the rod is substantially cylindrical. The length of the cylindrical body of aerosol-generating material may be approximately 34 mm to 50 mm, preferably approximately 38 mm to 46 mm, and preferably approximately 42 mm. The diameter of the cylindrical body of aerosol-generating material may be approximately 5.0 mm to 6.0 mm, preferably approximately 5.25 mm to 5.45 mm, preferably approximately 5.35 mm to 5.40 mm, and preferably approximately 5.39 mm. In some cases, the aerosol-generating material may fill at least approximately 85% of the void defined by the susceptor.

[0039] The aerosol-forming material may include a flavorant, as well as one or more of an aerosol-forming agent, a binder, a filler material, nicotine (which may be included in the tobacco material), and one or more additional flavorants.

[0040] The aerosol product may further comprise one or more of a filter, a cooling element, and a mouthpiece.

[0041] Optionally, the aerosol-producing article comprises a wrapper that at least partially surrounds other components of the article, including one or more of the filter, cooling element, mouthpiece, and aerosol-forming material. Optionally, the wrapper may surround the periphery of each of these components. The wrapper may have a thickness of approximately 10 μm to 50 μm, preferably approximately 15 μm to 45 μm or 20 μm to 40 μm. Optionally, the wrapper may comprise a paper layer, optionally having a basis weight of at least approximately 10 g m -2 , 15g·m -2 , 20g·m -2 , or 25g·m -2 ~approximately 50g·m -2 , 45g·m -2 , 40g·m -2 , or 35g·m -2 Optionally, the wrapper may comprise a non-combustible layer such as a metal foil. Suitably, the wrapper may comprise an aluminium foil layer, which may have a thickness of approximately 3 μm to 15 μm, preferably approximately 5 μm to 10 μm, preferably approximately 6 μm. The wrapper may comprise a laminate structure, which may optionally comprise at least one paper layer and at least one non-combustible layer.

[0042] In some cases, the wrapper is provided with ventilation openings, which may provide a ventilation rate (i.e., the amount of inhaled air flowing through the ventilation openings as a percentage of the aerosol volume) of approximately 5% to 85%, preferably at least 20%, 35%, 50%, or 60%. The ventilation openings may be located in portions of the wrapper surrounding one or more of the filter, cooling element, and mouthpiece.

[0043] Referring now to the drawings, Figure 1 shows an example of an aerosol-generating device 100 for generating an aerosol from an aerosol-generating medium / material. Generally, device 100 may be used to heat a replaceable item 110 containing an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0044] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end for inserting an item 110 therethrough for heating by the heating assembly. In use, the item 110 may be inserted in whole or in part into the heating assembly and heated by one or more components of the heating assembly.

[0045] The device 100 of this example includes a first end member 106 with a lid 108 that can be moved relative to the first end member 106 to close the opening 104 when the item 110 is not in place. While the lid 108 is shown in an open configuration in Figure 1, the lid 108 can also be moved to a closed configuration. For example, a user may slide the lid 108 in the direction of arrow "A."

[0046] Device 100 may also include a user-operable control element 112, such as a button or switch, that, when pressed, operates device 100. For example, a user may turn device 100 on by operating switch 112.

[0047] Device 100 may also include an electrical component, such as a socket / port 114, that can accept a cable to charge a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port. In some examples, socket 114 may additionally or alternatively be used to transfer data between device 100 and another device, such as a computing device.

[0048] 2 shows the device 100 of FIG. 1 without the outer cover 102 and without the item 110 present. The device 100 defines a longitudinal axis 134.

[0049] 2, a first end member 106 is disposed at one end of the device 100, and a second end member 116 is disposed at the opposite end of the device 100. The first and second end members 106, 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

[0050] The end of the device nearest opening 104 is considered to be known as the proximal end (or mouth end) of device 100, as it is closest to the user's mouth during use. During use, a user inserts item 110 into opening 104 and operates user control 112 to initiate heating of the aerosol-generating material and utilize the aerosol generated in the device. This causes the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0051] The other end of the device furthest from opening 104 is considered to be known as the distal end of device 100, as this is the end that will be farthest from a user's mouth when in use. When a user utilizes the aerosol generated in the device, the aerosol flows in a direction away from the distal end of device 100.

[0052] Device 100 further includes a power source 118. Power source 118 may be a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include lithium batteries (e.g., lithium-ion batteries), nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power as needed and heat the aerosol-forming material under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds battery 118 in place.

[0053] The device further includes at least one electronics module 122. The electronics module 122 may include, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also include one or more electrical tracks that electrically connect together various electronic components of the device 100. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via the electrical tracks.

[0054] In the exemplary device 100, the heating assembly is an induction heating assembly, comprising various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is a process for heating an electrical conductor (such as a susceptor) via electromagnetic induction. The induction heating assembly may comprise an induction element (e.g., one or more inductor coils) and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned relative to the induction element, generating eddy currents inside the susceptor. Because the susceptor has an electrical resistance to the eddy currents, the flow of eddy currents against this resistance heats the susceptor via Joule heating. Additionally, if the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e., the varying orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. Induction heating allows for faster heating than, for example, conduction heating, because heat is generated inside the susceptor. Furthermore, no physical contact between the induction heater and the susceptor is required, which allows for greater flexibility in design and application.

[0055] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as the "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are formed from an electrically conductive material. In this example, the first and second inductor coils 124, 126 are formed from litz wire / cable that is helically wound to provide the helical inductor coils 124, 126. Litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in electrical conductors. In the exemplary device 100, the first and second inductor coils 124, 126 are formed from copper litz wire with a rectangular cross section. In other examples, the litz wire may have other cross sections, such as a circular cross section.

[0056] The first inductor coil 124 is configured to generate a first varying magnetic field that heats a first portion of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field that heats a second portion of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along the longitudinal axis 134 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap). The susceptor structure 132 may comprise a single susceptor or may comprise two or more separate susceptors. Ends 130 of the first and second inductor coils 124, 126 are connectable to the PCB 122.

[0057] Of course, in some examples, the first and second inductor coils 124, 126 may have at least one characteristic that differs from one another. For example, the first inductor coil 124 may have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 2 , the first and second inductor coils 124, 126 have different lengths such that the first inductor coil 124 is wound around the susceptor 132 by a smaller amount than the second inductor coil 126. Therefore, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0058] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are activated at different times. For example, the first inductor coil 124 may be activated first to heat a first portion of the article 110, and then the second inductor coil 126 may be activated to heat a second portion of the article 110. Winding the coils in opposite directions can help reduce current induced in the inactive coil when used in conjunction with certain types of control circuitry. In FIG. 2, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124 and 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0059] The susceptor 132 in this example is hollow, thus defining a receptacle in which the aerosol-forming material is received. For example, the article 110 is insertable into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross section.

[0060] In this example, the first coil 124 (closer to the mouth end) is wound approximately one-third of the length of the susceptor 132, and the second coil 126 (closer to the distal end) is wound approximately two-thirds of the length of the susceptor 132. That is, the coil length ratio is 1:2, where the coil length represents the axial distance around which the coil is wound. Other length ratios may be employed. For example, in some cases, the ratio of the coil length of the first coil 124 to the second coil may range from approximately 1:4 to approximately 4:1.

[0061] 2 further includes an insulating member 128 that may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed of any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed of polyetheretherketone (PEEK). The insulating member 128 may help to insulate various components of the device 100 from heat generated in the susceptor 132.

[0062] Additionally, the insulating member 128 can support all or part of the first and second inductor coils 124, 126. For example, as shown in FIG. 2 , the first and second inductor coils 124, 126 are disposed around the insulating member 128 and are in contact with the radially outer surface of the insulating member 128. In some examples, the insulating member 128 does not contact the first and second inductor coils 124, 126. For example, a small gap may exist between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0063] In one particular example, the susceptor 132 , the insulating member 128 , and the first and second inductor coils 124 , 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0064] 3 is a partial cross-sectional side view of device 100. In this example, outer cover 102 is present. The rectangular cross-sectional shapes of first and second inductor coils 124, 126 are more clearly visible.

[0065] The device 100 further comprises a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0066] The device may also include a second printed wiring board 138 associated with the control element 112 .

[0067] The device 100 further includes a second lid / cap 140 and a spring 142 disposed at the distal end of the device 100. The spring 142 allows opening of the second lid 140 to provide access to the susceptor 132. A user may open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0068] The device 100 further includes an expansion chamber 144 extending from the proximal end of the susceptor 132 toward the opening 140 of the device. Disposed within the expansion chamber 144 is at least a portion of a retention clip 146 that contacts and holds an article 110 received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0069] FIG. 4 is an exploded view of the device 100 of FIG. 1 without the outer cover 102.

[0070] FIG. 5A shows a cross section of a portion of the device 100 of FIG. 1. FIG. 5B shows an enlarged view of a region of FIG. 5A. Both FIGS. 5A and 5B show an article 110 received within a susceptor 132, sized so that its outer surface is in contact with the inner surface of the susceptor 132, thereby providing the most efficient heating. In this example, the article 110 includes an aerosol-forming material 110a. The aerosol-forming material 110a is disposed within the susceptor 132. The article 110 may also include other components, such as a filter, packaging, and / or a cooling structure.

[0071] 5B shows that the outer surface of the susceptor 132 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 150, measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is approximately 3 mm to 4 mm, approximately 3 mm to 3.5 mm, or approximately 3.25 mm.

[0072] 5B shows that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152, measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is approximately 0.05 mm. In another example, the distance 152 is substantially 0 mm, such that the inductor coils 124, 126 abut and contact the insulating member 128.

[0073] In one example, the susceptor 132 has a wall thickness 154 of approximately 0.025 mm to 1 mm, or approximately 0.05 mm.

[0074] In one example, the susceptor 132 has a length of approximately 40 mm to 60 mm, approximately 40 to 45 mm, or approximately 44.5 mm.

[0075] In one example, the insulating member 128 has a wall thickness 156 of approximately 0.25 mm to 2 mm, 0.25 to 1 mm, or approximately 0.5 mm.

[0076] End member 116 may further house one or more electrical components, such as a socket / port 114. In this example, socket 114 is a female USB charging port.

[0077] 6A and 6B, which are a cutaway cross-sectional view and a perspective view of an example aerosol production article 110. In use, the article 110 is removably inserted into the device 100 at the opening 104 of the device 100 shown in FIG.

[0078] The example article 110 is in the form of a substantially cylindrical rod including a body of aerosol-generating material 303 and a filter assembly 305 in the form of a rod. The filter assembly 305 includes three segments: a cooling segment 307, a filter segment 309, and a mouth end segment 311. The article 110 has a first end 313, also known as the mouth end or proximal end, and a second end 315, also known as the distal end. The body of aerosol-generating material 303 is disposed at the distal end 315 of the article 110. In one example, the cooling segment 307 is disposed adjacent to the body of aerosol-generating material 303 between the body of aerosol-generating material 303 and the filter segment 309 so as to be in abutting relationship with the aerosol-generating material 303 and the filter segment 309. In other examples, there may be separation between the body of aerosol-generating material 303 and the cooling segment 307 and between the body of aerosol-generating material 303 and the filter segment 309. Filter segment 309 is disposed between cooling segment 307 and mouth end segment 311. Mouth end segment 311 is disposed adjacent filter segment 309 toward proximal end 313 of article 110. In one example, filter segment 309 is in abutting relationship with mouth end segment 311. In one embodiment, the overall length of filter assembly 305 is between 37 mm and 45 mm. More preferably, the overall length of filter assembly 305 is 41 mm.

[0079] In one embodiment, the body of aerosol-forming material 303 includes tobacco. However, in other embodiments, the body of aerosol-forming material 303 may consist entirely of tobacco, consist essentially entirely of tobacco, contain tobacco and aerosol-forming materials other than tobacco, contain aerosol-forming materials other than tobacco, or be tobacco-free. The aerosol-forming material may include an aerosol-forming agent, such as glycerol.

[0080] In one example, the length of the body of aerosol-forming material 303 is between 34 mm and 50 mm, more preferably between 38 mm and 46 mm, and even more preferably 42 mm.

[0081] In one example, the overall length of the article 110 is 71 mm to 95 mm, more preferably 79 mm to 87 mm, and even more preferably 83 mm.

[0082] The axial end of the body of aerosol-generating material 303 is visible at the distal end 315 of the article 110. However, in other embodiments, the distal end 315 of the article 110 may include an end member (not shown) that covers the axial end of the body of aerosol-generating material 303.

[0083] The body of aerosol-generating material 303 is attached to the filter assembly 305 by a ring of tipping paper (not shown) that surrounds and surrounds substantially the entire periphery of the filter assembly 305 and extends partially along the length of the body of aerosol-generating material 303. In one example, the tipping paper is made of 58 GSM standard tipping paper. In one example, the length of the tipping paper is between 42 mm and 50 mm, and more preferably 46 mm.

[0084] In one example, cooling segment 307 is an annular tube that is disposed around and defines the cavity therein. The cavity provides a chamber through which heated and volatilized components generated from the body of aerosol-generating material 303 flow. Cooling segment 307 is hollow to provide an aerosol accumulation chamber that is sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 110 during insertion into device 100. In one example, the wall thickness of cooling segment 307 is approximately 0.29 mm.

[0085] The cooling segment 307 provides a physical displacement between the aerosol-generating material 303 and the filter segment 309. The physical displacement provided by the cooling segment 307 results in a thermal gradient across the length of the cooling segment 307. In one example, the cooling segment 307 is configured to provide a temperature difference of at least 40° C. between the heated and volatilized components entering the first end of the cooling segment 307 and the heated and volatilized components exiting the second end of the cooling segment 307. In one example, the cooling segment 307 is configured to provide a temperature difference of at least 60° C. between the heated and volatilized components entering the first end of the cooling segment 307 and the heated and volatilized components exiting the second end of the cooling segment 307. This temperature difference across the length of the cooling segment 307 protects the temperature-sensitive filter segment 309 from the high temperatures of the aerosol-generating material 303 when heated by the heating configuration of the device 100. Without physical displacement between the filter segment 309 and the body of aerosol-generating material 303 and the heating element of the device 100, the temperature-sensitive filter segment 309 may be damaged during use and may not be able to effectively perform its required function.

[0086] In one example, the length of cooling segment 307 is at least 15 mm. In one example, the length of cooling segment 307 is between 20 mm and 30 mm, more particularly between 23 mm and 27 mm, more particularly between 25 mm and 27 mm, and even more particularly 25 mm.

[0087] The cooling segment 307 is constructed from paper, meaning that it is constructed from a material that does not produce compounds of concern (e.g., toxic compounds) when adjacent to the heater structure of the device 100 in use. In one example, the cooling segment 307 is fabricated from a spirally wound paper tube that provides a hollow interior chamber that maintains mechanical rigidity. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

[0088] In another example, cooling segment 307 is a recess made of stiff plug wrap or tipping paper that is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 110 during insertion into device 100.

[0089] For each example of cooling segment 307, the dimensional accuracy of the cooling segment is sufficient to meet the dimensional accuracy requirements of high speed manufacturing processes.

[0090] Filter segment 309 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated and volatilized components of the aerosol-generating material. In one example, filter segment 309 is constructed of a monoacetate material, such as cellulose acetate. Filter segment 309 provides cooling and suppression of the heated and volatilized components without reducing the amount of the heated and volatilized components to a level that is insufficient for the user.

[0091] The density of the cellulose acetate tow material of filter segment 309 controls the pressure drop across filter segment 309, which in turn controls the pull-out resistance of article 110. Therefore, the selection of material for filter segment 309 is important in controlling the pull-out resistance of article 110. Filter segment 309 also performs a filtration function in article 110.

[0092] In one example, the filter segment 309 is constructed of 8Y15 grade filter tow material, which provides filtration against heated and volatilized materials while simultaneously reducing the size of condensed aerosol droplets resulting from the heated and volatilized materials, thereby reducing the irritation and throat impact of the heated and volatilized materials to a sufficient level.

[0093] The presence of filter segment 309 provides an insulating effect by further cooling the heated and volatile components exiting cooling segment 307. This additional cooling effect reduces the temperature of the user's lips when they come into contact with the surface of filter segment 309.

[0094] One or more flavors may be added to the filter segment 309 by direct injection of a flavored liquid onto the filter segment 309 or by embedding or disposing one or more flavored frangible capsules or other flavor carriers within the cellulose acetate tow of the filter segment 309.

[0095] In one example, the filter segment 309 has a length of 6 mm to 10 mm, more preferably 8 mm.

[0096] The mouth-end segment 311 is an annular tube that is disposed around and defines the cavity therein. The cavity provides a chamber for heated and volatilized components to flow from the filter segment 309. The mouth-end segment 311 is hollow to provide an aerosol accumulation chamber that is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article during insertion into the device 100. In one example, the wall thickness of the mouth-end segment 311 is approximately 0.29 mm.

[0097] In one example, the length of the mouth end segment 311 is 6 mm to 10 mm, more preferably 8 mm, and in one example, the thickness of the mouth end segment is 0.29 mm.

[0098] The mouth end segment 311 may be manufactured from a spirally wound paper tube that provides a hollow interior chamber that maintains the necessary mechanical rigidity. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0099] The mouth end segment 311 serves the function of preventing direct user contact with liquid condensate that accumulates at the outlet of the filter segment 309 .

[0100] Of course, in one example, the mouth end segment 311 and the cooling segment 307 may be formed from a single tube, with the filter segment 309 positioned within the tube to separate the mouth end segment 311 and the cooling segment 307.

[0101] A ventilation region 317 is provided in the article 110 to allow air to flow from the exterior of the article 110 to the interior of the article 110. In one example, the ventilation region 317 is in the form of one or more ventilation holes 317 formed through an outer layer of the article 110. The ventilation holes may be located in the cooling segment 307 to aid in cooling the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, each row preferably located around the entire circumference of the article 110 in a cross section substantially perpendicular to the longitudinal axis of the article 110.

[0102] In one example, 1 to 4 rows of ventilation holes provide ventilation for the article 110. Each row of ventilation holes may have 12 to 36 ventilation holes 317. The diameter of the ventilation holes 317 may be, for example, 100 to 500 μm. In one example, the axial separation between rows of ventilation holes 317 is 0.25 mm to 0.75 mm. More preferably, the axial separation between rows of ventilation holes 317 is 0.5 mm.

[0103] In one example, ventilation holes 317 are uniformly sized. In another example, ventilation holes 317 vary in size. The ventilation holes can be configured using any suitable technique, such as one or more of the following techniques: laser techniques, mechanical drilling of cooling segment 307, or pre-drilling of cooling segment 307 before it is formed into article 110. Ventilation holes 317 are positioned to effectively cool article 110.

[0104] In one example, the row of ventilation holes 317 is located at least 11 mm from the proximal end 313 of the article. More preferably, the ventilation holes are located 17 mm to 20 mm from the proximal end 313 of the article 110. The location of the ventilation holes 317 is such that the user does not block the ventilation holes 317 when using the article 110.

[0105] By providing the row of ventilation holes 17-20 mm from the proximal end 313 of the article 110, the ventilation holes 317 can be conveniently located on the exterior of the device 100 when the article 110 is fully inserted into the device 100, as seen in Figure 1. Locating the ventilation holes on the exterior of the device allows unheated air from outside the device 100 to enter the article 110 through the ventilation holes and assist in cooling the article 110.

[0106] The length of cooling segment 307 is such that when item 110 is fully inserted into device 100, cooling segment 307 is partially inserted into device 100. The length of cooling segment 307 serves two functions: first, to provide a physical gap between the heater arrangement and heat-sensitive filter arrangement 309 of device 100, and second, to allow ventilation holes 317 to be located in the cooling segment while also being located outside of device 100 when item 110 is fully inserted into device 100. As can be seen in FIG. 1 , the majority of cooling element 307 is located within device 100; however, a portion of cooling element 307 extends from device 100. Ventilation holes 317 are located in the portion of cooling element 307 that extends from device 100.

[0107] In the illustrated embodiment, the article has a total length of 83 mm and includes a 42 mm long cylindrical tobacco rod (5.4 mm diameter) containing approximately 260 mg of aerosol-forming material. The article has a ventilation rate of 75%. It is used in a device with a susceptor that is 44.5 mm long and has an inner diameter of 5.55 mm.

[0108] In another embodiment (not shown), the article has a total length of 75 mm and includes a 34 mm long cylindrical tobacco rod (6.7 mm diameter) containing approximately 340 mg of aerosol-forming material. The article may have a ventilation rate of 60%. This is used in a device with a susceptor that is 36 mm long and has an inner diameter of 7.1 mm. [Example]

[0109] In the examples, the devices shown in the above-mentioned FIGS. 1 to 5B and the articles shown in the above-mentioned FIGS. 6A and 6B were employed.

[0110] The susceptor had a length of 44.5 mm and an inner diameter of 5.55 mm.

[0111] Many aerosol product articles were tested, and the data presented below are average values ​​(unless otherwise stated). The article had a total length of 83 mm and contained a 42 mm long cylindrical tobacco rod (5.4 mm diameter) containing approximately 260 mg of reconstituted tobacco material with a nicotine content of 0.8 wt% (±0.1 wt%) (DWB), a glycerol content of 15 wt% (±2 wt%) (DWB), and a menthol content of approximately 3 wt% (WWB). The ventilation rate was 75%.

[0112] The device was preprogrammed with two heating profiles, shown in Figures 7A and 7B. In each program, the mouth-end coil heats first, followed by the distal coil. Figures 8A and 8B show the tobacco temperature in each heating zone for the two preprogrammed heating profiles (for a number of samples (no smoking)).

[0113] In this example, a simulated puff regime was employed. In this regime, the first puff occurred 2 seconds after the device was turned on (to allow time for the heater to warm the tobacco). Thereafter, a 2-second draw of 55 mL was completed through the device's mouthpiece every 30 seconds (i.e., 50, 80, 110, 140, etc., after the device was turned on) (i.e., the airflow for each puff was 1.65 L / min). The thermal profile shown in Figure 7A represents a 3-minute session, allowing for 7 puffs in this regime (the final puff occurs after the heater has turned off, but still has enough heat to generate aerosol). The thermal profile shown in Figure 7B represents a 4-minute session, allowing for 9 puffs in this regime (again, the final puff occurs after the heater has turned off). (The lower maximum temperature in the profile in Figure 7B reduces aerosol generation early in the session, allowing for longer sessions.)

[0114] The average nicotine release from the tested articles is shown in Figure 9, which shows the nicotine release per puff and total nicotine release for each of the heating profiles in Figure 7.

[0115] The average glycerol release from the tested articles is shown in Figure 10. This figure shows the glycerol release per puff and total glycerol release for each of the heating profiles in Figure 7.

[0116] The average menthol release from the tested articles is shown in Figure 11. This figure shows the menthol release per puff and total menthol release for each of the heating profiles in Figure 7.

[0117] [Definition] As used herein, the term "aerosol generating agent" refers to a chemical that facilitates the generation of an aerosol. The aerosol generating agent may facilitate the generation of an aerosol by promoting the initial vaporization and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, the aerosol generating agent may improve the delivery of a functional component from the aerosol-generating material. Suitable aerosol generating agents include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol; monohydric alcohols; high-boiling hydrocarbons; acids such as lactic acid; glycerol derivatives; esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristates including ethyl and isopropyl myristates; and non-polyols such as aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. Suitably, the aerosol generating agent may comprise, consist essentially of, or consist of glycerol, propylene glycol, triacetin, and / or ethyl myristate. Optionally, the aerosol generating agent may comprise, consist essentially of, or consist of glycerol and / or propylene glycol.

[0118] As used herein, the terms "flavor" and "flavorant" refer to materials that can be used, where local regulations permit, to produce a desired flavor or aroma in products intended for adult consumers. These include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, peppermint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang). , sage, fennel, bell pepper, ginger, anise, coriander, coffee, or mint oil of any species of the genus Mentha), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. These may be imitation, synthetic, or natural ingredients, or mixtures thereof. They may also contain natural or Nature Identical flavors. They may be in any suitable form, such as, for example, an oil, liquid, powder, or gel.

[0119] As used herein, the term "filler" may refer to one or more inorganic filler materials, such as suitable inorganic adsorbents, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. Alternatively, the term filler may refer to one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. The filler may include both organic and inorganic filler materials.

[0120] As used herein, the term "binder" can refer to alginate, cellulose or modified cellulose, starch or modified starch, or natural gum. Suitable binders include, but are not limited to, alginate with any suitable cation, cellulose or modified cellulose such as hydroxypropyl cellulose and carboxymethyl cellulose, starch or modified starch, polysaccharides such as pectinates with any suitable cation, such as sodium, potassium, calcium, or magnesium pectinate, xanthan gum, guar gum, and any other suitable natural gum, and mixtures thereof. In some embodiments, the binder comprises, consists essentially of, or consists of one or more alginates selected from sodium alginate, calcium alginate, potassium alginate, or ammonium alginate.

[0121] As used herein, the term "tobacco material" refers to any material containing tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco materials include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extracts.

[0122] The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia, and / or Burley, and / or Oriental. It may also be tobacco particles ("fines" or granules), expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut roll stems. The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may contain tobacco fiber and may be formed by molding (a long-line paper-making process with the post-addition of tobacco extract) or extrusion.

[0123] All weight percentages (expressed as wt%) referred to herein are calculated on a dry weight basis (DWB) unless expressly stated otherwise. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis represent the totality of the extract, slurry, or material, excluding water, and may include components that are themselves liquids at room temperature and pressure, such as glycerol. In contrast, weight percentages quoted on a wet weight basis (WWB) represent all components, including water.

[0124] For the avoidance of doubt, wherever the term "comprises" is used in this specification to define the invention or a feature of the invention, it also discloses embodiments in which the invention or feature can be defined using the terms "consists essentially of" or "consists of" instead of "comprises."

[0125] The above-described embodiments are to be understood as illustrative examples of the invention. Other embodiments of the invention are contemplated. It is to be understood that any feature described with respect to any one embodiment can be used alone or in combination with other described features, and can also be used in combination with one or more features of any other embodiment or any combination thereof. Furthermore, equivalents and modifications not described above may be employed without departing from the scope of the invention as defined in the appended claims.

Claims

[Claim 1] The invention described in the specification.

Images