Methods for constructing and manufacturing susceptors

Abstract

The susceptor 106 used in the heating non-combustion device 100 and its manufacturing method uses metal pieces that are assembled into a single, integral piece using a variety of techniques, such as compression, heat and pressure, sintering, weaving, extrusion, etc., so that the susceptor is easily disassembled after use.

Description

[Technical field]

[0001] The present invention relates to methods of constructing and manufacturing susceptors, particularly for use in devices for aerosolizing pharmaceutical agents via elevated temperatures. [Background technology]

[0002] When faced with a condition that causes physical discomfort, such as a medical condition, disorder, illness, or general physical disability, most people turn to medicinal products, including drugs, supplements, and herbs, to provide immediate relief from the symptoms resulting from the underlying condition. There are legal and widely available over-the-counter drugs and supplements that provide beneficial effects when used for a variety of common conditions. There are also certain controlled narcotics and medications that are prescribed by doctors for a variety of more serious conditions.

[0003] One of the most common routes of administration for these OTC and prescription drugs is oral administration. However, like all oral administration of drugs, it must pass through the digestive tract. Oral administration has many drawbacks. For example, the onset of drug activation is slow because the drug must pass through the digestive tract. Furthermore, the drug may be inactivated or destroyed in the digestive tract, losing its potency or effectiveness. The drug itself may also cause side effects such as digestive problems, i.e. loss of appetite, diarrhea, and sour taste. Additionally, patients may be unwilling or unable to swallow oral medications in tablet form.

[0004] Certain medicines are intended to affect the brain or its functions and activities, but because they are administered intragastrointestinally, intravenously, or intramuscularly, these medicines may also cause a variety of unpleasant side effects due to the nature of how they are ingested or injected, including, but not limited to, gastrointestinal complications, gastrointestinal disorders, high blood pressure, and / or headaches, as well as user reluctance to self-administer medicines by injection.

[0005] Other routes of administration exist, such as intradermal injection, patch application, and inhalation, each of which has its own advantages and disadvantages, so there is still room to improve the routes of drug administration.

[0006] For example, various medicines are safer, more effective, and more efficient, with respect to both safety and efficacy, when taken by inhalation of aerosols, such as gases, vapors, mists, and other inhalants, containing the medicine or its active ingredient, rather than by gastrointestinal, intravenous, or intramuscular administration.

[0007] Additionally, certain methods of aerosolizing and administering these medicines also have drawbacks, specifically those that aerosolize the medicine itself, altering the molecular or chemical structure of the medicine, or those that may aerosolize at elevated temperatures - increasing the heating time and risk of altering the molecular or chemical structure of the active ingredient.Other drawbacks of current aerosolization technologies include the transportation, storage, and commercialization of some of these medicines in cartridges that are prone to leaking and are often designed and manufactured with environmentally unfriendly cartridge materials, including plastics and other materials that are not biodegradable.

[0008] To ensure that the drug is administered intact by the high temperature non-combustion induced method, it is preferred that the aerosolization method does not alter the chemical or fundamental molecular structure of the drug or other materials that make up the drug, or that, if such alterations occur, do not interfere with and / or improve the efficacy of the drug.

[0009] Thus, there remains a need for improved routes of administration of pharmaceuticals. In particular, there remains a need for improved methods of aerosolizing pharmaceuticals for inhalation that would also provide the added benefit of metering, monitoring, and measuring the exact dose in the inhaler without destroying the active ingredient or adding other chemicals to the aerosol as a result of energy inefficiencies or extended heating times. There is also a need for consumable embodiments that are biodegradable and do not contain materials that are not compatible with environmentally friendly disposal.

[0010] In addition to drug delivery systems, heat-not-burn (HNB) devices are a type of device that is generally used to heat tobacco at a temperature lower than that which would cause combustion to generate an aerosol containing nicotine and other tobacco components that is available to the user of the device. In some embodiments, a heating element or susceptor is placed inside the solid tobacco product with a coil wrapped around the tobacco product and the susceptor to heat the susceptor via an induction mechanism. Unlike traditional cigarettes, the goal is not to burn the tobacco, but to heat the tobacco sufficiently to release the nicotine and other components through the generation of an aerosol. Igniting and burning tobacco produces unwanted and harmful substances, which can be avoided with HNB devices. However, there is a delicate balance between providing enough heat to effectively release the tobacco components in the form of an aerosol and not burning or igniting the tobacco. Currently available HNB devices do not achieve that balance, either heating the tobacco to a temperature that results in an insufficient amount of aerosol or overheating the tobacco, creating an unpleasant or "burnt" flavor profile. Additionally, current methods leave the internal components of conventional HNB devices fouled with tobacco combustion by-products and accidental combustion by-products.

[0011] Furthermore, to ensure a rapid and energy-efficient state change from a solid or liquid state to an aerosol state via high temperature non-combustion induction heating, the formulation must be constructed to eliminate airflow between the formulation and the susceptor of the induction system.Therefore, there is a need for devices, methods, and formulations that provide users with the ability to control the power of the device to affect the temperature at which tobacco is heated via induction to reduce the risk of combustion - even if it is normally hot enough to ignite - while increasing the efficiency and flavor profile of the aerosol produced.

[0012] These devices use an induction heating method in which a susceptor embedded in an aerosol-generating substrate is heated by a coil wrapped around the aerosol-generating substrate and the susceptor. Current susceptors are generally made from pieces of metal and may contain heavy metals such as lead, cadmium, etc. One problem with current susceptors is that because they are flat pieces of metal, they can have very sharp corners and edges. Therefore, if the device and susceptor are not properly disposed of, they can be an environmental hazard, similar to razor blades lying around in the environment. Also, because current susceptors are solid pieces of metal, they do not decompose rapidly in the environment.

[0013] Therefore, there is a need for a susceptor and method of manufacture that is environmentally friendly without compromising the quality of heat production. Summary of the Invention

[0014] The present invention is directed to methods of constructing and manufacturing a susceptor that decomposes in a relatively short period of time, particularly when the susceptor is exposed to certain temperatures, as compared to standard susceptors made of metal alloys. In particular, the susceptor can be constructed of integrally fused metal particles that decompose more readily when removed from a heated non-combustion device and exposed to the environment, making the susceptor much more environmentally friendly than other HNB susceptors that do not decompose and are therefore an environmental hazard.

[0015] In some embodiments, the metal particles can be fused together to form a metal sheet. The susceptor can be manufactured using a variety of fusion processes, such as sintering, direct metal laser sintering, plasma spray powder, microwave assisted sintering, ultrasonic assisted sintering, direct pressure, electric current assisted sintering, powder metallurgy, etc.

[0016] In some embodiments, the susceptor can be formed by weaving "metal threads or wires" into a woven sheet or ribbon, then cutting the sheet to use as the susceptor. This embodiment also promotes faster decomposition in the environment. Both embodiments feature a textured surface, creating more surface area, optimizing adhesion between the substrate and the susceptor, simplifying the manufacturing process of the consumable, ensuring the best possible seal between the substrate and the susceptor, and allowing for high temperature, non-burning consumables that are inductively heated due to the lack of oxygen between the substrate and the susceptor.

[0017] In any embodiment, a protective coating on the susceptor may be used that burns off after the susceptor is heated, making the susceptor more susceptible to decomposition more rapidly when removed from the heating non-combustion device and exposed to the environment. An example of a protective coating is a thin coating of PG interspersed with PGA to form a gel seal around the susceptor, preventing oxidation and decomposition until the metal susceptor is used. Any suitable coating may be used, keeping in mind that any aerosols generated by the heated coating may be inhaled by the user. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a side view of the interior of an embodiment of the present invention assembled into an HNB device. [Figure 2A] FIG. 1 is a perspective view of an embodiment of the present invention assembled into a consumable-containing package. [Figure 2B] 2B is a perspective view of the embodiment shown in FIG. 2A with a portion of the consumable-containing package cut away and / or removed to expose the susceptor. [Figure 2C] 2C is a cross-sectional view of the embodiment shown in FIG. 2A taken along line 2C-2C. [Figure 2D] FIG. 2B is an exploded view of the consumable-containing package shown in FIG. 2A. [Figure 2E]1 is a perspective view of a consumable-containing package having another embodiment of a susceptor with a portion of the consumable-containing package cut away and / or removed to expose the susceptor. [Figure 3A] FIG. 2 is a perspective view of another embodiment of a susceptor. [Figure 3B] FIG. 3B is a side view of the susceptor shown in FIG. 3A. [Figure 3C] FIG. 3B is a top view of the susceptor shown in FIG. 3A. [Figure 4A] FIG. 2 is a perspective view of another embodiment of a susceptor. [Figure 4B] FIG. 4B is a side view of the susceptor shown in FIG. 4A. [Figure 4C] FIG. 4B is a top view of the susceptor shown in FIG. 4A. [Diagram 5] A close-up of the area designated 5 in FIG. 4A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] The detailed description set forth below in conjunction with the accompanying drawings is intended as a description of embodiments of the invention and is not intended to represent the only manner in which the invention may be constructed or utilized. The description sets forth functions and sequences of steps for constructing and operating the invention in conjunction with the illustrated embodiment. However, it will be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are intended to be encompassed within the spirit and scope of the invention.

[0020] The invention of the present application is a susceptor 106 for a device for generating an aerosol from a consumable-containing product for inhalation, commonly referred to as a heated-not-burned (HNB) device 100, where the susceptor 106 is decomposable after use in the HNB device 100. The susceptor 106 is a component that is inductively heated to heat the aerosol-generating substrate 104 from the inside. As such, the susceptor 106 is made of a metal that can be inductively heated, such as a ferrous metal. The HNB device 100 utilizes relatively high heat with minimal combustion of the consumable-containing product. The susceptor 106 of the present invention is configured to be decomposable after being heated during an inductive heating process during use of the HNB device 100.

[0021] For purposes of this application, the term "consumable" shall be interpreted broadly to encompass any type of medicinal agent, drug, chemical compound, active agent, ingredient, other agent, etc., regardless of whether the consumable is used to treat a condition or disease, is a nutritional supplement, a supplement, or is used recreationally. By way of example only, consumables may include, but are not limited to, pharmaceuticals, dietary supplements, and over-the-counter medicines, such as tobacco, cannabis, hemp, lavender, kava, coffee, caffeine, lobelia, hoodia, melatonin, epimedium, guarana, ginseng, etc.

[0022] An example of an HNB device is shown in Figures 1-2E and described in detail in U.S. Patent Nos. 10,750,787, PCT / US2019 / 012204, and PCT / US2020 / 040779, all of which are incorporated by reference in their entirety. The device 100 comprises a consumable-containing package 102 and an aerosol-generating device 200. The device 100 does not combust the aerosol-generating substrate 104 within the consumable-containing package 102, but generates an aerosol through a heating non-combustion process in which the aerosol-generating substrate 104 is exposed to aerosolization thermal conditions, such as high aerosolization temperatures and the absence of oxygen, that release the active ingredient from the aerosol-generating substrate 104 in the form of an inhalable aerosol product. Thus, the aerosol-generating substrate 104 is any product that contains an active ingredient that can be released in aerosol form when heated to the appropriate temperature and conditions. The description of the invention to a particular application, such as a tobacco product, is provided by way of example only and is not intended to be limiting. Thus, the present invention is not limited to use with tobacco products only.

[0023] 1, the aerosol generating device 200 comprises a container 151 for housing the consumable-containing package 102, an inductive heating element 160 for heating the susceptor 106, a system controller for controlling the inductive heating element 160, and a power source 220 for providing power to the device 100. A user interface 230 may be provided for ease of operation. A trigger 232 may be provided for actuating the device 100.

[0024] The consumable-containing package 102 is a component that is heated to release the consumable in aerosol form. The consumable-containing package 102 comprises an aerosol-generating substrate 104 and a susceptor 106 that surrounds the aerosol-generating substrate 104 to heat the aerosol-generating substrate 104 from the inside through an induction heating system. In some embodiments, the consumable-containing package 102 can have a housing 108 that houses the aerosol-generating substrate 104 and the susceptor 106.

[0025] The containment 108 may be configured with holes 120 that allow the aerosol to exit the containment 108, or the containment may be a permeable membrane that allows the aerosol to exit. The aerosol-generating substrate 104 may be disposed within a housing 150 that may mimic a cigarette. In some embodiments, a filter 140 may surround the containment 108. The housing 150 may be capped with an end cap 154 ​​at one end and a mouthpiece 158 at the opposite end. The end cap 154 ​​may be constructed of a type of filter material. The mouthpiece 158 allows the user to draw the heated consumable aerosol from the aerosol-generating substrate 104 along the housing 150 toward the mouthpiece 158 and into the user's mouth. Thus, the mouthpiece 158 may further comprise a filter of a similar type to that of the end cap 154.

[0026] The invention of the present application is directed to a susceptor 106 that can be used in these and other HNB devices. Unlike existing susceptors, which can be constructed of a single, solid piece of metal, the susceptors 106 of the present invention are constructed to be disassembled after use in the HNB device 100. As such, when existing susceptors are discarded, they maintain their original shape, which is often a flat, rectangular piece of metal. Furthermore, the edges of a flat, rectangular piece of metal can be very sharp. As such, if existing susceptors are not properly disposed of, for example, by being wrapped in paper or tape or placed in a container for collecting sharps, sharp razor-like susceptors can be introduced into the environment where they can cause harm to unsuspecting children, animals, and adults who may accidentally step on, pick up, or ingest these susceptors.

[0027] However, the susceptor 106 of the present invention is configured to be more environmentally safe than prior art susceptors. For example, the susceptor 106 can be made of a material that is a softer, more malleable metal than prior art susceptors and is therefore less likely to cause injury and / or have sharp edges. In some embodiments, the susceptor 106 can be made of a material that degrades (e.g., by oxidation) in a relatively short period of time. In some embodiments, the susceptor 106 can be configured to break down or dissociate into smaller pieces when exposed to certain conditions until it is no longer a single, integral piece, but rather multiple fragmented pieces. As a result, the susceptor 106 is no longer a single, integral piece with hard or sharp features, but rather can be friable in that the susceptor can be easily broken down into small pieces, crushed, or pulverized into powder. As such, when the degradable susceptor 106 is discarded, it begins to decompose and is therefore less harmful to the environment.

[0028] Examples of materials that can be used to manufacture the susceptor 106 include, but are not limited to, any one or more of iron or an iron-based alloy. Specifically, the susceptor may include about 50% to about 99.99% iron or an iron-based alloy. Preferably, the susceptor 106 may include about 98 percent or more iron or an iron-based alloy. In some embodiments, the susceptor 106 may include pure iron (100 percent iron).

[0029] Examples of conditions that may degrade the susceptor 106 include, but are not limited to, any one or more of time, heat, pressure, sudden force, chemicals, water, and the like. In a preferred embodiment, the susceptor 106 becomes more fragile than current susceptors when exposed to the environment, even in the absence of heat. Thus, prior to its first use, the susceptor 106 has structural integrity and rigidity to allow for ease of handling during the manufacturing process of the HNB device 100, particularly when the susceptor 106 is assembled with the aerosol-generating substrate 104. Once the susceptor 106 is assembled with the aerosol-generating substrate 104 and inserted into the device 100, it is ready for use. During use, the susceptor 106 is heated to an aerosolization temperature that releases the active ingredient (pharmaceutical) from the aerosol-generating substrate 104 in the form of an aerosol. That aerosolization temperature can be high enough to make the susceptor 106 fragile and decompose when removed from the heated non-combustion device and left in the environment. Since the aerosol-generating substrate 104 has been used in that region of the susceptor 106, it is not of concern to the user that the susceptor 106 in the used region becomes fragile.

[0030] In some embodiments, the susceptor 106 may be provided with a coating that protects the susceptor 106 from premature degradation until after the aerosol-generating substrate has been used. An example of this is providing a metal susceptor 106 with one or more coatings of propylene glycol (PG), vegetable glycerin (VG), polysorbates, paraffin, etc., and then adding a dispersing agent to the susceptor 106, such as an alginate (e.g., propylene glycol alginate (PGA)) or any type of starch that can turn the coating (e.g., PG, VG, polysorbates, paraffin, etc.) into a gel. By way of example only, the ratio of coating to dispersing agent can be about 99:1 to turn the coating into a gel.

[0031] Various techniques can be used to manufacture susceptors 106 that become fragile after use (or after exposure to high aerosolization temperatures). As shown in Figures 3A-5, the degradable susceptor 106 can be constructed of multiple metal pieces 601 that are integrated together as a monolithic piece. The susceptor 106 can be made of any metallic material that generates heat when exposed to a changing magnetic field, such as in the case of induction heating. Ferromagnetic metals are preferred. In a preferred embodiment, as the temperature of the susceptor 106 of the present invention increases during use, it becomes more fragile and therefore more susceptible to decomposition. Also, the protective coating of the susceptor vaporizes at the elevated aerosolization temperature, and the surface of the susceptor decomposes more rapidly when exposed to the environment. By way of example only, the aerosolization temperature that renders the susceptor 106 fragile can be from about 20°C to about 800°C. Preferably, the temperature that renders the susceptor 106 fragile can be from about 40°C to about 600°C. More preferably, the temperature that renders the susceptor 106 fragile can be from about 250° C. to about 500° C. For example, the aerosolization temperature that renders the susceptor 106 fragile can be from about 200° C. to about 350° C. In some examples, the aerosolization temperature that renders the susceptor 106 fragile can be from about 40° C. to about 150° C.

[0032] The susceptor 106 can have a generally cylindrical, block-like, flat, or even amorphous shape. Preferably, the integral piece is a flat "sheet" that includes metal. In a preferred embodiment, the susceptor has a first end 600, a second end 602, and a surface 604 therebetween. Because the susceptor 106 is composed of a number of small pieces 601 (e.g., shards, particles, metal flakes, metal powder, granules, fibers, strands, etc.), the surface 604 of the susceptor 106 can be uneven. While the overall appearance of the surface 604 may appear flat or smooth, upon closer inspection, it can be seen that the surface has a number of dents, cracks, ridges, depressions, and other irregularities that create an uneven surface, as shown in FIG. 5. An uneven surface also increases the overall surface area compared to a smooth surface. Due to the unevenness, the surface 604 feels textured rather than smooth. The textured surface 604 increases the contact area with the aerosol-generating substrate 104. Furthermore, the textured surface 604 can improve adhesion with the aerosol-generating substrate 104. The uneven points on the surface 604 of the susceptor 106 can be recessed into the aerosol-generating substrate 104. The recessed uneven points in the aerosol-generating substrate 104 increase the contact area between the susceptor 106 and the aerosol-generating substrate 104. When the aerosol-generating substrate 104 is recessed into the depressions and crevices in the surface 604 of the susceptor 106, oxygen between the susceptor 106 and the aerosol-generating substrate 104 is eliminated.

[0033] The aerosol-generating substrate 104 can be configured to minimize the amount of air to which it is exposed. This eliminates or reduces the risk of oxidation during storage or combustion during the heating process. As a result, it is possible to heat the aerosol-generating substrate 104 to temperatures that would cause combustion if used with prior art devices that allow more exposure to air in certain settings. Therefore, in some embodiments, the aerosol-generating substrate 104 is made from a powder form that is compressed into a hard compressed pellet or rod. Compression of the aerosol-generating substrate 104 reduces the oxygen that is trapped within the aerosol-generating substrate 104 and limits the movement and availability of oxygen within the aerosol-generating substrate 104 during heating.

[0034] In some embodiments, the aerosol-generating substrate 104 and / or the susceptor 106 can be mixed with a substance that does not interfere with the function of the device 100, but displaces the air in the interstices of the aerosol-generating substrate 104 and / or surrounds and isolates the aerosol-generating substrate 104 from the air. For example, the substance can be an additive such as a humectant, a flavoring, a filler that displaces oxygen, or a steam-generating substance. The additive can not only remove oxygen from the aerosol-generating substrate 104, but also aid in the absorption and transfer of thermal energy. The additive can also act as a corrosion inhibitor for the metal susceptor material.

[0035] In some embodiments, the susceptor 106 can be made of metal wool, as shown in Figure 2E. For example, the susceptor 106 can be composed of thin filaments of metal wool bound together in the form of a pad, such that the metal wool pad has many fine edges.

[0036] In some embodiments, the susceptor 106 may be doused, dipped, or completely filled with additives such as humectants, flavorings, steam generating substances, substances to retard oxidation of the susceptor 106, and / or fillers to eliminate air between the metal pieces 601. There may be cutouts or gaps 112 along the susceptor 106 to divide the aerosol-generating substrate 104 into individual segments for individual heating segments. Alternatively, individual susceptors 106 separated by spaces and / or consumables may be used such that each susceptor 106 is individually heated during use.

[0037] In a preferred embodiment, the susceptor 106 may be made from a metal alloy such as low carbon steel. Advantages of low carbon steel include, but are not limited to, ease of disposability from an environmental standpoint, as it begins to oxidize quickly after being heated, thereby becoming brittle, and is easily disassembled without dangerous sharp edges. Additionally, metals made of iron and carbon are relatively non-toxic.

[0038] However, alloy metals may contain elements and chemicals that are considered hazardous, such as nickel, chromium, lead, and other metals that are undesirable if released into the environment or potentially inhaled by a user. These elements may provide the structural properties that alloys such as low carbon steel exhibit. However, because it is desired that the susceptor 106 degrade after use, the susceptor 106 of the present application does not require the same structural integrity as used in prior art susceptors. Thus, in a preferred embodiment, the susceptor 106 has poorer structural properties (poor tensile, elastic, ductile, and malleable properties) compared to prior art susceptors made from metal alloys. The susceptor 106 of the present invention may be made of materials that can mechanically disintegrate (fall apart) and chemically degrade (oxidize) quickly if discarded in the environment. A brittle susceptor 106 with less structural integrity is desired, for example, to reduce the risk of harm to animals or humans if accidentally ingested or touched.

[0039] In some embodiments, pure iron powder can be used as an excellent low-cost, readily available ferromagnetic metal. Iron alone has poor structural properties when the particles are fused together, but retains the excellent ferromagnetic properties necessary for induction heating. Without being bound by theory, it is believed that the metal pieces must be fused together across grain boundaries to maximize susceptor performance. Thus, as shown in Figures 4A-4C and 5, the metal pieces 601 can be metal particles, metal shavings, metal powder, fibers, strands, etc., that can be fused together, or any combination thereof.

[0040] In some embodiments, the metal pieces 601 can be compressed in a press to fuse the metal pieces 601 together. In some embodiments, the metal pieces 601 can be fused together with heat. In some embodiments, the metal pieces 601 can be fused together using heat and pressure, for example in a hot press. In some embodiments, the metal pieces 601 can be fused together using a binder, such as copper, paraffin, or other metallurgical binders. Preferably, a sintering process is used to fuse the metal pieces 601 together.

[0041] In some embodiments, direct metal laser sintering (DMLS) can be used. A smooth, flat layer "bed" of ferrous metal powder can be spread on a flat surface. A laser can be used to trace and fill the shape of the desired susceptor on the bed of loose metal powder. The laser cycle fuses exposed particles together without completely liquefying all the powder particles.

[0042] In a preferred embodiment, pure iron powder (i.e., 99.9% laboratory grade pure reduced iron) can be used. Other powder metal types and alloys (mixtures) can also be employed. By way of example only, small pieces of iron, such as iron powder or iron grains, can be turned into small iron balls during DLMS or other sintering processes to enhance induction heating design properties. Each of the iron balls can be fused together to match the shape of the susceptor 106. This shape can be fully engineered by guiding the laser duration, power intensity, and laser beam travel pattern. Preferably, the roughness (i.e., surface texture) of how the iron balls are fused together provides a non-uniform, rough surface area for tobacco to adhere to the susceptor 106. Using powdered tobacco or other agents compressed onto a susceptor 106 with this rough surface area can result in better adhesion. After use (e.g., one heat), the susceptor 106 can break down into small iron balls that decompose (rust) in the environment faster than conventional susceptors.

[0043] Laser speed, energy and frequency can all have varying effects on the surface finish, strength, thickness and speed of the sintering production cycle. Metal particle size (mesh) and shape can also affect the final surface finish and strength of the final susceptor product. Laser speed refers to the linear speed of the beam travel across the surface of the powder bed. Laser energy refers to the optical power the laser can deliver per unit of time.

[0044] The size of the metal particles can range from 1 μm to about 2 mm in any direction. The advantage of laser sintered metal powder is that by using a variety of metal particle sizes, the porosity, density, and dielectric properties of the fused susceptor can be controlled. Another advantage of sintered metal susceptors is that a variety of particle sizes and shapes can be used so that the rate at which the susceptor decomposes in the environment can be controlled.

[0045] By way of example only, the power of the laser can be controlled to make the iron balls larger or smaller based on the intensity of the laser. The speed at which the laser moves across the surface of the small iron balls can be controlled to adjust the strength of the fusion of the bonds between each iron ball. The movement of the laser can be controlled to adjust the shape (width, height, length) of each susceptor 106, and can also create susceptors 106 in specific patterns. For example, the susceptors 106 can be custom designed to create letters or recognizable shapes, patterns, objects, animals, people, etc. Additionally, the shape of the susceptor 106 can be designed in a way that improves the attachment of the aerosol-generating substrate, such as by creating gaps in the susceptor 106 so that the aerosol-generating substrate (e.g., powdered tobacco) can attach to itself from two sides of the susceptor 106 through the gaps.

[0046] The laser sintering process is incredibly fast, resulting in a cheaper manufacturing process for the susceptor 106 than traditional susceptor manufacturing processes while keeping the susceptor 106 free of impurities, thereby avoiding the addition of other detrimental materials / alloys during the manufacturing process. By optimizing the aforementioned factors, a susceptor 106 with the ideal surface finish, strength, and thickness can be created. The susceptor 106 can be smooth to textured. Preferably, the surface is textured to increase the contact area with the aerosol-generating substrate 104.

[0047] The thickness T of the susceptor 106 may be in the range of about 1 μm to about 2 mm. Preferably, the thickness T of the susceptor 106 may be in the range of 100 μm to 1.5 mm. More preferably, the thickness T of the susceptor may be in the range of about 500 μm to 1 mm.

[0048] At the end of the laser sintering cycle, the fused susceptor 106 can be moved away from the bed surrounding the loose green powder, which can be re-flattened for another sintering cycle. In some embodiments, an inert shielding gas such as argon, nitrogen, carbon dioxide, or a gas mixture can be used to reduce oxidation during sintering. An infinite combination of susceptor shapes and patterns can be designed and "drawn" onto the bed of powder by the engraving laser.

[0049] Lasers of infrared (IR) and ultraviolet (UV) wavelengths can sinter metal particles. Lasers with other wavelengths of light can also be used, as can electron beam sintering.

[0050] In some embodiments, plasma spray powders can be used for the sintering process. Plasma spray powders are a process in which metal powders are superheated and sprayed at high pressure through a plasma flame towards the build surface, much like an inkjet printer sprays ink across an air gap onto the surface of a paper. The metal powder can be fed into the path of the plasma flame by a powder feeder. The plasma flame then heats the powder towards the build surface, forming a susceptor.

[0051] Other sintering processes can be used, such as microwave sintering, which can use a waveguide to direct microwave energy into a chamber where the metal particles are rapidly fused together, ultrasonically assisted sintering, direct pressure, electric current assisted sintering, and powder metallurgy, where the powder is pressed without heat to a "green" state and then post-processed in a kiln or oven to fuse the particles together.

[0052] In some embodiments, the susceptor 106 can be machine extruded. Once extruded, the aerosol-generating substrate 104 can be bonded to the susceptor 106 by compressing it around the susceptor 106 along the length of the susceptor 106. Alternatively, the susceptor 106 can be stamped out of flat metal stock or manufactured in any other suitable manner prior to assembling the aerosol-generating substrate 104 around the susceptor 106.

[0053] Preferably, the susceptor 106 is paper-thin. Thus, the thickness T of the planarized susceptor 106 may be less than 0.1 inches (2.54 mm). Preferably, the thickness of the susceptor 106 may be less than 0.05 inches (1.27 mm). More preferably, the thickness of the susceptor 106 may be less than 0.025 inches (0.635 mm), or even less than 0.01 inches (0.254 mm). In some embodiments, the susceptor 106 may be as thin as 0.0039 inches (0.099 mm). The length of the susceptor 106 may range from about 0.5 inches (12.7 mm) to about 1.25 inches (31.75 mm). The length of the susceptor may vary based on the implementation of the device and its intended use in the heating non-combustion device. Thus, references to particles 601 in this application refer to fragments, particles, shavings, powders, granules, fibers, strands, etc. that individually generally have a smaller total volume than the susceptor 106 that is produced when the particles 601 are combined and fused to form the susceptor 106.

[0054] A variety of techniques can be used to obtain the thin, flattened susceptor 106, including sintering techniques. In some embodiments, the susceptor 106 can undergo a series of stretching and compression until the desired thickness T is obtained. This can be accomplished by a stamping process followed by roll compression to obtain the required shape and texture, as well as other suitable methods. Once the desired thickness is obtained, the susceptor 106 can be cut to the desired shape and dimensions.

[0055] In certain embodiments, the use of steel wool in the susceptor and the thinning of the steel wool allows for easier cutting and longer cuts because the blades for cutting the steel wool last longer compared to traditional metal and thicker susceptors currently on the market. Additionally, the use of steel wool is less expensive to manufacture and requires less energy to heat. In some embodiments, it requires approximately one-third less energy to reach the same temperature as other non-steel wool susceptors. In some embodiments, the steel wool material used to make the steel paper may require the addition of lubricants while being scraped into smaller pieces of wool material. As a result, the finished steel wool material may have such lubricants added and may be less pure. Additionally, because steel wool is made by scraping larger steel sheets or bars, some softness may be required to make it easier to scrape the larger steel sheets or bars. Other alloys (such as lead) may be added to the steel sheets or bars to soften the steel, but the addition of other alloys reduces the purity of the steel. Such lubricants, alloys, or other materials used to make such susceptors may not be desirable for heating and / or inhalation.

[0056] In some embodiments, the metal pieces 601 are elongated metal fibers or strands. In this embodiment, the metal pieces 601 can be low grade carbon steel. As shown in Figures 3A-3C, the metal fibers can be woven into a woven sheet called a steel fabric. The steel fabric has a textured surface 604 that optimizes heat transfer and adhesion to the aerosol-generating substrate 104 and creates an increased surface area for removing oxygen between the susceptor 106 and the aerosol-generating substrate 104. The steel fabric can degrade over time, especially after exposure to high aerosolization temperatures. Preferably, the steel fabric is malleable enough to be bent and formed into a fine screen. Because the fibers are malleable enough, alloys can be added to the steel, but this reduces the purity of the susceptor 106.

[0057] By way of example only, a wire mesh loom can be used to make steel fabric. In one example, the warp threads (the long threads that run along the length of the roll) are evenly spread and threaded through two healds. Alternate wires are threaded through the front and back healds. The weft threads run across the width of the roll and are threaded through the warp as the loom is open. Every weft thread can be cut to the same length, wider than the required width of the mesh roll being produced. The distance between the weft wires can be controlled by a weaving reed attached to a reciprocating beam that presses all the weft threads into place. After all the weft wires are positioned, the front and back healds move to either an up or down position depending on where they were previously positioned (up or down). The last weft thread is fixed in place by the crossing of these warp threads.

[0058] This cycle is repeated until a length of woven mesh has been produced. After weaving, the machine then performs a calendering process. In calendering, the mesh is passed through opposing rollers set to create the desired compression from the woven "material". The applied compression forces the strands of mesh to be crushed where the warp and weft threads cross. The wires then change from round wires to an elliptical cross section. This changes the surface area of ​​the mesh, reducing the gaps between the wires without changing the mass. Calendering also creates a more compact and robust "material".

[0059] After calendering, the mesh "stock" is wound onto a rotating beam. The beam is then used to transport the "stock" to the next step, slitting. The beam is then loaded into a slitting machine, which passes the "stock" through a number of precisely positioned rotating blades that cut the mesh "stock" to the exact width required. The slitted material is wound onto drums and packaged.

[0060] Cleaning, drying and packaging steps can be used that prevent the material from decomposing / rusting during transport and storage (rolls can also be wrapped in containers with an oxygen free atmosphere).

[0061] Rolls made to the length of the aerosol-generating substrate (e.g., tobacco portion) minus the thickness of the aerosol-generating substrate can be specified at each end of the susceptor 106 to ensure complete encapsulation of the susceptor 106. Before being fed into the aerosol-producing substrate making machine, the roll of susceptor 106 material is inserted into a "susceptor preparation and testing machine" which unwinds and straightens the mesh "material", cleans the mesh "material" using a number of processes, and finally cuts the material to a specified width precisely and crimps it. Crimping can prevent loss of strands. The cutting can be done by a rotating knife positioned to ensure that it cuts between the weft wires to ensure that the mass and electromagnetic properties of each final susceptor 106 are the same. The final step or preparation can include each individual susceptor 106 being electromagnetically checked by a machine to ensure that the properties are as specified. "Good" susceptors 106 can be placed in a magazine from which the aerosol-producing substrate making machine picks them up.

[0062] Susceptor 106 preparation and testing machines can require output rates of up to 20,000 per minute, so there can be many rolls of susceptor material being unwound and processed in parallel. Initial machines may have lower output and only require one roll at a time, while up to five rolls may be processed in parallel. The most important function of the machines is to ensure a consistent, clean susceptor 106.

[0063] Consistency can be achieved by feeding material according to physical and material specifications. Precision cutting can be achieved by one of several methods, such as rotating self-sharpening knives and anvils, or rotary crimp cutting. Feeding only consistent susceptors 106 can be achieved by rotating electromagnetic coils and associated electronics to verify the characteristics of the susceptor 106 going into the product.

[0064] The susceptor 106 may be delivered according to specifications from the roll manufacturer, including product cleaning requirements and packaging specifications. The susceptor 106 must be free of bacteria and organic matter before being introduced into the aerosol-generating substrate portion, which may be accomplished by a combination of "washing" the unwind roll, inductive heating of the roll before unwinding, and / or use of known cleaning processes / techniques on the unwind roll or elsewhere in the process.

[0065] The metals used in the material manufacturing process may be different or the same, and the same or different wire diameters and shapes. The product can be calendered to different degrees by varying the settings / pressures applied.

[0066] The steel wool and steel fabric embodiments may have the disadvantage of being too loose and not having sufficient magnetic properties, which makes the heating process inefficient. To overcome these disadvantages, the steel wool or steel fabric susceptors can be integrally fused into a single, integral, fused metal sheet, for example, using a hot press to apply high temperature and pressure. In some embodiments, the metal pieces 601 can be fused together without first interweaving or entangling (as is the case with steel fabric or steel wool), forming what is called metal paper. The fused metal sheet has good magnetic properties and heats up faster than if it were loosely interwoven or entangled. However, in another embodiment, loose steel wool may be used for the appropriate application and induction power.

[0067] In any of the fused metal susceptor embodiments described herein, when the fused metal sheet is exposed to high temperatures, it may lose its cohesiveness and become degradable (or non-fusible). Also, exposure to water after heating the fused metal sheet may cause the metal sheet to corrode or degrade more quickly back into metal pieces 601. Additionally, heated metal may oxidize more quickly after heating, causing it to degrade even faster.

[0068] A surprising difference between the use of sintered susceptors and the use of steel fabric is how quickly and easily the steel susceptors 106 made by the sintering process tend to break down after heating. In one example, before use (i.e., heating), the susceptor 106 was a single, integral piece that could be held between ground tobacco and compressed at high pressure. However, after use (heating), the susceptor 106 crumbled into small pieces of sand-like, granular, or powdered material. Also, the iron grains could be rubbed between the fingers and had no sharp edges.

[0069] To improve the uniformity, efficiency, and consistency of the conduction of the susceptor 106, the manufacturing process should be capable of producing susceptors 106 with substantially the same properties (e.g., substantially the same density) over and over again. For example, steel fabric has a constant density due to the weave pattern. Steel wool can achieve a constant density through its compression and stretching stages. Loose metal pieces can be made to a constant density using a magnetic drum. The magnetic drum can pick up the magnetic metal pieces 601 and discard the non-magnetic metal pieces. After the magnetic metal pieces 601 are collected, they can be put through a press to a uniform density. At the same time, the pressed metal pieces can be exposed to heat for the fusion process. In some embodiments, heat can be applied after pressing.

[0070] As the susceptors 106 are formed, they may be exposed to a magnetic field and the electromagnetic induction properties of the susceptors 106 may be measured. Depending on the measured electromagnetic induction properties, a given susceptor 106 may pass or fail when the susceptor 106 leaves manufacturing. If a given susceptor 106 is rejected, the raw materials may be adjusted during the manufacturing process, i.e., while the susceptor is being manufactured and leaving manufacturing, to produce a susceptor 106 with magnetic properties that fall within the desired specifications. In other words, the magnetic properties of the susceptor may be measured and adjusted simultaneously.

[0071] The electromagnetic induction properties of the susceptor 106 include, but are not limited to, the magnetic permeability and bulk resistivity of the material that comprises the susceptor. Without being bound by theory, it is believed that the susceptor 106 of the present application has improved electromagnetic induction properties over prior art susceptors because there are two mechanisms that contribute to induction heating: (1) magnetic hysteresis and (2) eddy current heating. Magnetic hysteresis requires the use of a metal with high magnetic permeability, such as high purity iron. Eddy current heating relies on the susceptor material having high bulk resistivity. By using a composition made from crushed iron metal, the bulk resistivity of the susceptor is significantly increased, thereby further increasing the heating effect due to eddy currents. Some improvements of the susceptor 106 of the present application include, but are not limited to, the use of high purity iron with high magnetic permeability, the construction of the susceptor from smaller pieces 601 (i.e., shards, particles, powdered iron, etc.), and the fragmented surface structure of the susceptor that further contributes to the bulk resistivity of the susceptor.

[0072] The above description of the preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the present invention be limited not by this detailed description, but by the claims appended hereto and the equivalents of the claims.

[0073] Industrial Applicability The present invention has industrial application in the development, manufacture, and use of susceptors, which may be implemented in heated non-combustion devices, including other similar devices that use inductive heating to aerosolize pharmaceuticals for inhalation, to improve the quality, manufacturing process, and / or disposal of the susceptors.

Claims

1. A susceptor comprising a plurality of metal pieces integrally combined as an integrated piece, wherein the integrated piece is decomposable after use.

2. The susceptor according to claim 1, wherein the metal piece comprises a carbon steel thread.

3. The susceptor according to claim 2, wherein the integrated piece has a woven pattern.

4. The susceptor according to claim 1, wherein the metal piece is a steel piece.

5. The susceptor according to claim 4, wherein the steel piece is a metal particle.

6. The susceptor according to claim 5, wherein the steel pieces are integrally fused.

7. The susceptor according to claim 1, wherein the metal piece contains iron powder.

8. The susceptor according to claim 1, wherein the integrated piece is configured to decompose when heated.

9. A method for manufacturing a susceptor, comprising: a) collecting a plurality of metal pieces; b) combining the collected metal pieces into an integrated piece, thereby producing the susceptor, and the produced susceptor is configured to decompose when exposed to an aerosolization temperature. A method including the above steps.

10. The method according to claim 9, further comprising the step of flattening the integrated piece into a flat sheet with a press.

11. The method according to claim 9, wherein the metal piece is a carbon steel thread.

12. The step of combining the metal pieces into the integrated piece according to claim 11 includes integrally weaving the carbon steel threads.

13. The step of flattening the integrated piece according to claim 12 further includes exposing the integrated piece to heat to integrally fuse the metal pieces into the flat sheet.

14. The method according to claim 9, wherein the metal pieces are collected by a magnetic drum.

15. Combining the metal pieces into an integrated flat sheet according to claim 14 includes integrally fusing the metal pieces with pressure and heat.

16. After manufacturing the susceptor, the susceptor is exposed to a magnetic field to test its magnetic properties, according to claim 15.

17. The method according to claim 16 further includes the step of adjusting the amount of the metal pieces flattened by a press based on the magnetic properties.

18. The method according to claim 9 further includes the step of integrally fusing the metal pieces. The method according to claim 18, wherein the step of integrally fusing the metal pieces is performed by sintering. The method according to claim 19, wherein the metal pieces are sintered using a method selected from the group consisting of microwave sintering, ultrasonic assisted sintering, direct pressure sintering, current assisted sintering, electron beam sintering, and powder metallurgy sintering.

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