Aerosol Generation

Abstract

To provide a method of generating an aerosol and an aerosol generating system.SOLUTION: An aerosol generating system includes: (i) an aerosol generating article comprising an aerosol generating material, the aerosol generating material comprising nicotine and an aerosol generating agent; and (ii) an aerosol generating device comprising an induction heater, where (i) a mean particle or a droplet size in the generated aerosol is less than about 1,000 nm in an aerosol generated under an airflow of at least 1.50 L / m during a two-second period, and / or (ii) where aerosol density generated during a two-second period under an airflow of at least 1.50 L / m during the period, is at least 0.1 μg / cc.SELECTED DRAWING: Figure 9

Description

[Technical field]

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

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by the creation of 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. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Overview

[0003] A first aspect of the present invention provides an aerosol generation system comprising: (i) an aerosol product article comprising an aerosol-generating material comprising nicotine and an aerosol generating agent; and (ii) an aerosol generation device comprising an inductive 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 by use of the inductive heater, and wherein the average particle or droplet size of the generated aerosol is less than approximately 1000 nm for the aerosol generated under an air flow of at least 1.50 L / m for 2 seconds.

[0004] A second aspect of the invention provides a method of generating an aerosol from an aerosol-generating material comprising nicotine and an aerosol-generating agent, the method comprising the step of heating the aerosol-generating material to at least 150°C by use of an induction heater, wherein the mean particle or droplet size of the generated aerosol is less than approximately 1000 nm for aerosol generated under an air flow of at least 1.50 L / m for 2 seconds.

[0005] A further aspect of the invention provides an aerosol wherein the aerosol generated has a mean particle or droplet size of less than approximately 1000 nm, the aerosol being obtainable or obtainable by inductive heating of an aerosol-generating material to at least 150° C. under an air flow of at least 1.50 L / m for 2 seconds.

[0006] A fourth aspect of the present invention provides an aerosol generation system comprising: (i) an aerosol product article comprising an aerosol-generating material comprising nicotine and an aerosol generating 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 by use of the induction heater, and wherein the density of the aerosol generated in 2 seconds is at least 0.1 μg / cc under an air flow of at least 1.50 L / m for 2 seconds.

[0007] A fifth aspect of the present invention provides a method of generating an aerosol from an aerosol-generating material comprising nicotine and an aerosol-generating agent, the method comprising the step of heating the aerosol-generating material to at least 150°C by use of an induction heater, wherein the density of the aerosol generated in 2 seconds under an air flow of at least 1.50 L / m is at least 0.1 μg / cc.

[0008] A sixth aspect of the invention provides an aerosol having a density of at least 0.1 μg / cc and 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 in this specification 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 description of the drawings]

[0011] [Figure 1] FIG. 1 is a front view of an example of an aerosol generating device. [Diagram 2] FIG. 2 is a front view of the aerosol generating device of FIG. 1 with the outer cover removed. [Diagram 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. [Diagram 5] 5A is a cross-sectional view of a heating assembly in an aerosol generating device, and FIG. 5B is an enlarged view of a portion of the heating assembly of FIG. 5A. [Figure 6A] FIG. 1 is a cutaway cross-sectional view of an example aerosol product. [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] FIG. 7B shows the tobacco temperature in an aerosol product heated by the programmed aerosol generating device of FIG. 7A. [Figure 8B] FIG. 7C shows the tobacco temperature in the aerosol product heated by the programmed aerosol generating device of FIG. 7B. [Figure 9] FIG. 2 shows the median particle / droplet diameter in an aerosol generated from an aerosol product heated in accordance with one embodiment of the present invention. [Figure 10] FIG. 2 illustrates aerosol density in an aerosol generated from a heated aerosol product article according to one embodiment of the present invention. Detailed Description

[0012] As used herein, the term "aerosol generating material" includes materials that provide volatilization 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 mixture of materials, for example. Aerosol generating materials may also be known as "smoking material" or "aerosolizable material."

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

[0014] The aerosol generating device can receive and heat an article that includes an aerosol generating material. In this context, an "article" is a component that, in use, comprises or contains an aerosol generating material and is heated to volatilize the aerosol generating material and optionally other components during use. A user may insert the article into the aerosol generating device, which may then be heated to generate an aerosol that is subsequently inhaled by the user. 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 therefore higher temperatures to be achieved within a set period of time. Also, the heater is more responsive to commanded changes, allowing for greater control over the heat profile. The heat profile affects the state and composition of the aerosol. If the aerosol particle size is too large or too small, it is believed that mouthfeel and therefore user satisfaction will be adversely affected.

[0016] As mentioned above, a first aspect of the present invention provides a method of generating an aerosol from an aerosol-generating material comprising nicotine and an aerosol-generating agent, the method comprising the step of heating the aerosol-generating material to at least 150°C by use of an induction heater, wherein the mean particle or droplet size of the generated aerosol is less than approximately 1000 nm for aerosol generated under an air flow of at least 1.50 L / m for 2 seconds.

[0017] As defined herein, the term "mean particle or droplet size" refers to the average size of the solid or liquid components of an aerosol (i.e., the components suspended in the gas). When an aerosol includes suspended liquid droplets and suspended solid particles, the term refers to the average size of all components together.

[0018] As mentioned above, a fourth aspect of the present invention provides a method of generating an aerosol from an aerosol-generating material comprising nicotine and an aerosol-generating agent, the method comprising the step of heating the aerosol-generating material to at least 150°C by use of an induction heater, wherein the density of the aerosol generated in 2 seconds under an air flow of at least 1.50 L / m is at least 0.1 μg / cc.

[0019] The following discussion relates to one or both of the first and fourth aspects, to the extent applicable.

[0020] In some cases, the average particle or droplet size of the generated aerosol may be less than about 1000 nm, 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 25 nm, 50 nm, or 100 nm.

[0021] Optionally, the density of the aerosol generated in 2 seconds is at least 0.1 μg / cc. 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 about 2.5 μg / cc, 2.0 μg / cc, 1.5 μg / cc, or 1.0 μg / cc.

[0022] In some cases, the aerosol generated during the 2 seconds period contains at least 10 μg of aerosol generating agent. Suitably, at least 100 μg, 200 μg, 500 μg, or 1 mg of aerosol generating agent is aerosolized from the aerosol generating material under an airflow of at least 1.50 L / m during the period. Suitably, the aerosol generating agent may comprise or consist of glycerol.

[0023] In some cases, at least 10 μg of nicotine, preferably at least 30 μg or 40 μg of nicotine, is aerosolized from the aerosol-generating material in a 2 second period. In some cases, less than about 200 μg of nicotine, preferably less than about 150 μg or less than about 125 μg of nicotine, is aerosolized from the aerosol-generating material in a 2 second period.

[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 a 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 of reconstituted tobacco material. 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, preferably about 260 mg of reconstituted tobacco material. In some other cases, the aerosol-forming material comprises between about 320 mg and about 400 mg, preferably between about 320 mg and about 370 mg, preferably about 340 mg of reconstituted tobacco material.

[0026] Optionally, the aerosol-forming material (which may include tobacco material, preferably reconstituted tobacco material as discussed in the previous paragraph) may have a nicotine content of approximately 5 mg / g to 15 mg / g (on a 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-generating agent (preferably glycerol) content of approximately 130 mg / g to 170 mg / g, preferably approximately 145 mg / g to 155 mg / g (all on a dry weight basis). Optionally, the aerosol-forming material may have a moisture content of approximately 5 to 8 wt% (on a wet weight basis). Optionally, the aerosol-generating material comprises 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 and nicotine of at least 10:1, preferably at least 12:1, 14:1, or 16:1.

[0027] 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. In some cases, 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. In some cases, the air flow may be approximately 1.65 L / m.

[0028] Another aspect of the invention is an aerosol generating system comprising: (i) an aerosol product article comprising an aerosol-generating material comprising nicotine and an aerosol generating agent; and (ii) an aerosol generating device comprising an inductive 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 inductive heater; (i) when the aerosol is generated under an air flow of at least 1.50 L / m for 2 seconds, the mean particle or droplet size of the generated aerosol is less than about 1000 nm; and / or (ii) The density of the aerosol generated in 2 seconds under an airflow of at least 1.50 L / m for 2 seconds is at least 0.1 μg / cc; An aerosol generating system is provided.

[0029] Optionally, 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. Optionally, the aerosol-forming material comprises tobacco. Optionally, the aerosol-forming material is a solid and comprises tobacco.

[0030] In some cases, during operation, the article is inserted into the device and an aerosol is generated by heating the aerosol-generating material to at least 150° C. using an induction heater, and the average density of the aerosol generated from the aerosol-generating material over at least seven two second periods under an air flow of at least 1.50 L / m is 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 over seven two second periods.

[0031] In some cases, during operation, the article is inserted into the device and an aerosol is generated by heating the aerosol-generating material to at least 150° C. using an induction heater, and the average density of the aerosol generated from the aerosol-generating material over at least nine two second periods under an air flow of at least 1.50 L / m is 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 over nine two second periods.

[0032] The heater in the device is an induction heater. The susceptor defines a cylindrical chamber into which the article is inserted in use so that the aerosol-generating material is heated by the susceptor. The length of the cylindrical chamber may be about 40 mm to 60 mm, about 40 mm to 50 mm, about 40 mm to 45 mm, or about 44.5 mm. The diameter of the cylindrical chamber may be about 5.0 mm to 6.5 mm, preferably about 5.35 mm to 6.0 mm, preferably about 5.5 mm to 5.6 mm, preferably about 5.55 mm.

[0033] The aerosol product may include an aerosol-forming material and a wrapping 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 type, including Virginia, and / or Burley, and / or Oriental tobacco.

[0034] The aerosol-generating material may be a rod of aerosol-generating material. The wrapper may comprise a tube disposed around the rod of aerosol-generating material. As used herein, the term "rod" generally refers to an elongated body that may be of any suitable shape for use in an aerosol generating device. Optionally, the rod is substantially cylindrical. The length of the cylindrical body of aerosol-generating material may be between about 34 mm and 50 mm, preferably between about 38 mm and 46 mm, preferably between about 42 mm. The diameter of the cylindrical body of aerosol-generating material is between about 5.0 mm and 6.0 mm, preferably between about 5.25 mm and 5.45 mm, preferably between about 5.35 mm and 5.40 mm, preferably between about 5.39 mm. Optionally, the aerosol-generating material may fill at least about 85% of the void defined by the susceptor.

[0035] The aerosol-forming materials may include one or more of an aerosol-forming agent, a binder, a filler, and a flavoring agent.

[0036] Optionally, the aerosol-forming material may include a tobacco composition as described in WO 2017 / 097840, the contents of which are incorporated herein by reference.

[0037] The aerosol product may further comprise one or more of a filter, a cooling element, and a mouthpiece.

[0038] Optionally, the aerosol-producing article comprises a wrapper at least partially surrounding other components of the article, including one or more of the filter, cooling element, mouthpiece, and aerosol-generating 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 25 g·m -2 ~Approx. 50g·m -2 , 45g·m -2 , 40g·m -2 , or 35 g·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.

[0039] 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 holes 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 provided in portions of the wrapper surrounding one or more of the filter, the cooling element, and the mouthpiece.

[0040] 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. In general, the device 100 may be used to heat a replaceable item 110 that contains an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100.

[0041] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 can be inserted and heated by a 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.

[0042] 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. Although 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."

[0043] Device 100 may also include user-operable controls 112, such as buttons or switches, that, when pressed, cause device 100 to operate. For example, a user may turn device 100 on by operating switch 112.

[0044] Device 100 may also include electrical components, such as a socket / port 114, capable of accepting a cable to charge a battery of 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 adapted to transfer data between device 100 and another device, such as a computing device.

[0045] 2 shows the device 100 of FIG. 1 without the outer cover 102 and without the presence of an article 110. The device 100 defines a longitudinal axis 134.

[0046] 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, a bottom surface of the second end member 116 at least partially defines a 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 a top surface of the device 100.

[0047] The end of the device closest to the opening 104 may be considered known as the proximal end (or mouth end) of the device 100, as it is closest to the user's mouth during use. In use, a user inserts an article 110 into the opening 104 and operates user controls 112 to initiate heating of the aerosol-generating material and utilize the aerosol generated in the device, which causes the aerosol to flow through the device 100 along a flow path toward the proximal end of the device 100.

[0048] The other end of the device furthest from opening 104 will be known as the distal end of device 100, as this is the end that will be furthest 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.

[0049] The device 100 further comprises a power source 118. The power source 118 may be a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power as needed and heat the aerosol-generating material under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

[0050] The device further comprises at least one electronics module 122. The electronics module 122 may comprise, 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 comprise 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.

[0051] In the exemplary device 100, the heating assembly is an induction heating assembly, which includes various components that heat the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may include 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 and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, so that the flow of eddy currents against this resistance heats the susceptor by Joule heating. Also, if the susceptor includes 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. Inductive heating allows for rapid heating as heat is generated inside the susceptor, as compared to, for example, heating by conduction, and furthermore does not require any physical contact between the induction heater and the susceptor, allowing greater freedom of design and application.

[0052] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are constructed from an electrically conductive material. In this example, the first and second inductor coils 124, 126 are constructed from a Litz wire / cable that is helically wound to provide the helical inductor coils 124, 126. The Litz wire comprises a number of individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect losses of electrical conductors. In the exemplary device 100, the first and second inductor coils 124, 126 are constructed from copper Litz wire that is rectangular in cross section. In other examples, the Litz wire can have other cross sections, such as circular.

[0053] 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 a 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.

[0054] Of course, in some examples, the first and second inductor coils 124, 126 may have at least one characteristic different from each other. For example, the first inductor coil 124 may have at least one characteristic different 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 portion of the first inductor coil 124 wound around the susceptor 132 is smaller than the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming that the spacing between the 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.

[0055] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when both inductor coils are activated at different times. For example, the first inductor coil 124 may be activated to heat a first portion of the article 110 first, 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 helps reduce current induced in the non-activated 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, 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.

[0056] The susceptor 132 in this example is hollow, thus defining a receptacle in which the aerosol-generating 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.

[0057] 2 further comprises 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 insulate various components of the device 100 from heat generated in the susceptor 132.

[0058] Additionally, the insulating member 128 can support all or a portion 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 about the insulating member 128 and are in contact with a radially outer surface of the insulating member 128. In some examples, the insulating member 128 is not adjacent to 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.

[0059] 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 .

[0060] 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 visualized.

[0061] The device 100 further includes 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.

[0062] The device may also include a second printed wiring board 138 associated with the control element 112 .

[0063] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward a 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.

[0064] 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 retains adjacent to an article 110 received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0065] FIG. 4 is an exploded view of the device 100 of FIG.

[0066] FIG. 5A shows a cross-section of a portion of the device 100 of FIG. 1. FIG. 5B shows an enlarged region of FIG. 5A. FIGS. 5A and 5B show an article 110 received within a susceptor 132, with the article 110 sized such that its outer surface is adjacent to the inner surface of the susceptor 132, which allows for most efficient heating. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also include other components, such as a filter, a packaging material, and / or a cooling structure.

[0067] FIG. 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.

[0068] 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 are adjacent to and in contact with the insulating member 128.

[0069] In one example, the susceptor 132 has a wall thickness 154 of between about 0.025 mm and 1 mm, or about 0.05 mm.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 6A and 6B, which are cut-away cross-sectional and perspective views of an example aerosol product 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.

[0074] The article 110 in one example 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 comprises 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 toward 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 such that the cooling segment 307 is in a side-by-side 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. The filter segment 309 is disposed between the cooling segment 307 and the mouth end segment 311. The mouth end segment 311 is disposed adjacent the filter segment 309 toward the proximal end 313 of the article 110. In one example, the filter segment 309 is in adjacent relationship with the mouth end segment 311. In one embodiment, the overall length of the filter assembly 305 is between 37 mm and 45 mm. More preferably, the overall length of the filter assembly 305 is 41 mm.

[0075] In one embodiment, the body of aerosol-generating material 303 includes tobacco, although in other embodiments the body of aerosol-generating material 303 may consist entirely of tobacco, consist substantially entirely of tobacco, contain tobacco and aerosol-generating materials other than tobacco, contain aerosol-generating materials other than tobacco, or be tobacco-free. The aerosol-generating material may include an aerosol-generating agent, such as glycerol.

[0076] In one example, the length of the body of aerosol-generating material 303 is between 34 mm and 50 mm, more preferably between 38 mm and 46 mm, and even more preferably 42 mm.

[0077] In one example, the overall length of the article 110 is between 71 mm and 95 mm, more preferably between 79 mm and 87 mm, and even more preferably 83 mm.

[0078] 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.

[0079] The body of aerosol-generating material 303 is attached to the filter assembly 305 by a ring of tipping paper (not shown) disposed substantially entirely around and surrounding the filter assembly 305 and extending partially along the length of the body of aerosol-generating material 303. In one example, the tipping paper is constructed from 58 GSM standard tipping paper. In one example, the length of the tipping paper is between 42 mm and 50 mm, more preferably 46 mm.

[0080] In one example, the cooling segment 307 is an annular tube that is disposed about 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. The cooling segment 307 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 110 during insertion into the device 100. In one example, the wall thickness of the cooling segment 307 is about 0.29 mm.

[0081] 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 element 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 a 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 become damaged during use and may not be able to effectively perform its required function.

[0082] In one example, the length of the cooling segment 307 is at least 15 mm. In one example, the length of the 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, more particularly 25 mm.

[0083] The cooling segment 307 is constructed of paper, meaning that it is constructed of a material that does not generate compounds of concern (e.g., toxic compounds) when adjacent to the heater components of the device 100 in use. In one example, the cooling segment 307 is manufactured 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.

[0084] 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 manufacture and use of article 110 during insertion into device 100.

[0085] For each example of cooling segment 307, the dimensional accuracy of the cooling segment is sufficient to meet the dimensional accuracy requirements of rapid manufacturing processes.

[0086] Filter segment 309 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated and volatilized components from 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 depleting the heated and volatilized components to an insufficient level for the user.

[0087] The density of the cellulose acetate tow material of filter segment 309 controls the pressure drop across filter segment 309, which controls the pull-out resistance of article 110. Thus, 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.

[0088] In one example, the filter segment 309 is constructed of 8Y15 grade filter tow material, which provides filtration against the 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.

[0089] 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 contact of the user's lips with the surface of filter segment 309.

[0090] One or more flavorings 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 flavoring carriers within the cellulose acetate tow of the filter segment 309.

[0091] In one example, the filter segment 309 is between 6 mm and 10 mm in length, more preferably 8 mm in length.

[0092] 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 about 0.29 mm.

[0093] 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.

[0094] 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.

[0095] 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 .

[0096] 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 disposed within the tube to separate the mouth end segment 311 and the cooling segment 307.

[0097] A ventilation region 317 is provided in the article 110 to allow air 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 of holes preferably located around the entire circumference of the article 110 in a cross section substantially perpendicular to the longitudinal axis of the article 110.

[0098] In one example, 1-4 rows of ventilation holes provide ventilation for the article 110. Each row of ventilation holes may have 12-36 ventilation holes 317. The diameter of the ventilation holes 317 may be, for example, 100-500 μm. In one example, the axial separation between the rows of ventilation holes 317 is 0.25 mm-0.75 mm. More preferably, the axial separation between the rows of ventilation holes 317 is 0.5 mm.

[0099] In one example, the ventilation holes 317 are uniformly sized. In another example, the 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 the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed into the article 110. The ventilation holes 317 are positioned to effectively cool the article 110.

[0100] 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 17-20 mm from the proximal end 313 of the article 110. The location of the ventilation holes 317 is such that a user cannot block the ventilation holes 317 when the article 110 is in use.

[0101] By providing a row of ventilation holes 17-20 mm from the proximal end 313 of the item 110, the ventilation holes 317 can be conveniently located on the exterior of the device 100 when the item 110 is fully inserted into the device 100, as seen in Figure 1. Locating the ventilation holes on the exterior of the apparatus allows unheated air to enter the item 110 from outside the device 100 through the ventilation holes to assist in cooling the item 110.

[0102] The length of the cooling segment 307 is such that when the item 110 is fully inserted into the device 100, the cooling segment 307 is partially inserted into the device 100. The length of the cooling segment 307 provides a first function of providing a physical gap between the heater arrangement and the thermal filter arrangement 309 of the device 100, and a second function of allowing the ventilation holes 317 to be located in the cooling segment while being located outside the device 100 when the item 110 is fully inserted into the device 100. As can be seen in FIG. 1, the majority of the cooling element 307 is located within the device 100. However, a portion of the cooling element 307 extends from the device 100. The ventilation holes 317 are located in the portion of the cooling element 307 that extends from the device 100.

[0103] In the illustrated embodiment, the overall length of the article is 83 mm and comprises a 42 mm long cylindrical tobacco rod (5.4 mm diameter) containing approximately 260 mg of aerosol-forming material. The ventilation rate of the article is 75%. It is used in a device having a susceptor that is 44.5 mm long and has an inner diameter of 5.55 mm.

[0104] In another embodiment (not shown), the article has a total length of 75 mm and comprises a 34 mm long cylindrical tobacco rod (diameter 6.7 mm) containing about 340 mg of aerosol-forming material. The ventilation rate of the article may be 60%. It is used in a device having a susceptor that is 36 mm long and has an inner diameter of 7.1 mm. EXAMPLES

[0105] In the examples, the devices shown in the above-mentioned Figs. 1 to 5B and the articles shown in Figs. 6A and 6B were employed.

[0106] The susceptor had a length of 44.5 mm and an inner diameter of 5.55 mm.

[0107] 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 (diameter 5.4 mm) containing approximately 260 mg of reconstituted tobacco material with a nicotine content of 0.8 wt% (± 0.1 wt%) and a glycerol content of 15 wt% (± 2 wt%) calculated on a dry weight basis. The ventilation rate was 75%.

[0108] The device was preprogrammed with two heating profiles, which are shown in Figures 7A and 7B. In each program, the mouth-end coil is heated first and the distal coil is heated second. Figures 8A and 8B show the tobacco temperature in each heating zone for the two preprogrammed heating profiles (for a number of samples (no puffs)).

[0109] In this example, a simulated puff regime was employed, in which the first puff was taken 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., airflow for each puff was 1.65 L / min). The thermal profile shown in FIG. 7A is for a 3 minute session, allowing 7 puffs in this regime (the last puff is taken after the heater has been turned off, but still has enough heat to generate aerosol). The thermal profile shown in FIG. 7B is for a 4 minute session, allowing 9 puffs in this regime (again, the last puff is taken after the heater has been turned off) (the lower maximum temperature in the profile in FIG. 7B reduces aerosol generation early in the session, allowing for longer sessions).

[0110] The median particle size was measured for each puff from the five aerosol product formulations, and the average values ​​are shown in Figure 9.

[0111] Particle densities were measured for each puff from the five aerosol products, and the average values ​​are shown in FIG.

[0112] (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 facilitating 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 point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristates including ethyl myristate and isopropyl myristate, 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.

[0113] As used herein, the terms "flavour" and "flavourant" refer to materials that can be used, where local regulations permit, to produce a desired flavour 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), flavour enhancers, bitter 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 include natural or Nature Identical flavours. They may be in any suitable form, for example, oil, liquid, powder, or gel.

[0114] 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 organic and inorganic filler materials.

[0115] As used herein, the term "binder" may refer to alginates, cellulose or modified celluloses, starches or modified starches, or natural gums. Suitable binders include, but are not limited to, alginates with any suitable cation, cellulose or modified celluloses such as hydroxypropyl cellulose and carboxymethyl cellulose, starches or modified starches, polysaccharides such as pectates with any suitable cation, such as sodium, potassium, calcium, or magnesium pectate, xanthan gum, guar gum, and any other suitable natural gums, 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.

[0116] As used herein, the term "tobacco material" refers to any material that contains 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.

[0117] 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 particulates), expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. Reconstituted tobacco material may include tobacco fiber and may be formed by molding (a long-line paper machine-based papermaking die process with the post-addition of tobacco extract) or extrusion.

[0118] All weight percentages (expressed as wt%) referred to herein are calculated on a dry weight basis 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 other than water, and may include ingredients that are themselves liquids at room temperature and pressure, such as glycerol. In contrast, weight percentages quoted on a wet weight basis represent all ingredients, including water.

[0119] For the avoidance of doubt, where the term "comprises" is used in this specification to define an invention or a feature of the invention, it also discloses embodiments in which the invention or feature can be defined using the term "consists essentially of" or "consists of" instead of "comprises."

[0120] The above-described embodiments are to be understood as illustrative examples of the invention. Other embodiments of the invention are also 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. Moreover, equivalents and modifications not described above can be employed without departing from the scope of the invention as defined in the appended claims.

Claims

1. 1. An aerosol generating system comprising: (i) an aerosol product article comprising an aerosol generating material including nicotine and an aerosol generating agent; and (ii) an aerosol generating device comprising an inductive heater, 1. An aerosol generating system, wherein in operation, the 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 the density of the aerosol generated in the 2 seconds is at least 0.1 μg / cc under an air flow of at least 1.50 L / m for the 2 seconds.

2. 10. The aerosol generating system of claim 1, wherein the aerosol generating material is solid and comprises tobacco.

3. 3. The aerosol generating system of claim 1 or 2, wherein the density of the generated aerosol is less than approximately 2.5 μg / cc.

4. 4. An aerosol generating system according to any one of claims 1 to 3, wherein in operation, an aerosol is generated by using the induction heater to heat the aerosol generating material to at least 150°C, and the average density of the aerosol generated for at least seven 2 second periods under an air flow of at least 1.50 L / m is at least approximately 0.6 μg / cc, preferably at least 0.8 μg / cc.

5. 5. An aerosol generating system according to any one of claims 1 to 4, wherein in operation, an aerosol is generated by using the inductive heater to heat the aerosol generating material to at least 150°C, and the average density of the aerosol generated for at least nine 2 second periods under an air flow of at least 1.50 L / m is at least approximately 0.4 μg / cc, preferably at least 0.6 μg / cc.

6. 1. A method for generating an aerosol from an aerosol-generating material comprising nicotine and an aerosol-generating agent, the method comprising the step of heating the aerosol-generating material to at least 150°C by use of an induction heater, wherein the density of the aerosol generated in 2 seconds under an air flow of at least 1.50 L / m is at least 0.1 μg / cc.

7. 7. The method of claim 6, wherein the density of the aerosol generated during the 2 second period is at least about less than 0.3 μg / cc.

8. 8. The method of claim 6 or 7, wherein the density of the aerosol generated during the 2 second period is less than approximately 2.5 μg / cc, preferably less than approximately 1.5 μg / cc.

9. The method of any one of claims 6 to 8, wherein the aerosol-forming material is a solid and comprises tobacco.

10. 10. The method according to any one of claims 6 to 9, wherein the aerosol generated during the 2 seconds period comprises at least 10 μg of an aerosol generating agent, which may suitably comprise glycerol.

11. 11. The method of any one of claims 6 to 10, wherein the aerosol generated during the 2 seconds period contains at least 10 μg of nicotine.

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