Capsules containing susceptor particles and carriers

Abstract

The present invention relates to a capsule for use in an aerosol-generating article, the capsule comprising an active agent, susceptor particles configured to be heatable upon induction heating, and one or both of a carrier gel or a carrier liquid, the susceptor particles being dispersed in the carrier gel or the carrier liquid, and the susceptor particles having a particle size of about 10 to 70 μm.

Description

Technical Field

[0001] The present invention relates to capsules used in aerosol-generating articles. The present invention further relates to aerosol-generating articles comprising capsules. The present invention also provides an aerosol-generating system comprising an aerosol-generating article, and a method of operating the aerosol-generating system.

Background Art

[0002] Aerosol-generating devices are known that heat but do not burn an aerosol-forming substrate in an aerosol-generating article such as tobacco. Such devices heat the aerosol-forming substrate to a temperature sufficient to generate an aerosol for inhalation by a user. These aerosol-generating devices typically include a region for receiving the aerosol-forming substrate. These devices are typically portable, hand-held devices and are required to be compact.

[0003] Aerosol-forming articles typically contain an aerosol-forming substrate that includes an aerosol-forming body and a further substrate material such as tobacco, which contains volatile compounds for the formation of an aerosol. Some aerosol-forming articles also include capsules containing additional components. These additional components may be unstable components that may decompose or evaporate before use when not contained in a capsule. These capsules are typically broken by the user before use, which is time-consuming and has an adverse effect on the user experience. Furthermore, breaking the capsule by bending the aerosol-generating article may deform the aerosol-generating article and may also have an adverse effect on the air management inside the article. Other aerosol-generating devices include complex mechanisms for breaking the capsule and often require additional actions by the user.

Summary of the Invention

Problems to be Solved by the Invention

[0004] It would be desirable to provide a capsule that can be broken with little or no additional user action, except for the user inserting the aerosol-forming article into the aerosol-generating device. It would be desirable to provide a capsule that can release additional components without the need to apply additional force beyond that required to insert the aerosol-forming article into the aerosol-generating device.

Means for Solving the Problems

[0005] According to one embodiment of the present invention, a capsule for use in an aerosol-generating article is provided. The capsule may contain an active agent. The capsule may contain susceptor particles. Further, the capsule may contain one or both of a carrier gel and a carrier liquid, and the susceptor particles are dispersed in one or both of the carrier gel and the carrier liquid. Therefore, the capsule may contain both a carrier gel and a carrier liquid. The capsule may contain only the carrier gel, or the capsule may contain only the carrier liquid.

[0006] According to another embodiment of the present invention, a capsule for use in an aerosol-generating article is provided. The capsule contains an active agent. Further, the capsule contains susceptor particles. The capsule also contains one or both of a carrier gel and a carrier liquid. The susceptor particles are dispersed in one or both of the carrier gel and the carrier liquid. Thus, the capsule contains both a carrier gel and a carrier liquid. The capsule may also contain only the carrier gel, or the capsule may contain only the carrier liquid.

[0007] The capsule may be received within an aerosol generating device. The aerosol generating device may include a heating element, specifically an inductive heating element such as an induction coil. With the inductive heating of the capsule received within the aerosol generating device, the susceptor particles may be heated by the alternating magnetic field of the inductive heating element. This may also heat the capsule. Heating of the capsule may at least partially liquefy any carrier gel present within the capsule. Heating may also at least partially assist in the decomposition of the capsule. Heating may also decrease the viscosity of the carrier liquid. With heating, the susceptor particles may become mobile when the carrier particles are dispersed within the carrier gel. Movement of the susceptor particles dispersed within the carrier liquid may also increase with heating. The susceptor particles, which are also magnetic, may agglomerate within the alternating magnetic field of the inductive heating element. The susceptor particles may form clusters that align along the orientation of the magnetic field. The formation of the clusters and agglomeration may be due to the magneto-viscous effect of the magnetic susceptor particles within the alternating magnetic field. This may primarily form channels in which the liquefied carrier gel or carrier liquid is present together with the active agent. This magneto-viscous effect may align the susceptor particles along the lines of magnetic flux when an alternating magnetic field is applied. The susceptor particles may form a network of interconnected agglomerations and clusters. The formation of the clusters and agglomeration of the susceptor particles may facilitate the formation of an aerosol containing at least the active agent. The combination of heating of the capsule due to inductive heating and the formation of agglomeration and clusters due to the magneto-viscous effect may enhance the release of the active agent from the capsule. This may enable the release of the active agent from the capsule without the need to apply any pressure (specifically mechanical pressure) to the capsule.

[0008] Generally, susceptor particles comprise, or are made of, a material having the ability to generate heat when penetrated by an alternating magnetic field. When located within the alternating magnetic field, if the susceptor particles are conductive, eddy currents are typically induced by the alternating magnetic field. If the susceptor particles are magnetic, another effect that typically contributes to heating is generally referred to as hysteresis loss. Hysteresis loss is mainly caused by the movement of magnetic domain blocks within the susceptor particles. This is because these magnetic orientations align with the alternating magnetic induction field. Another effect contributing to hysteresis loss is when the magnetic domains expand or contract within the susceptor particles. Generally, all of these changes occurring at the nanoscale and below within the susceptor particles generate heat within the susceptor particles and are thus called "hysteresis loss". Therefore, if the susceptor is both magnetic and conductive, both hysteresis loss and the generation of eddy currents will contribute to heating the susceptor particles. If the susceptor particles are magnetic but not conductive, hysteresis loss will be the only means of heating the susceptor when penetrated by an alternating magnetic field. According to the present invention, the susceptor particles may be magnetic and conductive. The alternating magnetic field generated by one or several induction coils heats the susceptor particles, which then transfers heat to one or both of the other components of the capsule, the carrier gel or the carrier liquid, and the active agent. This may facilitate the formation of an aerosol. Heat transfer may mainly be by conduction of heat.

[0009] One or both of the carrier gel or the carrier liquid is at least one polyhydric alcohol, and at least one ester of the polyhydric alcohol, and It may contain one or more of at least one aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid. These compounds may function as carriers for the dispersion of susceptor particles. These compounds may also function as aerosol formers. With the heating of the capsule, the compounds of the carrier gel or carrier liquid may facilitate the formation of a high-density, stable aerosol that may be substantially resistant to thermal decomposition at the temperature at which the capsule is heated.

[0010] The carrier gel or carrier liquid may contain a polyhydric alcohol (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), an ester of a polyhydric alcohol (such as glycerol monoacetate, diacetate, or triacetate, etc.), and an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). Particularly preferred compounds may be a polyhydric alcohol or a mixture thereof (such as triethylene glycol, 1,3-butanediol, glycerin, etc.). The carrier gel or carrier liquid may contain propylene glycol. The aerosol former may contain both glycerin and propylene glycol. Preferably, the carrier gel or carrier liquid may contain glycerol.

[0011] At least one polyhydric alcohol, at least one ester of a polyhydric alcohol, and at least one aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid may be present in an amount of 30 weight percent to 75 weight percent of the capsule, more preferably 48 weight percent to 65 weight percent. These weight percent ranges may be particularly suitable for these compounds to function as a carrier gel or carrier liquid for the dispersion of susceptor particles.

[0012] Unless otherwise stated, the term "weight percent" of a component of the capsule is the ratio of the mass of this component to the total mass of all components of the capsule.

[0013] The active agent may be dissolved or dispersed in the carrier gel or carrier liquid. This may facilitate the release of the active agent upon heating of the capsule. One or more active agents may be uniformly dispersed in the carrier gel or carrier liquid within the capsule. This may significantly enhance the stability of the capsule. Upon application of an electric field to the capsule, only the formation of any kind of aggregation or clusters may occur.

[0014] The carrier gel may contain a gelling agent. The gelling agent may facilitate the gelation of the carrier liquid to produce the carrier gel of the capsule. Therefore, the carrier gel may contain the carrier liquid and the gelling agent. The gelling agent may be one or both of a polysaccharide or a protein. The gelling agent may contain one or more of natural gums, starch, pectin, alginate, carrageenan, agar, gelatin. The gelling agent may be present in an amount of 4 to 8 weight percent of the capsule, preferably in an amount of 5 to 7 weight percent.

[0015] The susceptor particles may be ferromagnetic. Ferromagnetic susceptor particles may aggregate particularly easily and form clusters in a magnetic field. Ferromagnetic susceptor particles may exhibit a strong magnetorheological effect within a magnetic field. This may significantly enhance the formation of clusters and aggregation of the susceptor particles. This may also enhance the formation of aerosol upon heating of the capsule. The ferromagnetic susceptor particles may contain or consist of a metal or a metal oxide. The ferromagnetic susceptor particles may contain one or more of iron, cobalt, nickel, or their oxides. Preferably, the susceptor particles may contain or consist of Fe2O3.

[0016] The susceptor particles may have a particle size of about 10 to 70 micrometers, preferably about 20 micrometers to 50 micrometers. These particle sizes may enable the formation of clusters or aggregation within a magnetic field when the capsule is being heated.

[0017] The susceptor particles may be present in an amount of 5 to 45 weight percent of the capsule, preferably in an amount of 15 to 35 weight percent. These weight percent ranges may allow the susceptor particles to be distributed in either the gel carrier or the liquid carrier. These weight percent ranges may also allow for the aggregation of susceptor particles and the formation of clusters within the capsule upon heating of the susceptor particles in an alternating magnetic field.

[0018] The capsule may further contain fibers. The fibers may be present in an amount of 0.5 weight percent to 17 weight percent of the capsule, more preferably in an amount of 0.75 weight percent to 11 weight percent. The fibers may stabilize the overall shape of the capsule. The fibers may contain one or both of cellulose and cellulose derivatives.

[0019] The capsule may contain one or more active agents. Using two or more active agents may lead to the formation of an aerosol containing multiple active agents. One or more active agents may be prone to reacting with atmospheric components such as oxygen. One or more active agents may be highly volatile and may diffuse without the use of containment. Containing these highly sensitive active agents in the capsule may prevent any degradation of the active agents before the capsule is used.

[0020] One or more active agents may contain one or more of a flavoring agent, nicotine, and a drug. For example, one or more active agents may contain a flavoring oil. One or more active agents may contain one or more of mint oil, menthol, nicotine oil, coffee derivative flavoring agents, caffeine, guarana, taurine, glucuronolactone, or other flavoring agents. The active agent may be present in an amount of 0.5 weight percent to 3 weight percent of the capsule, more preferably in an amount of 0.75 weight percent to 3 weight percent. The capsule may be used to carry a pharmaceutically active ingredient to the user as an active agent.

[0021] The capsule may further contain a C3-C6 alkylhydroxycarboxylic acid, preferably lactic acid. The C3-C6 alkylhydroxycarboxylic acid may increase the solubility of some components of the active agent (specifically nicotine) in one or both of the carrier gel and the carrier liquid. The C3-C6 alkylhydroxycarboxylic acid may protonate nicotine and thereby increase its solubility.

[0022] The capsule may comprise a shell. The shell may encapsulate one or both of the active agent, the susceptor particles, and the carrier gel or the carrier liquid. The shell may contain a material that becomes permeable to fluids upon heating. This may enable the release of the active agent and the gel carrier or the liquid carrier from the capsule. The shell may contain a polysaccharide, specifically cellulose. The shell may contain a solid polymer material that encapsulates one or both of the active agent and the gel carrier or the liquid carrier containing the distributed susceptor particles.

[0023] The capsule may comprise a shell containing a flexible gelatin film plasticized by the addition of glycerin, sorbitol, or a similar polyol. These capsules are also known as "soft gel capsules".

[0024] Preferably, the capsule may contain a carrier gel. When the capsule contains a carrier gel, the carrier gel may be sufficiently solidified to provide a self-supporting capsule. In this case, the capsule may not need to include an extra shell to encapsulate the carrier gel or the carrier liquid together with the active agent and the susceptor particles. The self-supporting carrier gel may be formed by adding a larger amount of gelling agent to the carrier liquid. This may be done by adding 6-8% by weight of the gelling agent of the capsule to the carrier liquid to induce gelation of the carrier liquid.

[0025] One or more frangible capsules may have a burst strength of from about 0.5 kilograms by weight to about 3.0 kilograms by weight, preferably from about 1.3 to about 2.7 kilograms by weight, and most preferably from about 1.9 to about 2.5 kilograms by weight.

[0026] The capsule may contain a carrier liquid, and the carrier liquid and the susceptor particles may form a magnetorheological fluid. The susceptor particles of the magnetorheological fluid may form clusters and agglomerate particularly easily with the heating of the capsule when an alternating magnetic field is applied.

[0027] Another embodiment of the present invention may provide an aerosol generating article comprising a capsule as described herein. The aerosol generating article may comprise a capsule portion containing the capsule. The capsule portion may contain one or more capsules as described herein. For example, the capsule portion may contain two capsules, three capsules, or at least four capsules. The capsule portion may contain a holding material, and the capsule may be located adjacent to the holding material or embedded within the holding material. A hollow tubular portion may be present within the capsule portion. The hollow tubular portion may contain a holding material. The hollow tubular portion in the capsule portion may surround the capsule. The holding material may absorb an active agent and one or both of a gel carrier and a liquid carrier as the capsule is released. This may prevent any leakage of components of the capsule outside the aerosol generating article.

[0028] The holding material may contain a fibrous material. The holding material may contain one or more of cellulose acetate fibers, paper, a porous polymer, and charcoal. The cellulose acetate fibers may be cellulose acetate tow. The porous polymer may be a porous resin such as a phenyl-formaldehyde resin. Preferably, the holding material may contain cellulose acetate.

[0029] The capsule portion of the aerosol-generating article may include a first filter element that may be located upstream of the capsule. The capsule portion may also include a second filter element that may be located downstream of the capsule.

[0030] As used herein, the terms "upstream" and "downstream" are used to describe the relative positions of components or parts of components of an aerosol-generating article or aerosol-generating device with respect to the direction in which air flows along an airflow path through the aerosol-generating article or aerosol-generating device during its use. An aerosol-generating article according to the present invention has a proximal end through which an aerosol exits the device during use. The proximal end of the aerosol-generating article may also be referred to as the mouth-side end or the downstream end. The mouth-side end is downstream of the distal end. The mouth-side end may include a mouthpiece. The distal end of the aerosol-generating article may also be referred to as the upstream end. Components or parts of components of the aerosol-generating article may be described as being upstream or downstream of each other relative to the airflow path through the aerosol-generating article based on these relative positions.

[0031] The first filter element and the second filter element may include the same material as the holding material described above. The first filter element and the second filter element may prevent any leakage of the active agent and the gel carrier or liquid carrier to the upstream or downstream portion of the aerosol-generating article.

[0032] The first filter element may include a non-porous material. This non-porous material may be a low-density closed-cell foam, such as a set foam of a low-density and low-compressibility silicon compound. The low-density closed-cell foam may have a density of 97 to 192 kg / m 3 as determined by ASTM-D-3574. The first filter element may also include a porous material. The porous material may include cellulose acetate tow. The porous material may also include a polymer made from natural and sustainable raw materials based on acetol made from wood pulp, for example, commercially available under the brand name CERDIA (registered trademark).

[0033] The second filter element may also include cellulose acetate tow.

[0034] In a further embodiment of the present invention, the capsule portion of the aerosol-generating article may be wrapped with a capsule wrapper, and the capsule wrapper includes a breathable material. This may allow air to pass through the capsule wrapper and reach the capsule portion of the aerosol-generating article. This may further facilitate the formation of an aerosol containing the active agent of the capsule.

[0035] The aerosol-generating article may have a central longitudinal axis. The aerosol-generating article may also have a transverse axis extending perpendicular to the central longitudinal axis. The capsule wrapper containing the breathable material may increase the airflow into the capsule portion along the transverse axis.

[0036] The capsule wrapper containing the breathable material may exhibit a basis weight of 9 g / m 2 ~28 g / m 2 , preferably 11 g / m 2 ~25 g / m 2 , more preferably 12 g / m 2 ~24 g / m 2 . The capsule wrapper may have a thickness of 0.01 to 0.07 millimeters. The capsule wrapper may exhibit a wet bursting strength of at least 350 millimeters of water column. The capsule wrapper may have an air permeability of 80 cm 3 / cm 2 ·s to 170 cm 3 / cm 2 ·s, preferably 90 cm 3 / cm 2 ·s to 160 cm 3 / cm 2·s may exhibit air permeability. The tensile strength in the longitudinal direction (MD) may be at least 0.052 kn / m. The tensile strength in the width direction (CM) of the capsule wrapper may be at least 0.012 kn / m. The filtration rate of particle retention of the capsule wrapper may be 5S / 8 layers or less. Specifically, the capsule wrapper may include a material generally called "tea bag paper" that is used for manufacturing tea bags. The breathable capsule wrapper may include filter paper.

[0037] The aerosol generating article may include only the capsule portion as described above as the only part of the aerosol generating article that contains the aerosol forming material for aerosol formation. Specifically, the aerosol generating article may include only the capsule portion that includes the holding material and one or more capsules as described above. The aerosol generating article may further include the additional first filter element and the second filter element contained in the capsule portion as described above. This aerosol generating article may also include the capsule wrapper as described above. One or more active agents of one or more capsules may also include one or both of nicotine and other flavoring agents for forming an aerosol.

[0038] The aerosol generating article that includes only the capsule portion may have a diameter of 4 to 12 millimeters, preferably 5 to 9 millimeters. The length of the aerosol generating article may be 8 millimeters to 27 millimeters, preferably 10 millimeters to 19 millimeters. This length may include the length of the holding material having one or more capsules including the first filter element and the second filter element. The thickness of both the first filter element and the second filter element may be 3 to 7 millimeters, preferably 4 to 5 millimeters. The length of only the portion of the aerosol generating article that contains the holding material forming the hollow tubular portion may be 7 to 19 millimeters, preferably 8 to 13 millimeters.

[0039] The aerosol-generating article may additionally comprise a substrate part. The substrate part may comprise an aerosol-forming substrate. Thus, the aerosol-generating article may, as described above, comprise a capsule part and may additionally comprise a substrate part.

[0040] In one embodiment of the aerosol-generating article, the capsule part may be adjacent to the substrate part. This may facilitate the formation of aerosol-containing constituents from both the substrate part and the capsule part.

[0041] The aerosol-forming substrate of the substrate part may comprise a plug of the formed aerosol-forming substrate. The plug may be a press-formed or molded substrate part containing the aerosol-forming substrate, or a pre-packaged substrate part comprising a wrapper such as paper wrapped around the aerosol-forming substrate. The aerosol-forming substrate may also comprise a gel. The aerosol-forming substrate may comprise a non-volatile carrier material together with one or both of a volatile aerosol-forming agent capable of forming part of the aerosol and one or more active agents. Examples of the non-volatile carrier material may be paper or cotton. The aerosol-forming substrate is a substrate having the ability to release a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may comprise homogenized tobacco. Alternatively, the aerosol-forming substrate may comprise a non-tobacco-containing material. The aerosol-forming substrate may comprise a homogenized plant-derived material.

[0042] The aerosol-forming substrate may comprise at least one aerosol-forming agent. The aerosol-forming agent is any suitable well-known compound or mixture of compounds that facilitates the formation of a high-density stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the system. Suitable aerosol-forming agents are well known in the art and include polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate, etc.), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.), but are not limited thereto. The aerosol-forming agent may be a polyhydric alcohol or a mixture thereof (such as triethylene glycol, 1,3-butanediol, glycerin, etc.). The aerosol-forming agent may be propylene glycol. The aerosol-forming agent may comprise both glycerin and propylene glycol.

[0043] The capsule portion may be located downstream of the substrate portion within the aerosol-generating article. The capsule portion may be located adjacent to the substrate portion within the aerosol-generating article. This may facilitate incorporating any active agent released upon heating of the capsule into the aerosol formed from the aerosol-forming substrate of the substrate portion. The active agent in the capsule may in particular comprise a flavorant in order to change the flavor and the user's perception when inhaling the aerosol.

[0044] The aerosol-generating article may be shaped as a rod. Such rod-shaped articles may be easily received by the cavity of the aerosol-generating device. One or both of the capsule portion and the substrate portion of the aerosol-generating article may be shaped as a rod. Preferably, both the capsule portion and the substrate portion are shaped as a rod.

[0045] One or more active agents contained in one or more easily breakable capsules may be solid or may be liquid. The one or more active agents may include a gel. The one or more active agents may be volatile. Containing a volatile active agent in one or more easily breakable capsules may ensure that the volatile active agent does not evaporate before the aerosol generating article is used.

[0046] Alternatively, the aerosol generating article may include an aerosol forming substrate and one or more capsules embedded in the aerosol forming substrate. Thus, the aerosol forming article may include one combined substrate / capsule portion. When the aerosol forming substrate is heated, one or more active agents of the capsules may be released. The one or more active agents may then form an aerosol together with the components of the aerosol forming substrate.

[0047] The aerosol generating article may comprise a hollow tubular article portion. The hollow tubular article portion may have a tubular empty core structure. The hollow tubular article portion may be, for example, a hollow acetate tube (HAT), a fine hollow acetate tube (FHAT), or a plug of tow wound around a central cardboard tube, or a tube formed from cardboard, all of these structures being known from the manufacture of filter elements. The hollow tubular article portion may be located downstream of the capsule portion of the aerosol generating article. The hollow tubular article portion may function to cool the aerosol generated from the substrate portion and the capsule portion of the aerosol generating article.

[0048] If desired or required, for example to achieve a sufficiently high draw resistance of the aerosol generating article, an additional filter portion may be included in the aerosol generating article. Preferably, such an additional filter portion may be included downstream of the substrate portion and the capsule portion. If the hollow tubular article portion is also included in the aerosol generating article, the filter portion may be located downstream of the hollow tubular article portion. Such an additional filter portion preferably includes a filtering material such as cellulose acetate.

[0049] The present invention also provides an aerosol generation system which may include an aerosol generator that may include a cavity and a heating element. The aerosol generation system may also include an aerosol generation article as described herein. The heating element of the aerosol generator may include an induction heating element configured to generate an alternating magnetic field.

[0050] There is also provided an aerosol generation system comprising an aerosol generator including a cavity and a heating element. The aerosol generation system also includes an aerosol generation article as described herein. The cavity of the aerosol generator is configured to receive the aerosol generation article. The heating element of the aerosol generator includes an induction heating element configured to generate an alternating magnetic field.

[0051] One or more active agents contained in one or more capsules located within the capsule portion of the aerosol generation article may be released when heating the aerosol generation article received within the cavity of the aerosol generator. With the heating of the aerosol generation article using the heating element, the aerosol may be formed from an aerosol forming substrate and one or more active agents.

[0052] The heating element may be an induction heating element. For induction heating, the heating element preferably includes an induction coil. An alternating current may be supplied to the induction coil to generate an alternating magnetic field. The alternating current may have a high frequency. As used herein, the term "high-frequency oscillating current" means an oscillating current having a frequency in the range of 500 kilohertz to 30 megahertz. The high-frequency oscillating current may have a frequency of about 1 megahertz to about 30 megahertz, preferably has a frequency of about 1 megahertz to about 10 megahertz, and more preferably has a frequency of about 5 megahertz to about 8 megahertz.

[0053] The heating element may be configured to heat the aerosol generation article to a temperature in the range of 220 degrees Celsius to 400 degrees Celsius, preferably 250 degrees Celsius to 290 degrees Celsius.

[0054] The cavity of the aerosol generating device may be configured as a heating chamber. The cavity may have a cylindrical shape. The cavity may have a hollow cylindrical shape. The cavity may have a shape corresponding to the shape of the aerosol generating article received therein. The cavity may have a circular cross-section. The cavity may have an elliptical or rectangular cross-section. The cavity may have an inner diameter corresponding to the outer diameter of the aerosol generating article.

[0055] The air flow channel may extend through the cavity. Ambient air may be drawn through the air flow channel into the aerosol generating device, into the cavity, and towards the user. Downstream of the cavity, a mouthpiece may be provided, or the user may directly inhale the aerosol generating article. The air flow channel may extend through the mouthpiece.

[0056] As used herein in connection with the present invention, the term "smoking" does not refer to conventional smoking in which the aerosol-forming substrate is completely or at least partially burned. The aerosol generating device of the present invention is arranged to heat the aerosol-forming substrate to a temperature below the combustion temperature of the aerosol-forming substrate but above the temperature at which one or more volatile compounds of the aerosol-forming substrate are released to form an inhalable aerosol.

[0057] The aerosol generating device may comprise an electrical circuit. The electrical circuit may comprise a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of a controller. The electrical circuit may comprise further electronic components. The electrical circuit may be configured to regulate the supply of power to the heating element, specifically to the induction coil. The power may be continuously supplied to the heating element following activation of the aerosol generating device, or may be supplied intermittently (e.g., for each puff). The power may be supplied to the heating element in the form of current pulses. The electrical circuit may be configured to monitor the electrical resistance of the heating element and preferably may be configured to control the supply of power to the heating element in response to the electrical resistance of the heating element.

[0058] The aerosol generating device may comprise a power source (typically a battery) within the main body of the aerosol generating device. The power source may be configured to operate at the above frequencies. This may provide an alternating current for generating an alternating magnetic field. In one embodiment, the power source is a lithium-ion battery. Alternatively, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery (e.g., a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery). As an alternative, the power source may be another form of charge storage device such as a capacitor. The power source may require recharging and may have a capacity that allows sufficient energy storage for one or more usage experiences. For example, the power source may have a capacity sufficient to continuously generate aerosol for about 6 minutes, or a multiple of 6 minutes. In another example, the power source may have a capacity sufficient to provide a predetermined number of puffs, or discontinuous activation of the heating element.

[0059] One or both of the power source and the electrical circuit may be configured to provide an alternating current to the inductive heating element. The alternating current induces an alternating magnetic field in the susceptor particles, leading to heating of the susceptor particles. The alternating magnetic field may also induce a magnetorheological effect in the susceptor particles. This may lead to aggregation and cluster formation, which may facilitate the release of one or more active agents from the capsule.

[0060] Alternatively, in order to heat the susceptor particles, it may also be possible to first apply an alternating current to the inductive heating element. This may liquefy any carrier gel present in the capsule. Furthermore, the viscosity of the carrier liquid present in the capsule may also be reduced with heating. In a second step, a direct current may be applied to the inductive heating element so as to apply a constant magnetic field to the capsule. Such a constant magnetic field may increase the magnetorheological effect and thus the clustering and formation of aggregates in the capsule.

[0061] One embodiment of the present invention may also provide a method of operating an aerosol generation system, where the system is as described herein. The method may include - a method step of receiving an aerosol generating article in a cavity of an aerosol generator; - a method step of heating the aerosol generating article by an inductive heating element, thereby releasing one or more active agents from the capsule.

[0062] The method may employ an aerosol generating article, which may comprise a substrate section as described above, separate from the capsule section described herein. Heating the aerosol generating article by the inductive heating element may then lead to the formation of an aerosol comprising components of the aerosol-forming substrate from the substrate portion and one or more active agents from the capsule portion of the aerosol generating article.

[0063] The following provides a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more of the features of any other example, embodiment, or aspect described herein.

[0064] Example A: A capsule for use in an aerosol-generating article, an active agent, susceptor particles, and one or both of a carrier gel or a carrier liquid, wherein the susceptor particles are dispersed in one or both of the carrier gel or the carrier liquid. Example B: The capsule according to Example A, wherein one or both of the carrier gel or the carrier liquid contains at least one polyhydric alcohol, at least one ester of the polyhydric alcohol, and at least one aliphatic ester of a monocarboxylic acid, a dicarboxylic acid, or a polycarboxylic acid. Example C: The capsule according to any one of Examples A to B, comprising a carrier gel, wherein the carrier gel contains a gelling agent. Example D: The capsule according to any one of Examples A to C, wherein the susceptor particles are ferromagnetic. Example E: The capsule according to any one of Examples A to D, wherein the susceptor particles contain a metal or a metal oxide. Example F: The capsule according to any one of Examples A to E, wherein the susceptor particles have a particle size of about 10 μm to 70 μm. Example G: The capsule according to any one of Examples A to F, wherein the susceptor particles are present in an amount of 5 to 45 weight percent. Example H: The capsule according to any one of Examples A to G, further comprising a fiber. Example I: The capsule according to any one of Examples A to H, further comprising a C3 - C6 alkyl hydroxycarboxylic acid. Example J: The capsule according to any one of Examples A to I, wherein the active agent contains one or more of a flavoring agent, nicotine, and a drug. Example K: A capsule according to any of Examples A - J, including a shell that encapsulates one or both of an activator, susceptor particles, and a carrier gel or carrier liquid. Example L: A capsule according to any of Examples A - K, including a carrier liquid, wherein the carrier liquid and the susceptor particles form a magnetorheological fluid. Example M: An aerosol generating article comprising a capsule according to any of Examples A - L. Example N: An aerosol generating article according to Example M, comprising a capsule portion containing a holding material, wherein the capsule is located adjacent to the holding material within the capsule portion. Example O: An aerosol generating article according to Example N, wherein the holding material includes a filter material. Example P: An aerosol generating article according to any of Examples M - O, wherein the capsule portion comprises a first filter element located upstream of the capsule and a second filter element located downstream of the capsule. Example Q: An aerosol generating article according to any of Examples M - P, wherein the capsule portion is wrapped with a capsule wrapper, and the capsule wrapper includes a breathable material. Example R: An aerosol generating article according to any of Examples M - Q, further comprising an aerosol - forming substrate. Example S: An aerosol generating system, - an aerosol generating article according to any of Examples M - R, and - an aerosol generating device, comprising a cavity (configured to receive the aerosol generating article) and an induction heating element. Example T: A method of operating the aerosol generating system according to Example S, comprising: - a method step of receiving the aerosol generating article into the cavity of the aerosol generating device, and - a method step of heating the aerosol generating article with the induction heating element, thereby releasing the activator from the capsule.

[0065] The features described with respect to one embodiment may equally apply to other embodiments of the present invention.

[0066] By way of illustration only, the present invention will be further described with reference to the following accompanying drawings.

Brief Description of the Drawings

[0067]

Fig. 1A

Fig. 1B

Fig. 2A

Fig. 2B

Fig. 3

Embodiments for Carrying Out the Invention

[0068] In the following, all the same elements are denoted by the same reference numerals throughout all the figures.

[0069] FIG. 1A depicts a partial cross-sectional view of capsule 10. Shell 16 encloses gel carrier or liquid carrier 14, and susceptor particles 12 are dispersed in the gel carrier or liquid carrier. In the absence of a magnetic field, the susceptor particles are uniformly dispersed in the gel carrier or liquid carrier. One or more active agents (not shown in the figure) are dissolved in either the gel carrier or the liquid carrier.

[0070] Figure 1A shows a partial cross-sectional view of capsule 10 shown in Figure 1A after an alternating magnetic field 20 has been applied to the capsule. The magnetic field lines 20 lead to the formation of clusters 12A of susceptor particles 12 along the magnetic field lines 20 in either the liquefied gel carrier or the liquid carrier. Additionally, the shell of the capsule 10 becomes permeable to the fluid after heating of the susceptor particles in the alternating magnetic field, as indicated by the shell fracture region 16A. Channels are formed between the clusters of susceptor particles, which also facilitates the release of one or more active agents dissolved in the liquid or gel carrier. Therefore, applying an alternating magnetic field to the capsule on the one hand leads to heating of the susceptor particles due to the induction of eddy currents or hysteresis losses, and on the other hand enables the formation of clusters or agglomerations of susceptor particles. Both effects significantly facilitate the release of one or more active agents from the capsule without the need to apply any mechanical pressure to break the capsule.

[0071] Figure 2A depicts an exploded assembly view of capsule portion 28. Capsule 10 is shown embedded within the hollow tubular portion 22 of the holding material. The holding material is intended to absorb any liquid carrier material or any liquefied gel carrier material released from the capsule upon heating of the capsule, as well as any active agents. A first filter element 24 is present upstream of the hollow tubular portion 22, and a second filter element 26 is present downstream. These filter elements also absorb any liquefied gel carrier or liquid carrier and active agents.

[0072] Figure 2B shows the assembled elements of capsule portion 28 including capsule 10 surrounded by the hollow tubular portion 22 of the holding material, as shown in Figure 2A. The complete capsule portion is preferably wrapped in a capsule wrapper 30 made of a breathable material. Such a capsule portion 28 may be the only part of the aerosol generating article that includes the capsule. Alternatively, additional parts such as a substrate portion including an aerosol-forming substrate may be present in the aerosol generating article.

[0073] Figure 3 depicts different airflow paths through the capsule portion 28. Air can penetrate through the capsule portion 28 from the upstream, indicated by reference numeral 34, and also exit the capsule portion 28 downstream of the capsule portion (indicated by reference numeral 32). When the capsule wrapper includes a breathable material, additional lateral airflows 36, 38 are possible, which facilitate the formation of at least an aerosol containing the active agent of the capsule.

Claims

1. An aerosol generating article comprising a capsule for use in an aerosol generating article, wherein the capsule comprises an active agent, susceptor particles configured to be heatable upon inductive heating, one or both of a carrier gel or a carrier liquid, wherein the susceptor particles are dispersed in the one or both of the carrier gel or the carrier liquid, and the susceptor particles have a particle size of about 10 to 70 μm, the aerosol generating article further comprises a capsule portion containing the capsule, the capsule portion comprises a first filter element located upstream of the capsule and a second filter element located downstream of the capsule, and the first filter element and the second filter element are configured to avoid any leakage of the active agent and the carrier gel or the carrier liquid to the upstream or downstream portion of the aerosol generating article, An aerosol generating article.

2. one or both of the carrier gel or the carrier liquid comprises at least one polyhydric alcohol, at least one ester of the polyhydric alcohol, at least one aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid, and the aerosol generating article according to claim 1.

3. comprising a carrier gel, wherein the carrier gel comprises a gelling agent, the aerosol generating article according to any one of claims 1 to 2.

4. the susceptor particles are ferromagnetic, the aerosol generating article according to any one of claims 1 to 3.

5. the susceptor particles are present in an amount of 5 to 45 weight percent, the aerosol generating article according to any one of claims 1 to 4.

6. An aerosol generating article according to any one of claims 1 to 5, further comprising fibers.

7. An aerosol generating article according to any one of claims 1 to 6, wherein the active agent comprises one or more of a flavoring agent, nicotine, and a drug.

8. An aerosol generating article according to any one of claims 1 to 7, comprising a carrier liquid, wherein the carrier liquid and the susceptor particles form a magnetorheological fluid.

9. An aerosol generating article according to claim 1, wherein the capsule portion contains a holding material, and the capsule is located adjacent to the holding material within the capsule portion.

10. An aerosol generating article according to claim 9, wherein the capsule portion is wrapped with a capsule wrapper, and the capsule wrapper comprises a breathable material.

11. An aerosol generating system, comprising: - an aerosol generating article according to any one of claims 9 to 10; and - an aerosol generating device comprising a cavity (configured to receive the aerosol generating article) and an induction heating element.

12. A method of operating the aerosol generating system according to claim 11, comprising: - a method step of receiving the aerosol generating article into the cavity of the aerosol generating device; and - a method step of heating the aerosol generating article by the induction heating element, thereby releasing the active agent from the capsule.

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