Hybrid aerosol generator

Abstract

An aerosol generation system is provided comprising an aerosol generation device (100) for simultaneously generating an aerosol from a first aerosol-forming substrate (205) and from a second aerosol-forming substrate (124). The aerosol generation device (100) comprises a device housing (101) defining a first substrate receiving portion (106a) for receiving the first aerosol-forming substrate (205) and a second substrate receiving portion (120) for receiving the second aerosol-forming substrate (124). The device housing (101) also defines a primary airflow path extending through the first substrate receiving portion (106a) and a secondary airflow path extending through the device (100), whereby in use the secondary airflow path is in fluid communication with the second aerosol-forming substrate (124) received in the second substrate receiving portion (120). The secondary airflow pathway merges with the primary airflow pathway at a junction downstream of the first substrate receiving portion.

Description

Technical Field

[0001] The present disclosure relates to an aerosol generating device for simultaneously generating an aerosol from a first aerosol-forming substrate and an aerosol from a second aerosol-forming substrate. The present disclosure also relates to an aerosol generating system comprising the aerosol generating device.

Background Art

[0002] Aerosol generating devices configured to generate an aerosol from an aerosol-forming substrate, such as a tobacco-containing substrate, are known in the art. Such well-known devices may generate an aerosol from the substrate by applying heat to the substrate rather than by combustion of the substrate. The aerosol-forming substrate may be present as a component of an aerosol-generating article, in which case the aerosol-generating article is physically separated from the aerosol generating device. In use, the aerosol generating device may be received by the aerosol-generating article. The device may provide power to enable transfer of heat from a heat source to the aerosol-forming substrate of the aerosol-generating article. During use of such well-known aerosol generating devices and aerosol-generating articles, volatile compounds are released from the aerosol-forming substrate by heat transfer from the heat source and entrained in the air drawn through the aerosol-generating article. The released compounds condense as they cool to form an aerosol, which is inhaled by the consumer.

[0003] Some well-known aerosol generators are configured to generate aerosols from two aerosol-forming substrates simultaneously. Typically, such aerosol generators are configured to accept a first solid aerosol-forming substrate and a second liquid aerosol-forming substrate. The first aerosol-forming substrate may be contained in an aerosol-forming article comprising a rod containing a plug of solid tobacco-containing substrate at the distal end of the rod, or toward the distal end of the rod, and the article is receptacleable within the housing of the aerosol generator. The second aerosol-forming substrate may be contained in a separate container or cartridge, also receptacleable within the housing of the aerosol generator. Such aerosol generators are sometimes called hybrid aerosol generators.

[0004] During the use of a well-known hybrid aerosol generator, volatile compounds are typically released from both the first and second aerosol-forming substrates as a result of heat transfer from one or more heat sources to the first and second aerosol-forming substrates. A single airflow path is defined through the aerosol generator and the aerosol-generating article, so that the single airflow path passes over the second aerosol-forming substrate and then over the first aerosol-forming substrate. Volatile compounds from the second aerosol-forming substrate are entrained into the air within the airflow path, and therefore must also pass through the first aerosol-forming substrate, thereby entraining volatile compounds from the first aerosol-forming substrate into the airflow path as well. As the compounds released from the first and second aerosol-forming substrates cool, they condense to form aerosols, which are inhaled by consumers.

[0005] The hybrid aerosol generator has the advantage of allowing the user to obtain not only the flavor or smoking experience of a first or second heated aerosol-forming substrate, but also a combination of the two. Different combinations of the first and second aerosol-forming substrates can be selected by the user to achieve a desired inhalation experience, for example, to modify the flavor of the inhaled aerosol. [Overview of the project] [Problems that the invention aims to solve]

[0006] Well-known hybrid systems have numerous problems resulting from volatile compounds from the second aerosol-forming substrate being drawn through the first aerosol-forming substrate during use. It is crucial that the emitted first and second aerosols mix with each other before being inhaled by the consumer. However, in the prior art, airflow control does not facilitate an optimized mixing of the two aerosols. The blend of the two aerosols may not be uniform during inhalation, or may vary from one inhalation to the next.

[0007] Furthermore, when the volatile compounds of the second aerosol-forming substrate pass through the first aerosol-forming substrate, they pass through a high-temperature region, which can degrade the flavor of the second aerosol, for example, by causing thermal decomposition. This is a problem specific to when the aerosolization temperature of the first aerosol-forming substrate is higher than that of the second aerosol-forming substrate.

[0008] Furthermore, since the airflow path in a well-known hybrid system passes through a first aerosol-forming substrate, the draw resistance largely depends on the porosity of the first aerosol-forming substrate. This can mean that the draw resistance may be unacceptably or unpleasantly high for the user.

[0009] It is desirable to provide an aerosol generator for simultaneously generating an aerosol from a first aerosol-forming substrate and an aerosol from a second aerosol-forming substrate, wherein the blend or mixture of the two aerosols is optimized and uniform between uses, the deterioration of the flavor of the second aerosol is minimized, and the extraction resistance is low. [Means for solving the problem]

[0010] According to a first aspect of the present disclosure, an aerosol generator is provided for simultaneously generating an aerosol from a first aerosol-forming substrate and an aerosol from a second aerosol-forming substrate. The aerosol generator may include a device housing. The device housing may define a first substrate receiving portion for receiving the first aerosol-forming substrate. The device housing may define a second substrate receiving portion for receiving the second aerosol-forming substrate. The device housing may define a primary airflow path. The primary airflow path may extend through the first substrate receiving portion. The device housing may also define a secondary airflow path. The secondary airflow path may extend through the device, so that during use the secondary airflow path is in fluid communication with the second aerosol-forming substrate received in the second substrate receiving portion. The secondary airflow path may merge with the primary airflow path at a junction downstream of the first substrate receiving portion. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 illustrates a perspective view of the aerosol generator according to this disclosure. [Figure 2] Figure 2 shows a schematic cross-sectional view of the aerosol generator shown in Figure 1. In Figure 2, the aerosol generating article and cartridge are housed within the aerosol generator, and together the aerosol generator, aerosol generating article, and cartridge form an aerosol generating system. [Figure 3] Figure 3 shows a perspective view of the cavity of the aerosol generator shown in Figures 1 and 2, separate from the rest of the device. [Figure 4] Figure 4 shows a perspective view of the aerosol-generating object shown in Figure 2. [Figures 5a-5c] Figures 5a, 5b, and 5c illustrate three different side elevation views of the aerosol-generating article shown in Figure 4. [Figure 6] Figure 6 shows a schematic cross-sectional view of a second embodiment of the aerosol generator according to the present disclosure, in which the aerosol generating article and cartridge are housed inside the aerosol generator. [Figure 7] Figure 7 shows a schematic cross-sectional view of a third embodiment of the aerosol generator according to the present disclosure, in which the aerosol generating article and cartridge are housed inside the aerosol generator. [Modes for carrying out the invention]

[0012] During use, the first aerosol-forming substrate may be received in the first receiving portion, and the second aerosol-forming substrate may be received in the second substrate receiving portion, and the device may generate volatile compounds from both the first and second aerosol-forming substrates. The user may draw air through the primary airflow path downstream of the junction between the primary and secondary airflow paths (i.e., after these airflow paths merge), thereby drawing air through both the primary and secondary airflow paths. The primary airflow path may be configured so that the primary airflow path passes through the first aerosol-forming substrate when the first aerosol-forming substrate is received in the first substrate receiving portion. Therefore, volatile compounds released from the first aerosol-forming substrate may be entrained in the air drawn through the primary airflow path. The secondary airflow path is preferably in fluid communication with the second aerosol-forming substrate received in the second substrate receiving portion, so that volatile compounds released from the second aerosol-forming substrate may be carried along with the air drawn through the secondary airflow path. The volatile compounds from the second aerosol-forming substrate may merge with the volatile compounds from the first aerosol-forming substrate at the junction between the primary and secondary airflow paths. The volatile compounds may cool and form an aerosol, which is then inhaled by the user. The volatile compounds from the first and second aerosol-forming substrates may cool and form an aerosol before or after the junction.

[0013] Since the secondary airflow path merges with the primary airflow path at the junction downstream of the first substrate receiving portion, volatile compounds released from the secondary aerosol-forming substrate are advantageously not drawn through the primary aerosol-forming substrate. This allows for improved uniformity of the mixture between the aerosols emitted from the primary and secondary aerosol-forming substrates. The blend of the two aerosols may be advantageously uniform between fume extractions or between uses. Furthermore, this arrangement may advantageously avoid any degradation of volatile compounds in the second aerosol-forming substrate, which would otherwise occur if those volatile compounds passed through the heated first substrate receiving portion. This advantageously reduces or eliminates the risk of thermal decomposition of volatile compounds released from the second aerosol-forming substrate, and may be particularly advantageous when the aerosolization temperature of the first aerosol-forming substrate received in the first substrate receiving portion is higher than the aerosolization temperature of the second aerosol-forming substrate.

[0014] By providing a primary and a secondary airflow path (in which case only the primary airflow path passes through the first substrate receiving portion), the draw resistance experienced by the user drawing air through the airflow path does not depend solely on the porosity of the first aerosol-forming substrate received in the first substrate receiving portion. Specifically, a lower overall draw resistance can be achieved by providing a low-resistance secondary airflow path (i.e., a lower resistance compared to the draw resistance of the primary airflow path). The balance of aerosols emitted from the first and second aerosol-forming substrates, inhaled by the user, may be determined by the selection of the draw resistance of the secondary airflow path compared to the primary airflow path.

[0015] The secondary airflow path is preferably separated from the primary airflow path upstream of the junction. The two airflow paths may also be separated by the device housing upstream of the junction. This separation of the airflow paths ensures that volatile compounds released from the received second aerosol-forming substrate do not pass through the received first aerosol-forming substrate during use.

[0016] The first substrate receiving portion may be configured to receive a portion of an aerosol generating article containing a first aerosol-forming substrate. The aerosol generating article may be in the form of a rod, with the first aerosol-forming substrate at or toward the distal end of the rod. The rod may also be provided with a mouthpiece at the end opposite to the distal end of the rod. The user of the device may inhale through the mouthpiece. When the aerosol generating article is received in the first substrate receiving portion, the primary airflow path may extend through the length of the rod, through the first aerosol-forming substrate and the mouthpiece.

[0017] The second substrate receiving portion may be configured to receive a second aerosol-forming substrate, which is preferably a liquid. The second substrate receiving portion may be configured to receive a removable container or cartridge (hereinafter referred to as a cartridge). The cartridge may or may form a liquid storage portion containing the second aerosol-forming substrate. The removable cartridge may be advantageously replaceable when the aerosol-forming substrate is depleted or when it is desirable to select a cartridge containing a different second aerosol-forming substrate to achieve a different inhalation experience. Alternatively, the second substrate receiving portion may itself form a liquid storage portion integrated with the rest of the aerosol generator. In any case, the secondary airflow path may preferably be configured to fluidly communicate with the second aerosol-forming substrate in the removable or integrated liquid storage portion.

[0018] The aerosol-generating article may include a fluid-permeable region downstream of the first aerosol-forming substrate. The secondary airflow path may be configured to extend through the fluid-permeable region of the aerosol-generating article when the article is received within the first substrate receiving portion. The secondary airflow path may then merge with the primary airflow path.

[0019] As used herein, the term "aerosol generating device" is used to describe a device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol. The aerosol generating device preferably is a hybrid smoking device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol that is directly inhalable into a user's lungs through the user's mouth, while at the same time interacting with a second (preferably liquid) aerosol-forming substrate contained by or received within a second substrate receiving portion.

[0020] The aerosol-generating article preferably is a smoking article that generates an aerosol that is directly inhalable into a user's lungs through the user's mouth. More preferably, the aerosol-generating article is a smoking article that generates a nicotine-containing aerosol that is directly inhalable into a user's lungs through the user's mouth.

[0021] As used herein, the term "aerosol-forming substrate" means a substrate that consists of or contains an aerosol-forming material having the ability to release a volatile compound upon heating to generate an aerosol.

[0022] As used herein, the term "aerosol-forming material" refers to a material having the ability to release a volatile compound upon heating to generate an aerosol. The aerosol-forming substrate can comprise or be constituted by the aerosol-forming material.

[0023] As used herein, the terms "upstream" and "downstream" are used to describe the relative position of an element or portion of an element of an aerosol generating device or aerosol-generating article with respect to the direction in which a user draws on the aerosol-generating article or device during its use.

[0024] The device housing may define a cavity wall that defines a cavity. At least a portion of the cavity may form a first substrate receiving portion.

[0025] As used herein, “substrate receiving portion” means a portion of the apparatus housing configured to receive an aerosol-forming substrate. When the first aerosol-forming substrate is contained distal to or toward the distal of an aerosol-generating article, the first substrate receiving portion is the portion of the housing that immediately surrounds the first substrate when the article is received. Any portion of the cavity that does not surround the first substrate when the article is received within the cavity, such as a portion surrounding a feature of the article downstream of the substrate, does not form part of the first substrate receiving portion.

[0026] The cavity wall may, advantageously, have a shape corresponding to the shape of the aerosol-generating article that the constructed cavity wall receives. Conveniently, the cavity wall may be tubular. This may be particularly suitable when the device is intended to be used with an aerosol-generating article that defines a rod shape, and the cavity has a tubular shape corresponding to the geometric contour of such a rod. For example, if the aerosol-generating article is a smoking article, the use of a rod-shaped geometric shape for the article corresponds to the geometric shapes found in well-known smoking articles such as conventional cigarettes and e-cigarettes. The cavity wall may also be cylindrical.

[0027] As used herein, the term "rod" is used to mean a generally cylindrical element having a substantially circular, oval, or elliptical cross-section.

[0028] The cavity wall may have a fluid-permeable region. A secondary airflow path may extend through the fluid-permeable region. The secondary airflow path may merge with the primary airflow path within the cavity. Preferably, the fluid-permeable region of the cavity wall may be downstream of the first substrate receiving portion. This is advantageous as it ensures that air entering the cavity via the secondary airflow path enters the cavity downstream of the first receiving portion and downstream of the first aerosol-forming substrate received within the first receiving portion. Preferably, the fluid-permeable region is provided immediately downstream of the first substrate receiving portion. This ensures maximum mixing of the first emitted aerosol and the second emitted aerosol before inhalation by the user. However, the fluid-permeable region may be axially separated from the first substrate receiving portion, provided that the separation is sufficiently low. The separation between the fluid-permeable region and the first substrate receiving portion may be less than 5 millimeters, preferably less than 2 millimeters.

[0029] The fluid-permeable portion of the cavity wall may comprise one or more of a porous material, multiple slits, or multiple holes. For example, and without limitation, the fluid-permeable portion of the cavity wall may be provided as a mesh having gaps in the mesh that define openings within the mesh, thereby providing permeability to air flowing through the mesh and volatile compounds entrained in that air. Alternatively, the fluid-permeable portion may be an opening provided in the cavity wall without any mesh or other limitations. In a further alternative, the fluid-permeable portion of the cavity wall may comprise multiple pores, in which the multiple pores define a cavity within the wall material. The size of any pores, slits, or holes that may form part of the fluid-permeable portion of the cavity wall directly affects the permeability of the fluid-permeable portion to fluid flow.

[0030] When an aerosol-generating article containing a first aerosol-forming substrate is received in a cavity, it is preferable that the fluid-permeable region of the cavity wall coincides with the corresponding fluid-permeable portion of the outer wall of the aerosol-generating article. Coinciding the fluid-permeable portion of the cavity wall of the aerosol generator with the outer wall of the aerosol-generating article allows for efficient guidance of airflow from the secondary airflow path of the device into the interior of the aerosol-generating article.

[0031] As used herein, the term “fluid permeability” is used in relation to entities that allow gases or liquids to pass through. Specifically, fluid permeability is used to refer to entities that allow air containing entrained volatile compounds, which may form aerosols, to pass through. The term “fluid permeability” also encompasses the volume properties of suitable materials, such as materials having porosity in all or part of their volume.

[0032] As used herein, the term “match” is used to mean exactly or partially overlapping.

[0033] The cavity wall is preferably tubular. The fluid-permeable portion of the cavity wall may comprise at least one annular fluid-permeable band. Providing one or more fluid-permeable portions of the cavity wall as annular bands allows for radial guidance of air in the secondary airflow path, encompassing volatile compounds from the second aerosol-forming substrate, into the cavity around the periphery of the tubular cavity wall. During use, this may advantageously promote uniform mixing of volatile compounds from the accepted second aerosol-forming substrate, encompassed in the air from the secondary airflow path, and volatile compounds from the accepted first aerosol-forming substrate, encompassed in the air from the primary airflow path. This may advantageously improve the mixing of volatile compounds from the first and second aerosol-forming substrates. This may have the effect of improving the uniformity of the inhaled aerosol during use of the device or between separated periods of use.

[0034] When the device is used with an aerosol-generating article received in a cavity, and the aerosol-generating article has an outer wall having a corresponding fluid-permeable portion provided as an annular band, the matching alignment of the annular band of the device with the annular band of the article may provide a uniform radial inflow of air into the interior of the aerosol-generating article around the periphery of the outer wall of the article.

[0035] The cavity may be provided with an open end and a closed end. The aerosol generator may be configured to receive an aerosol generating article comprising a first aerosol-forming substrate through the open end of the tubular cavity. The cavity may be configured to receive the first aerosol-forming substrate in the longitudinal direction through the open end.

[0036] The primary airflow path may extend through the cavity in a direction substantially parallel to the longitudinal axis. When the aerosol-generating article is received in the first substrate receiving portion, the primary airflow path may pass through the aerosol-forming article in a direction parallel to the longitudinal axis.

[0037] The secondary airflow path may be substantially perpendicular to the longitudinal axis where it merges with the primary airflow path. This may be advantageous in use, as it may improve the mixing of volatile compounds from the first and second aerosol-forming substrates where the primary and secondary airflow paths merge. Mixing may be optimized when the secondary airflow path merges with the primary airflow path so that the airflow paths are perpendicular to each other.

[0038] Conveniently, the aerosol generator may be an electric device. The aerosol generator may include a first heating means configured to heat a first aerosol-forming substrate, which is received in a first substrate receiving portion, when in use. The first heating means may heat the first aerosol-forming substrate by induction heating, resistance heating, or both. The device may include a power source for supplying power to the first heating means. The power source may preferably be a battery, thereby providing the device with the advantage of portability. The battery may preferably be a rechargeable battery.

[0039] In some embodiments, the first heating means may be configured to heat the first substrate receiving portion, thereby transferring heat to the received first aerosol-forming substrate.

[0040] In one embodiment of the induction heating version of the first heating means, the first heating means may include an inductor coil adjacent to or surrounding the first substrate receiving portion. At least a portion of the first substrate receiving portion may include a susceptor portion. The susceptor portion may be configured to be heatable by an alternating magnetic field. During use, power supplied to the inductor coil (e.g., by the power supply of the device as described above) causes the inductor coil to induce eddy currents within the susceptor portion. These eddy currents then cause the susceptor portion of the first substrate receiving portion to generate heat. Power is supplied to the inductor coil as an alternating magnetic field. The alternating current may have any suitable frequency. The alternating current may preferably be a high-frequency alternating current. The alternating current may have a frequency of 100 kilohertz (kHz) to 30 megahertz (MHz). When an aerosol-generating article is received within a first substrate receiving portion, heat generated by the susceptor portion may be transferred to the article, heating the first aerosol-forming substrate within the article to a temperature sufficient to cause aerosols to be emitted from the substrate. The susceptor portion is formed of a material having the ability to absorb electromagnetic energy and convert it into heat. For example, and without limitation, the susceptor portion may be formed of a ferromagnetic material such as steel.

[0041] Preferably, the first substrate receiving portion forms at least a part of the cavity wall as described above, and the inductor coil is a helical coil surrounding the first substrate receiving portion which includes the susceptor portion. Preferably, the inductor coil may surround the susceptor portion radially outward. Positioning the inductor coil radially outward from the susceptor portion prevents damage to the inductor coil from contact with aerosol-generating articles during insertion of articles into the cavity.

[0042] In a variation of the induction heating version of the first heating means outlined earlier, the first substrate receiving portion may lack any susceptor portion. Instead, the susceptor may be provided as part of the aerosol generating article, preferably entirely or partially enclosed within the aerosol-forming substrate of the aerosol generating article. In such embodiments, the device may still include an inductor coil that surrounds the cavity wall, preferably radially outward from the wall, when the first substrate receiving portion forms part of the cavity wall.

[0043] As used herein, “susceptor” or “susceptor portion” means a conductive element that heats up when subjected to a changing magnetic field. This may be the result of eddy currents and / or hysteresis losses induced within the susceptor element. Possible materials for the susceptor include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and virtually any other conductive element. Advantageously, the susceptor element is a ferrite element. The material and geometric shape for the susceptor element can be chosen to provide the desired electrical resistance and heat generation. The susceptor element may include, for example, a mesh, a flat spiral coil, a fiber, or a fabric. Advantageously, the susceptor is in contact with a first aerosol-forming substrate. Advantageously, the susceptor element may be fluid-permeable.

[0044] In one embodiment of the resistance heating version of the first heating means, the first heating means may include a resistance heating element. A power source (such as the power source described above) may be configured to supply current to the resistance heater. The resistance heating element may be arranged to surround the first substrate receiving portion, so as to surround the first aerosol-forming substrate received within the first substrate receiving portion. For example, the resistance heating element may have the form of an annular sleeve. As described above, if the first receiving portion forms part of the cavity wall, the annular sleeve may be located within the cavity wall or may form part of the cavity wall.

[0045] Alternatively, the resistance heating element may be positioned to protrude into the first aerosol-forming substrate so as to be insertable into the interior of the receiving aerosol-generating article during use, either in close proximity to or in direct contact with the aerosol-forming substrate of the article. For example, the resistance heating element may have the form of a blade. During use, power is supplied to the resistance heating element (e.g., by the power supply of the device as described above), thereby causing the resistance heating element to heat up. The heat is then transferred from the resistance heating element to the first aerosol-forming substrate received in the first substrate receiving portion, heating the aerosol-forming substrate to a temperature sufficient to cause aerosols to be emitted from the substrate.

[0046] The aerosol generator may further include a second heating means configured to heat a second aerosol-forming substrate, which is received in a second substrate receiving portion, during use. The second heating means may heat the second aerosol-forming substrate by induction heating, resistance heating, or both. The same power source may supply power to the second heating means, as well as to the first heating means.

[0047] In some embodiments, the second heating means may be configured to heat the second substrate receiving portion during use. The heat may then be transferred to the receiving second aerosol-forming substrate.

[0048] In one embodiment of the induction heating version of the second heating means, at least a portion of the second substrate receiving portion may comprise a susceptor portion. The apparatus may also comprise an inductor coil adjacent to or surrounding the susceptor portion. The apparatus may further comprise a power supply configured to supply alternating current to the inductor coil. During use, the power supplied to the inductor coil (e.g., by the power supply of the apparatus as described above) causes the inductor coil to induce eddy currents within the susceptor portion. These eddy currents then cause the susceptor portion of the second substrate receiving portion to generate heat. The power is supplied to the inductor coil as an alternating magnetic field. The alternating current may have any suitable frequency. The alternating current may preferably be a high-frequency alternating current. The alternating current may have a frequency of 100 kilohertz (kHz) to 30 megahertz (MHz).

[0049] In one embodiment of the resistance heating version, the second heating means may include a resistance heating element. The resistance heating element may be arranged to surround the second substrate receiving portion, so as to surround the second aerosol-forming substrate received within the second substrate receiving portion.

[0050] Alternatively, if the second aerosol-forming substrate is contained in a replaceable cartridge that can receive the second substrate in the receiving portion, the aerosol generator may not have to include a susceptor or resistance heating element. Instead, the susceptor or resistance heating element may be provided as part of the cartridge.

[0051] In one embodiment of the induction heating version, the susceptor may be provided as part of the cartridge. In such embodiments, the device may still include an inductor coil.

[0052] In one embodiment of the resistance heating version, a resistance heating element may be provided within the cartridge. In such embodiments, the aerosol generator and cartridge may include an electrical connection that allows a connection between the power supply of the device and a second heating means of the cartridge when the cartridge is received in the second substrate receiving portion.

[0053] The aerosol generator may further include a controller to control the power supplied from the power source to either or both of the first and second heating means. Therefore, the controller may control the heating of the first and second aerosol-forming substrates. Generally, the controller may be configured to power both the first and second heating means when the device is in use, and to simultaneously generate aerosols from both the received first and second aerosol-forming substrates. In some embodiments, the controller may be configured to power the first and second heating means independently, allowing control over which of the first and second aerosol-forming substrates generates aerosols. This may change during fume extraction or use of the device.

[0054] In a second aspect of this disclosure, an aerosol generating system is provided. The aerosol generating system may comprise an aerosol generating device according to a first aspect of this disclosure. The aerosol generating system may further comprise an aerosol generating article. The aerosol generating article may comprise a first aerosol-forming substrate. The aerosol generating article may be receivable into a first substrate receiving portion of the aerosol generating system. The aerosol generating system may comprise a cartridge. The cartridge may comprise a second aerosol-forming substrate. The cartridge may be receivable into a second substrate receiving portion.

[0055] The first aerosol-forming substrate is preferably a solid aerosol-forming substrate. However, the first aerosol-forming substrate may contain both solid and liquid components. Alternatively, the first aerosol-forming substrate may be a liquid aerosol-forming substrate.

[0056] The first aerosol-forming substrate preferably contains nicotine. More preferably, the aerosol-forming substrate contains tobacco. Alternatively, or additionally, the aerosol-forming substrate may contain a non-tobacco-containing aerosol-forming material.

[0057] When the first aerosol-forming substrate is a solid aerosol-forming substrate, the solid first aerosol-forming substrate may contain one or more of the following: herb leaves, tobacco leaves, tobacco stems, puffed tobacco, and homogenized tobacco, and may also contain one or more of the following: powder, granules, pellets, fragments, yarn, splinters, or sheets.

[0058] Optionally, the solid aerosol-forming substrate may contain tobacco or non-tobacco volatile flavor compounds, which are released upon heating of the solid aerosol-forming substrate. The solid aerosol-forming substrate may also contain, for example, one or more capsules containing additional tobacco volatile flavor compounds or non-tobacco volatile flavor compounds, which may melt during heating of the solid aerosol-forming substrate.

[0059] Optionally, the solid aerosol-forming substrate may be provided on or embedded within a thermally stable carrier. The carrier may take the form of a powder, granules, pellets, fragments, yarns, strips, or sheets. The solid aerosol-forming substrate may be deposited on the surface of the carrier, for example, in the form of a sheet, foam, gel, or slurry. The solid aerosol-forming substrate may be deposited over the entire surface of the carrier, or, alternatively, in a pattern to provide non-uniform flavor delivery during use.

[0060] In one preferred embodiment, the aerosol-forming substrate comprises homogenized tobacco material. As used herein, the term “homogenized tobacco material” refers to material formed by agglomerating particulate tobacco.

[0061] The aerosol-forming substrate preferably comprises an aggregate of homogenized tobacco material sheets. As used herein, the term “sheet” refers to a layered element having a width and length substantially greater than its thickness. As used herein, the term “aggregated” is used to describe a sheet that is wrapped, folded, or otherwise compressed or compressed substantially transversely to the longitudinal axis of the aerosol-generating article.

[0062] The aerosol-forming substrate preferably contains an aerosol-forming compound. As used herein, the term "aerosol-forming compound" is used to describe any suitable well-known compound or mixture of compounds that facilitates aerosol formation during use and is substantially resistant to thermal decomposition at the operating temperature of the aerosol-generating article.

[0063] Suitable aerosol-forming materials are well known in the art and include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (such as dimethyl dodecanediate and dimethyl tetradecanediate). Preferred aerosol-forming materials are polyhydric alcohols or mixtures thereof (such as propylene glycol, triethylene glycol, 1,3-butanediol, most preferably glycerin).

[0064] The aerosol-forming substrate may contain a single aerosol-forming body. Alternatively, the aerosol-forming substrate may contain a combination of two or more aerosol-forming bodies.

[0065] The aerosol generating system may include a first heating means configured to heat a first aerosol-forming substrate, which is received in a first substrate receiving portion, during use. The first heating means may heat the first aerosol-forming substrate by induction heating, resistance heating, or both. The device may include a power source for supplying power to the first heating means. The power source may preferably be a battery, thereby providing the device with the advantage of portability. The battery may preferably be a rechargeable battery.

[0066] In some embodiments, the first heating means may be configured to heat the first substrate receiving portion, thereby transferring heat to the received first aerosol-forming substrate.

[0067] Alternatively, in one embodiment of the induction heating version of the first heating means, the susceptor may be provided as part of the aerosol generating article, preferably completely or partially enclosed within the aerosol-forming substrate of the aerosol generating article. In such embodiments, the device comprises an inductor coil. During use, power may be supplied to the inductor coil (for example, by the power supply of the device as described above), which may cause the inductor coil to induce eddy currents within the susceptor. These eddy currents may then result in the generation of heat in the susceptor, which may be transferred to the first aerosol-forming substrate to heat the first aerosol-forming substrate to a temperature sufficient to cause aerosols to emanate from the substrate.

[0068] The aerosol generating article preferably defines a rod. The rod contains a first aerosol-forming substrate. The outer wall of the rod has a fluid-permeable portion. The fluid-permeable portion of the outer wall of the rod is located downstream of the first aerosol-forming substrate. The device housing of the aerosol generator may have a cavity wall defining a cavity. At least a portion of the cavity wall may form a first substrate receiving portion. The cavity wall may have a fluid-permeable region downstream of the first substrate receiving portion. The fluid-permeable portion of the rod may be configured to coincide with the fluid-permeable portion of the cavity wall when the aerosol generating article is received in the cavity. In this way, air may be drawn out through a secondary airflow path when a user inhales at the mouth end of the aerosol generating article. The air may flow through the device housing, through the fluid-permeable region of the cavity wall, through the permeable region of the outer wall of the rod, and into the interior of the rod. This air may then merge with the air drawn out through the primary airflow path.

[0069] The rod of the aerosol generating article has a mouth end and a distal end, preferably with the mouth end located downstream of the distal end. The primary airflow path of the aerosol generating device may extend through the aerosol generating article when the aerosol generating article is received in the cavity of the aerosol generating device. The primary airflow path may extend through the aerosol forming substrate and downstream toward the mouth end along the interior of the rod, so that when the user applies suction at the mouth end, air is drawn into the aerosol generating article and passes through the aerosol forming substrate along the interior of the rod downstream toward the mouth end. During use, volatile compounds may be released from the first aerosol forming substrate and entrained in the air passing through the primary airflow path. The secondary airflow path may extend from an air intake in the device housing and through a fluid permeable portion of the outer wall of the rod, and then merge with the second primary airflow path at a joint downstream of the first substrate receiving portion. The secondary airflow path may be in fluid communication with the second aerosol-forming substrate received in the second substrate receiving portion, thereby entraining the volatile compounds released from the second aerosol-forming substrate into the air drawn out through the secondary airflow path. The air containing the entrained volatile compounds is drawn out through the fluid-permeable portion of the outer wall into the mixing region inside the rod of the aerosol-generating article of the rod. The mixing region may be downstream of the first aerosol-forming substrate, and preferably immediately adjacent thereto. This ensures mixing of the volatile compounds from the first aerosol-forming substrate and the volatile compounds from the second aerosol-forming substrate without the need for the volatile compounds from the second aerosol-forming substrate to pass through the first aerosol-forming substrate.

[0070] Conveniently, the aerosol-forming substrate is located at the distal end, or closer to the distal end than the oral end.

[0071] The inside of the rod is preferably free of obstructions from the mixing region to the mouth end, so that the mixed flow is not obstructed when it flows from the mixing region to the mouth end during use. For example, the aerosol generating article may lack a mouthpiece filter or aerosol cooling element that obstructs the downstream flow path toward the mouth end, as is commonly found in well-known e-cigarettes. The absence of any such obstructions inside the rod downstream of the aerosol-forming substrate may help reduce the draw resistance of the primary and secondary airflow paths, and may also help reduce the amount of inhalation that the user needs to apply at the mouth end to inhale a given amount of mixed flow of aerosol and cooling air. Furthermore, this may also help reduce the complexity of manufacturing the aerosol generating article.

[0072] The fluid-permeable portion of the rod's outer wall may comprise one or more of a porous material, multiple slits, or multiple holes. For example, and not limited to, the fluid-permeable portion of the rod's outer wall may be provided as a mesh, having gaps in the mesh that define openings within the mesh, thereby providing permeability to airflow through the mesh (i.e., through the outer wall). In a further alternative, the fluid-permeable portion of the rod's outer wall may comprise multiple voids, in which case the multiple voids define cavities within the material of the outer wall. The size of any voids, slits, or holes that may form part of the fluid-permeable portion of the rod's outer wall directly affects the permeability of the fluid-permeable portion to airflow. The size of any such voids, slits, or holes may be selected according to the desired volumetric flow rate of cooling air inside the aerosol-generating article.

[0073] The outer wall of the rod may be provided as a wrapper, which surrounds the first aerosol-forming substrate. For example, the wrapper may be cigarette paper. The wrapper may be provided with perforations to form a fluid-permeable portion of the outer wall of the rod. The wrapper preferably has a thickness of approximately 0.02 to 0.07 mm, or approximately 0.03 to 0.05 mm. The aerosol-generating article defined by the rod preferably has a diameter of approximately 3 to 10 mm, or approximately 4.4 to 8 mm. The aerosol-generating article may have an overall length of approximately 30 mm to approximately 100 mm. Preferably, the aerosol-generating article may have an overall length of approximately 30 mm to approximately 60 mm. In one preferred embodiment, the aerosol-generating article has an overall length of approximately 45 mm.

[0074] The fluid-permeable portion of the rod's outer wall preferably comprises at least one annular fluid-permeable band. The use of an annular fluid-permeable band provides a uniform radial inflow of cooling air from around the periphery of the article into the interior of the aerosol-generating article. This may advantageously improve the mixing of volatile compounds from the first aerosol-forming substrate and the second aerosol-forming substrate. This may have the effect of improving the uniformity of inhaled aerosols during use of the device or between separated periods of use.

[0075] Preferably, the fluid-permeable portion of the outer wall of the rod may have an axial length of 0.2 to 4 mm, more preferably 0.2 to 2.5 mm, more preferably 0.2 to 1.8 mm, or more preferably 0.2 to 1.5 mm. Limiting the axial length of the fluid-permeable portion of the outer wall of the rod may help concentrate the mixture of volatile compounds released from the first aerosol-forming substrate and the second aerosol-forming substrate through the fluid-permeable portion.

[0076] Conveniently, the fluid-permeable portion of the rod's outer wall may extend downstream of the first aerosol-forming substrate by only 4 millimeters or less, preferably 2.5 millimeters or less, more preferably 1.8 millimeters or less, more preferably 1.5 millimeters or less, or more preferably 0.2 millimeters or less. By limiting the fluid-permeable portion to extend only to a specified distance downstream from the first aerosol-forming substrate, mixing of volatile compounds released from the first and second aerosol-forming substrates can be achieved just downstream of the first aerosol-forming substrate in the rod. This helps ensure that when the mixed flow reaches the mouth end of the rod, the user receives a fully mixed, inhalable vapor, thereby enhancing the user experience.

[0077] The second aerosol-forming substrate contained in the cartridge is a substrate capable of releasing volatile compounds that can form aerosols. The volatile compounds may be released by heating the second aerosol-forming substrate. The second aerosol-forming substrate may be solid, liquid, or contain both solid and liquid components. The second aerosol-forming substrate is preferably liquid.

[0078] The second aerosol-forming substrate may contain plant-derived materials. The second aerosol-forming substrate may contain tobacco. The second aerosol-forming substrate may contain tobacco-containing materials that contain volatile tobacco-flavored compounds released from the aerosol-forming substrate upon heating. Preferably, the second aerosol-forming substrate may, by alternative means, contain non-tobacco-containing materials.

[0079] The second aerosol-forming substrate may contain at least one aerosol-forming compound. The aerosol-forming compound is any suitable and well-known compound or mixture of compounds that facilitates the formation of a high-density and stable aerosol during use and is substantially resistant to thermal decomposition at the system's operating temperature. Suitable aerosol-forming compounds are well-known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (e.g., dimethyl dodecanediol, dimethyl tetradecanediol). Preferred aerosol-forming compounds are polyhydric alcohols or mixtures thereof (e.g., triethylene glycol, 1,3-butanediol, and most preferably glycerin). The aerosol-forming substrate may contain other additives and components, such as flavorings.

[0080] The second aerosol-forming substrate may be loaded onto a carrier or support by adsorption, coating, impregnation, or other means. In one embodiment, the aerosol-forming substrate is a liquid substrate held within a capillary material. The capillary material may have a fibrous or spongy structure. Preferably, the capillary material contains a bundle of capillaries. For example, the capillary material may contain a plurality of fibers or threads, or other microtubules. The fibers or threads may generally be aligned to transport the liquid to a heater. Alternatively, the capillary material may contain a spongy or foamy material. The structure of the capillary material forms a plurality of small holes or tubes through which the liquid can move by capillary action. The capillary material may contain any suitable material or combination of materials. Examples of suitable materials include sponge or foam materials, ceramic or graphite materials in the form of fibers or sintered powders, foamable metal or plastic materials, and fibrous materials, such as spun or extruded fibers (cellulose acetate, polyester, or bonded polyolefins, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics). The capillary material may have any suitable capillary action and porosity for use with different liquid physical properties. The liquid has physical properties, including but not limited to viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, that allow the liquid to move through the capillary material by capillary action.

[0081] The aerosol generation system may further include a second heating means configured to heat a second aerosol-forming substrate, which is received in a second substrate receiving portion, during use. The second heating means may heat the second aerosol-forming substrate by induction heating, resistance heating, or both. The same power source may supply power to the second heating means, as well as to the first heating means.

[0082] In one embodiment of the induction heating version of the second heating means, at least a portion of the second substrate receiving portion may comprise a susceptor portion. The apparatus may also comprise an inductor coil adjacent to or surrounding the susceptor portion. During use, power supplied to the inductor coil (e.g., by the power supply of the apparatus described above) causes the inductor coil to induce eddy currents within the susceptor portion. These eddy currents then cause the susceptor portion of the first substrate receiving portion to generate heat. Power is supplied to the inductor coil as an alternating magnetic field. The alternating current may have any suitable frequency. The alternating current may preferably be a high-frequency alternating current. The alternating current may have a frequency of 100 kilohertz (kHz) to 30 megahertz (MHz).

[0083] In a variation of the induction heating version of the second heating means outlined earlier, the second substrate receiving portion may also lack any susceptor. Instead, the susceptor may be provided as part of the cartridge. In such embodiments, the device may still include an inductor coil.

[0084] The cartridge may include a housing whose outer surface encloses an aerosol-forming substrate. At least a portion of the outer surface may be formed by a fluid-permeable susceptor element. The susceptor element may have a plurality of openings formed in the susceptor element to allow fluid to permeate through the susceptor element. Specifically, this susceptor element may allow the aerosol-forming substrate (in a gaseous state, or in both gaseous and liquid states) to permeate through the susceptor element. The susceptor element may be in the form of a sheet extending across the openings in the cartridge housing. The susceptor element may extend around the perimeter of the cartridge housing. The susceptor element may be provided on the wall of the cartridge housing, configured to be positioned adjacent to the inductor coil when the cartridge housing is engaged with the device housing. During use, it is advantageous to have the susceptor element close to the inductor coil in order to maximize the voltage induced within the susceptor element.

[0085] In one embodiment of the resistance heating version of the second heating means, the cartridge comprises a resistance heating element. The resistance heating element may be arranged to surround the second substrate receiving portion so as to surround the first aerosol-forming substrate received in the first substrate receiving portion. Alternatively, the resistance heating element may be provided as part of the cartridge. In such embodiments, the aerosol generator and cartridge may include an electrical connection that enables a connection between the power supply of the device and the second heating means of the cartridge when the cartridge is received in the second substrate receiving portion.

[0086] If the cartridge includes capillary material, as described above, the capillary material may be configured to transport the second aerosol-forming substrate to the cartridge's susceptor element or resistance heating element.

[0087] The present invention is defined in the claims. However, a non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of other embodiments, forms, or aspects described herein.

[0088] Example 1. An aerosol generator for simultaneously generating an aerosol from a first aerosol-forming substrate and an aerosol from a second aerosol-forming substrate, wherein the aerosol generator comprises a device housing, and the device housing is A first substrate receiving portion for receiving a first aerosol-forming substrate, and a second substrate receiving portion for receiving a second aerosol-forming substrate, A primary airflow path extending through the first substrate receiving portion, A secondary airflow path extends through the device, thereby defining a secondary airflow path that, during use, is in fluid communication with a second aerosol-forming substrate received in a second substrate receiving portion. An aerosol generator in which the secondary airflow path merges with the primary airflow path at a junction downstream of the first substrate receiving portion. Example 2. The aerosol generator according to Example 1, wherein the secondary airflow path is separated from the primary airflow path upstream of the joint. Example 3. The aerosol generating apparatus according to Example 1 or Example 2, wherein the first substrate receiving portion is configured to receive a portion of an aerosol generating article containing the first aerosol forming substrate. Example 4. An aerosol generator according to any one of Examples 1 to 3, wherein the second substrate receiving portion is configured to receive a second aerosol-forming substrate. Example 5. The aerosol generator according to Example 4, wherein the second substrate receiving portion is configured to receive a removable container or cartridge comprising a liquid storage portion containing a second aerosol-forming substrate. Example 6. The aerosol generator according to Example 4, wherein the second substrate receiving portion forms an integrated liquid storage portion with the rest of the aerosol generator. Example 7. An aerosol generator according to any one of Examples 1 to 6, wherein the apparatus housing defines a cavity wall that defines a cavity, and at least a portion of the cavity forms a first substrate receiving portion. Example 8. The aerosol generator according to Example 7, wherein the cavity wall may, advantageously, have a shape corresponding to the shape of the aerosol-generating article that the constructed cavity wall receives. Example 9. The aerosol generator according to Example 8, wherein the cavity wall is tubular. Example 10. The aerosol generator according to Example 8 or Example 9, wherein the cavity wall is cylindrical. Example 11. An aerosol generator according to any one of Examples 7 to 10, wherein the cavity wall has a fluid permeable region. Example 12. The aerosol generator according to Example 11, wherein the fluid permeable region of the cavity wall is located downstream of the first substrate receiving portion. Example 13. The aerosol generator according to Example 11 or Example 12, wherein the fluid permeable region is provided immediately downstream of the first substrate receiving portion. Example 14. An aerosol generator according to Example 11 or Example 12, wherein the fluid permeable region is axially separated from the first substrate receiving portion, and the separation between the fluid permeable region and the first substrate receiving portion is less than 5 mm, preferably less than 2 mm. Example 15. An aerosol generator according to any one of Examples 11 to 14, wherein the fluid permeable portion of the cavity wall comprises one or more of a porous material, multiple slits, and multiple holes. Example 16. An aerosol generator according to any one of Examples 11 to 15, wherein the cavity wall is tubular and the fluid permeable portion of the cavity wall comprises at least one annular fluid permeable zone. Example 17. An aerosol generator according to any one of Examples 7 to 16, wherein the cavity is provided with an open end and a closed end. Example 18. The aerosol generator according to Example 17, wherein the aerosol generator is configured to receive an aerosol generating article comprising a first aerosol-forming substrate through an open end of a tubular cavity in the longitudinal direction. Example 19. The aerosol generator according to Example 18, wherein the primary airflow path extends through a cavity in a direction substantially parallel to the longitudinal axis. Example 20. The aerosol generator according to Example 18 or Example 19, wherein the secondary airflow path is substantially perpendicular to the longitudinal axis at which it merges with the primary airflow path. Example 21. An aerosol generator according to any one of Examples 1 to 20, wherein the aerosol generator comprises a first heating means configured to heat a first aerosol-forming substrate received in a first substrate receiving portion when in use. Example 22. The aerosol generator according to Example 21, wherein the first heating means heats the first aerosol-forming substrate by either induction heating or resistance heating or both, and the apparatus includes a power supply for supplying power to the first heating means. Example 23. The aerosol generator described in Example 22, wherein the power source is a battery. Example 24. The aerosol generator according to Example 23, wherein the battery is a rechargeable battery. Example 25. An aerosol generator according to any one of Examples 21 to 24, wherein the first heating means comprises an inductor coil adjacent to or surrounding the first substrate receiving portion. Example 26. The aerosol generator according to Example 25, wherein at least a portion of the first substrate receiving portion comprises a susceptor portion. Example 27. The aerosol generator according to Example 26, wherein the first substrate receiving portion forms at least a part of the cavity wall. Example 28. An aerosol generator according to any one of Examples 25 to 27, wherein the inductor coil is a helical coil surrounding a first substrate receiving portion having a susceptor portion. Example 29. The aerosol generator according to Example 28, wherein the inductor coil surrounds the susceptor portion radially outward. Example 30. An aerosol generator according to any one of Examples 21 to 24, wherein the first heating means comprises a resistance heating element. Example 31. The aerosol generator according to Example 30, wherein the resistance heating element is arranged to surround the first substrate receiving portion, the first aerosol-forming substrate receiving portion being received within the first substrate receiving portion. Example 32. An aerosol generator according to Example 30 or Example 31, wherein the resistance heating element has the form of an annular sleeve. Example 33. The aerosol generating apparatus according to Example 30, wherein the resistance heating element is arranged to protrude into the first aerosol forming substrate so that it can be inserted into the inside of the received aerosol generating article when in use. Example 34. The aerosol generator according to Example 33, wherein the resistance heating element may have the shape of a blade. Example 35. An aerosol generator according to any one of Examples 21 to 34, further comprising a second heating means configured to heat a second aerosol-forming substrate received in a second substrate receiving portion during use. Example 36. The aerosol generator according to Example 35, wherein the second heating means is configured to heat the second aerosol-forming substrate by either induction heating or resistance heating or both. Example 37. The aerosol generator according to Example 35 or Example 36, wherein at least a portion of the second substrate receiving portion may be a susceptor portion. Example 38. The aerosol generator according to Example 35 or Example 36, wherein the second heating means comprises a resistance heating element. Example 39. The aerosol generator according to Example 38, wherein the resistance heating element is arranged to surround the second substrate receiving portion, the second aerosol-forming substrate receiving portion being received within the second substrate receiving portion. Example 40. Aerosol generating system, An aerosol generator according to any one of Examples 1 to 39, An aerosol generating article comprising a first aerosol-forming substrate, which is receivable in a first substrate receiving portion of an aerosol generating device, An aerosol generating system comprising: a cartridge having a second aerosol-forming substrate, the cartridge being receivable within a second substrate-receiving portion; and a cartridge. Example 41. The aerosol generation system according to Example 40, wherein the first aerosol-forming substrate is a solid aerosol-forming substrate. Example 42. The aerosol generating system according to Example 40 or Example 41, wherein the first aerosol-forming substrate contains nicotine. Example 43. An aerosol generating system according to any one of Examples 40 to 42, wherein the aerosol-forming substrate contains tobacco. Example 44. An aerosol generating system according to any one of Examples 40 to 43, wherein the aerosol generating article defines the rod. Example 45. The aerosol generating system according to Example 44, wherein the rod contains the first aerosol-forming substrate. Example 46. The aerosol generating system according to Example 45 or Example 46, wherein the outer wall of the rod includes a fluid permeable portion. Example 47. The aerosol generating system according to Example 46, wherein the fluid permeable portion of the outer wall of the rod is located downstream from the first aerosol-forming substrate. Example 48. The aerosol generating system according to Example 47, wherein the apparatus housing of the aerosol generating device comprises a cavity wall defining a cavity, at least a portion of the cavity wall forming a first substrate receiving portion, the cavity wall having a fluid permeable region downstream of the first substrate receiving portion, and the fluid permeable portion of the rod coincides with the fluid permeable portion of the cavity wall when an aerosol generating article is received in the cavity. Example 49. An aerosol generating system according to any one of Examples 46 to 48, wherein the rod of the aerosol generating article has a mouth end and a distal end, and the mouth end is located downstream of the distal end. Example 50. The aerosol generating system according to Example 49, wherein the first aerosol-forming substrate is located at the distal end, or is located closer to the distal end than the oral end. Example 51. An aerosol generating system according to any one of Examples 46 to 50, wherein the fluid permeable portion of the outer wall of the rod may comprise one or more of a porous material, a plurality of slits, or a plurality of holes. Example 52. An aerosol generating system according to any one of Examples 46 to 51, wherein the fluid permeable portion of the outer wall of the rod comprises at least one annular fluid permeable band.

[0089] Here, we will further describe the examples with reference to the figures.

[0090] Figure 1 shows the aerosol generator 100. The device 100 has a housing 101. The start button 102 is built into the housing 101.

[0091] As shown in Figure 2, the power source in the form of a rechargeable battery 103 is located within the housing 101. The control electronics 104 is also located within the housing 101. The control electronics 104 is positioned adjacent to the rechargeable battery 103. The housing 101 has a tubular cavity 105 extending into the interior of the device 100. The cavity 105 is defined by a tubular cavity wall 106 extending into the device 100 along the longitudinal axis 107. The cavity 105 has an open end 108 and a closed end 109, the open and closed ends located at opposite ends of the cavity. The cavity 105 is configured to receive an aerosol generating article 200 via the open end 108 along the longitudinal axis 107. In Figure 2, the aerosol generating article 200, comprising a first aerosol forming substrate 205, is received within the cavity. The housing 101 is provided with a sliding cover 110 that can be moved to expose or close the open end 108 of the cavity 105. In Figure 1, the cover 110 is shown in the closed position, with the open end of the cavity 105 closed. In Figure 2, the cover 110 is shown in the open position, with the open end of the cavity 105 open, so that it can receive the aerosol-generating article 200.

[0092] As shown in Figures 2 and 3, the tubular cavity wall 106 has a lower portion 106a and an upper portion 106b. The lower portion 106a is a first substrate receiving portion configured to receive the distal end of an aerosol generating article 200 containing an aerosol-forming substrate. The lower portion 106a is formed of a different material from the upper portion 106b. The lower portion 106a is formed of a material that has the ability to absorb electromagnetic energy and convert it into heat. Therefore, in this embodiment, the lower portion 106a is a susceptor portion. Accordingly, the terms lower portion and susceptor portion are used interchangeably with reference numeral 106a. In this embodiment, the susceptor portion 106a is made of steel. However, in other embodiments (not shown), the susceptor portion 106a may be made of other materials that have the ability to absorb electromagnetic energy and convert it into heat. In other embodiments, the lower portion 106a (i.e., the first substrate receiving portion) may be partially formed only of a material having the ability to absorb electromagnetic energy and convert it into heat. The remaining portion of the lower portion 106a may be formed from a thermally conductive material suitable for conducting heat away from the susceptor portion and toward the aerosol-generating article receiving it. In any case, the inductor coil 111 circumferentially surrounds the lower portion 106a.

[0093] The upper portion 106b of the tubular wall 106 is formed of a polymer material. The annular region of the upper portion 106b of the tubular wall 106 of the cavity 105 is provided with a uniform distribution of pores extending radially through the tubular wall, forming an annular fluid permeable zone 112. The annular fluid permeable zone 112 and the susceptor portion 106a are shown more clearly in Figure 3.

[0094] As shown in Figure 2, a single air intake 115 is provided on the bottom surface of the housing 101 directly below the closed end 109 of the cavity 105, and the primary airflow channel 209 extends from the air intake 115 to an opening formed in the closed end 109 of the cavity 105, and then through the cavity 105, specifically through the aerosol-generating article 200 received inside the cavity. The fluid streamlines are included in Figure 2, showing how the air entering through the air intake 115 fluidly communicates with the closed end 109 of the cavity 105.

[0095] The aerosol generator further comprises a second substrate receiving portion 120. As shown in Figure 2, a cartridge 122 containing a second aerosol-forming substrate 124 is received within the second substrate receiving portion. The second aerosol-forming substrate 124 is a liquid, and therefore the cartridge 122 may be considered a liquid storage portion. In the embodiment shown in Figure 2, the cartridge 122 is removable from the second substrate receiving portion 120. In other embodiments, the second receiving portion 120 itself may form a liquid storage portion integrated with the rest of the device.

[0096] As shown in Figure 2, the cartridge 122 further comprises a heater element 126. In this embodiment, the heater element 126 is a resistive heater element and is fluid permeable. The resistive heater element is connectable to a battery via electrical contacts on the cartridge 122 that are connectable to electrical contacts located in the second substrate receiving portion 120. The electrical contacts of the cartridge contact the electrical contacts of the second substrate receiving portion when the cartridge 122 is received in the substrate receiving portion 120. The electrical contacts are not shown, nor are any wires shown connecting the electrical contacts of the second substrate receiving portion 120 to the battery, or connecting the electrical contacts of the cartridge to the resistive heater element 126.

[0097] The second aerosol-forming substrate 124 is supplied to the heater element 126 under the influence of gravity. Alternatively, a capillary material (not shown) may be provided in a cartridge in which the second aerosol-forming substrate 124 may be held. The capillary material may move the second aerosol-forming substrate 124 to the heater element 126. The capillary element may fill the cartridge 122.

[0098] In some embodiments, the resistive heater element 126 may be replaced by a susceptor element, and the device may also include a second inductor coil configured to generate heat during use within the susceptor element. In some embodiments, the heater element may be provided in the second receiving portion rather than the cartridge so that heat can be conducted from the second receiving portion to the cartridge.

[0099] As shown in Figure 2, the secondary airflow path is defined between the air intakes 114 provided on the side walls of the housing 101. As shown by the fluid streamlines in Figure 2, the air entering the housing 101 through the air intakes 114 flows through the interior of the housing and fluidly communicates with the annular fluid permeable zone 112. The secondary airflow path passes through the fluid permeable heater element 126. Therefore, the secondary airflow path is in fluid communication with the second aerosol-forming substrate 124 contained in the cartridge 122 when the cartridge is received in the second substrate receiving portion 120 (as shown in Figure 2).

[0100] The aerosol generating article 200 is shown more clearly in the perspective view of Figure 4. The aerosol generating article 200 has the form of an elongated cylindrical rod. Accordingly, the terms aerosol generating article and rod are used interchangeably in this specification for reference numeral 200. The aerosol generating article 200 has a distal end 201 and an oral end 202. The aerosol generating article 200 has a cigarette paper wrapper 203. The wrapper 203 forms the outer wall of the rod 200. As shown in Figures 5b and 5c, the porous front plug 204, the plug of the aerosol forming substrate 205, and the tubular core element 206 are assembled sequentially and coaxially within the wrapper 203. The porous front plug 204 is located at the distal end 201. The plug of the aerosol forming substrate 205 is located immediately downstream of the front plug. The tubular core element 206 is positioned immediately downstream of the plug of the aerosol-forming substrate 205 and extends toward the mouth end 202. In the shown embodiment, the hollow interior 207 of the tubular core element 206 is free from obstructions such as a mouthpiece filter element to define an empty space. Thus, the hollow interior 207 means that the interior of the rod 200 between the downstream end of the aerosol-forming substrate 205 and the mouth end 202 defines an unobstructed flow path. However, in an alternative embodiment (not shown), the filter element may be located within the rod 200 adjacent to the mouth end 202. In the embodiments shown and described herein, the aerosol-forming substrate 205 is a solid substrate containing tobacco. The annular region of the wrapper 203 is provided with a uniform distribution of holes extending radially through the tubular wall, forming an annular fluid-permeable zone 208 within the wrapper 203 (i.e., the outer wall) of the rod 200.

[0101] The aerosol-generating article 200 shown in the figure and described herein is a smoking article intended for use in an aerosol generator 100 to generate an aerosol from an aerosol-forming substrate 205 for inhalation by the user. The aerosol generator 100 is reusable, while the aerosol-generating article 200 is disposable and intended for single use only.

[0102] The primary airflow path 209, mentioned above, extends through the aerosol-forming substrate 205 along the hollow interior of the tubular core element 206. The secondary airflow path 210 extends through the annular fluid-permeable zone 208 to a mixing region 211 located within the rod 200. The mixing region 211 is where the primary airflow path 209 and the secondary airflow path 210 coincide and merge, and where their respective fluid flows mix and combine, as will be described in more detail below.

[0103] During use, the user will first slide the sliding cover 110 to expose the open end 108 of the cavity 105. The user will then insert a new, unused aerosol-generating article 200 into the cavity 105 through the open end 108 until the distal end 201 of the article touches the closed end 109 of the cavity. At this position, the aerosol-generating article 200 is said to be received in the cavity 105 of the aerosol generator 200. The user may also insert or replace a removable cartridge into the second substrate receiving portion 220. However, this may not be necessary, as the removable cartridge typically contains enough second aerosol-forming substrate for several uses. The combination of the aerosol generator 100, cartridge 122, and aerosol-generating article 200 forms an aerosol delivery system. When the aerosol generating article 200 is received within the cavity 106, the annular fluid permeable zone 112 of the tubular wall 106 of the cavity 105 coincides with the annular fluid permeable zone 208 of the wrapper 203 of the aerosol generating article 200. Furthermore, when the aerosol generating device 200 is received within the cavity 106, the plug of the aerosol forming substrate 205 is fully positioned within the susceptor portion 106b (i.e., the first substrate receiving portion) and the inductor coil 111.

[0104] As the user presses the start button 102, the control electronics 104 controls the supply of power from the rechargeable battery 103 to the inductor coil 111 and to the heater element 126. The resulting flow of current through the inductor coil 111 induces eddy currents in the steel susceptor portion 106a. These eddy currents then result in heating of the susceptor portion 106a. The heat from the susceptor portion 106a is radiated onto the aerosol generating article 200 housed in the cavity 105. Since the plug of the aerosol forming substrate 205 is located entirely within the susceptor portion 106a and the inductor coil 111, the heat from the susceptor portion is radiated onto the wrapper 203 of the aerosol generating article 200 and conducted to the plug of the aerosol forming substrate 205. The resulting heating of the aerosol forming substrate 205 results in the substrate emitting a first aerosol. Simultaneously, the flow of current through the resistive heating element 126 causes the heating element to heat up. Heat from the heating element 126 is transferred to a second aerosol-forming substrate 124 that is in contact with or near the heating element 126. The resulting heating of the aerosol-forming substrate 120 causes the substrate to emit a second aerosol.

[0105] The control electronic equipment 104 is configured to adjust the temperatures of the susceptor portion 106b and the heating element 126 according to predetermined thermal profiles optimized for the first aerosol-forming substrate and the second aerosol-forming substrate, respectively. When the susceptor portion 106a reaches a temperature high enough to generate an aerosol from the plug of the aerosol-forming substrate 205, and the heating element 126 reaches a temperature high enough to generate an aerosol from the aerosol-forming substrate contained in the cartridge 120, the user may then inhale the mouth end 202 of the aerosol-generating article 200 to apply inhalation to the mouth end. Each inhalation performed by the user with the aerosol-generating article 200 is generally referred to as "smoke inhalation."

[0106] The suction from the user sucking on the mouth end 202 causes air to be drawn into the aerosol generator 100 through the inlet opening 115 and the primary airflow path 209, so that it is carried through the closed end 109 of the cavity 105, enters the aerosol generating article 200 through the porous forward plug 204, and advances through the plug of the aerosol forming substrate 205. This air, due to heating by the susceptor portion 106a, becomes co-located with the aerosol emitted from the first aerosol forming substrate 205, and continues to flow along the first airflow path 209, emerging into the mixing region 211 from the downstream end of the plug of the aerosol forming substrate 205.

[0107] The suction resulting from the user sucking on the mouth end 202 also draws external air into the housing 101 of the aerosol generator 100 through the air intake 114, passing through the secondary airflow path 210, and thus through the interior of the housing 101, and through the heater element 126. As the air passes through the heater element 126, it becomes accompanied by aerosols emitted from the second aerosol-forming substrate 124 due to heating by the heater element. The air then moves forward into and continues through an annular fluid-permeable zone 112 defined in the upper portion 106b of the tubular wall 106 of the cavity 105. The coincident alignment of the annular fluid permeable zone 112 defined in the tubular wall 106 of the cavity 105 of the device 100 and the annular fluid permeable zone 208 defined in the wrapper 203 of the aerosol generating article 200 results in most of the air flowing through the fluid permeable zone 112, then across the radial gap separating the tubular wall 106 and the article 200, and then through the fluid permeable zone 208 along the second airflow path 210. In this way, air entrained with aerosols emitted from the second aerosol-forming substrate can be supplied through the inside of the housing 101 of the aerosol generator 100 and then supplied into the aerosol-forming article 200 received in the cavity 105. After passing through the annular fluid permeable zone 208 defined in the wrapper 203 of the article 200, the air entrained with aerosols emitted from the second aerosol-forming substrate enters the mixing region 211.

[0108] In the mixing region 211, heated aerosols emitted from the first aerosol-forming substrate flowing along the first airflow path 209 mix with heated aerosols emitted from the second aerosol-forming substrate flowing along the secondary airflow path 210. Importantly, since the fluid permeable zone 112 is downstream of the first substrate receiving portion 106a, and the fluid permeable zone 208 of the aerosol-generating article is downstream of the first aerosol-forming substrate 205, aerosols emitted from the second aerosol-forming substrate do not pass through the first aerosol-forming substrate. Instead, the second aerosols enter the mixing chamber immediately downstream of the first aerosol-forming substrate. This promotes optimal mixing of the first and second aerosols. The mixed flow cools in the mixing chamber and then flows downstream along the hollow interior 207 of the tubular core element 206 of the aerosol-generating article and toward the mouth end 202, where it is inhaled by the user.

[0109] In the case of the aerosol-generating article 200 shown in the figure, the annular fluid permeable zone 208 has an axial length L of 4 millimeters. 208 The annular band 208 has an upstream end that coincides with the downstream end of the plug of the aerosol-forming substrate 205. In an alternative embodiment, the axial length L208 may be as little as 0.2 millimeters. The aerosol-generating article 200 shown in the figure has a length of approximately 30 millimeters to approximately 100 millimeters.

[0110] Figure 6 illustrates a second embodiment of the aerosol generator 400. Many of the features of the aerosol generator 400 in Figure 6 are the same as those of Figure 2, and the same reference numerals are used for the same features. The difference in this embodiment is that the device 400 does not have a susceptor element. Instead, the susceptor 402 is provided within the substrate of the aerosol generating article 404. The susceptor 402 is made of steel. The susceptor 402 is surrounded by the inductor coil 111 because it is within the substrate of the aerosol generating article when the article is received in the cavity 105. Therefore, when in use, the inductor coil 111 induces eddy currents within the steel susceptor 402, which results in heating of the susceptor 402, and as a result the substrate emits a first aerosol. Control electronics 104 are configured to regulate the temperature of the susceptor 402 according to a predetermined thermal profile.

[0111] Otherwise, the aerosol generator 400 operates similarly to the aerosol generator 100, in which the aerosol emitted from the first aerosol-forming substrate is carried into the air passing through the primary airflow path, mixed with the air passing through the secondary airflow path in the mixing region downstream of the first aerosol-forming substrate, and then inhaled by the user.

[0112] Figure 7 illustrates a third embodiment of the aerosol generator 500. Many of the features of the aerosol generator 500 in Figure 7 are the same as those of Figure 2, and the same reference numerals are used for the same features. The difference in this embodiment is that the device 500 employs a resistance heating arrangement to heat the first aerosol-forming substrate. The resistance heating arrangement comprises a heater blade 502 electrically connected to a rechargeable battery. The heater blade comprises an electrical track 504 formed on a thermally conductive substrate 506. The electrical track is conductive and is formed of a material having appropriate resistivity for heating when current passes through it. The heater blade 502 protrudes upward from the closed end of the cavity 105, thereby penetrating the aerosol-forming article located in the first aerosol-forming substrate when the aerosol-forming article 501 is received in the cavity 105. During use, control electronics 104 control the supply of power from the rechargeable battery 103 to the heater blade 502. This causes the electric track 504 to heat up, and the heat is transferred to the thermally conductive substrate 506 and the first aerosol-forming substrate of the aerosol-generating article. The control electronics 104 are configured to adjust the temperature of the heater blade 502 according to a predetermined thermal profile.

[0113] Otherwise, the aerosol generator 500 operates similarly to the aerosol generator 100, and the aerosol emitted from the first aerosol-forming substrate is carried into the air passing through the primary airflow path, mixed with the air passing through the secondary airflow path in the mixing region downstream of the first aerosol-forming substrate, and then inhaled by the user.

[0114] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., should be understood in all cases as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein. Thus, in this context, the number “A” is understood as “A” ± 10%. In this context, the number “A” may be considered to include a number that falls within the general standard error of the measurement of the characteristic that the number “A” modifies. In some cases as used in the appended claims, the number “A” may deviate by the percentages listed above, provided that the amount of deviation does not substantially affect the basic and novel characteristics(s) of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein.

Claims

1. An aerosol generation system comprising an aerosol generating device for simultaneously generating an aerosol from a first aerosol-forming substrate and an aerosol from a second aerosol-forming substrate, wherein the aerosol generating device comprises a device housing, and the device housing is A first substrate receiving portion for receiving the first aerosol-forming substrate, and a second substrate receiving portion for receiving the second aerosol-forming substrate, A primary airflow path extending through the first substrate receiving portion, A secondary airflow path extending through the aforementioned apparatus is defined, thereby defining a secondary airflow path that, during use, is in fluid communication with the second aerosol-forming substrate received in the second substrate receiving portion. The secondary airflow path merges with the primary airflow path at the joint downstream of the first base receiving portion. The aerosol generating system comprises an aerosol generating article having the first aerosol forming substrate, which is receivable in the first substrate receiving portion of the aerosol generating device, A cartridge comprising the second aerosol-forming substrate, further comprising a cartridge that is receivable within the second substrate receiving portion, The aerosol generating article comprises a defined rod, the outer wall of which has a fluid permeable portion downstream of the first aerosol forming substrate, in the aerosol generating system.

2. The aerosol generating system according to claim 1, wherein the apparatus housing comprises a cavity wall defining a cavity, and at least a portion of the cavity wall forms the first substrate receiving portion.

3. The aerosol generating system according to claim 2, wherein the cavity wall comprises a fluid permeable region downstream of the first substrate receiving portion, and the secondary airflow path extends through the fluid permeable region.

4. The aerosol generating system according to claim 3, wherein the fluid permeable region is defined by the region of the cavity wall formed by one or more of a porous material, a plurality of slits, and a plurality of holes.

5. The aerosol generating system according to claim 3 or claim 4, wherein the fluid permeable region is an annular band formed in the cavity wall.

6. The aerosol generating system according to any one of claims 2 to 5, wherein the cavity is provided with an open end and a closed end, and the cavity is configured to receive the first aerosol-forming substrate in the longitudinal direction through the open end.

7. The aerosol generating system according to claim 6, wherein the secondary airflow path is substantially perpendicular to the longitudinal axis at which the secondary airflow path merges with the primary airflow path.

8. The aerosol generating system according to any one of claims 1 to 7, further comprising a first heating means configured to heat the first aerosol-forming substrate received in the first substrate receiving portion when in use.

9. The aerosol generating system according to claim 8, wherein the first heating means comprises an inductor coil adjacent to or surrounding the first substrate receiving portion, and the device further comprises a power supply configured to supply alternating current to the inductor coil.

10. The aerosol generating system according to claim 9, wherein the first substrate receiving portion includes a susceptor material.

11. The aerosol generating system according to claim 8, wherein the first heating means comprises a resistance heater and a power supply configured to supply current to the resistance heater.

12. The aerosol generating system according to any one of claims 8 to 11, further comprising a second heating means configured to heat the second aerosol-forming substrate received in the second substrate receiving portion when in use.

13. The aerosol generating system according to any one of claims 1 to 12, wherein the apparatus housing of the aerosol generating device comprises a cavity wall defining a cavity, at least a portion of the cavity wall forming the first substrate receiving portion, the cavity wall having a fluid permeable region downstream of the first substrate receiving portion, and the fluid permeable portion of the rod is configured to coincide with the fluid permeable portion of the cavity wall when the aerosol generating article is received in the cavity.

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