Aerosol generator with a heated mouthpiece

Abstract

The present invention relates to an aerosol generating device comprising a main body (12), a mouthpiece (14) having a peripheral wall (44) defining an airflow passage (38), and a cavity (22) for receiving a cartridge (16). The cavity (22) is arranged between the main body (12) and the mouthpiece (14). The peripheral wall (44) of the mouthpiece (14) includes a surface heater (42). The present invention also relates to an aerosol generating system (10) comprising an aerosol generating device and a cartridge (16).

Description

Technology Field

[0001] The present invention relates to an aerosol generating device and an aerosol generating system comprising an aerosol generating device and a cartridge. Background Technology

[0002] It is known to provide an aerosol generator for generating inhalable vapor. Such a device can heat an aerosol-forming substrate to a temperature at which one or more components of the aerosol-forming substrate volatilize without burning the aerosol-forming substrate. The aerosol-forming substrate may be provided as part of a cartridge. Together with the aerosol generator, the cartridge may form an aerosol-generating system. The cartridge may be accommodated in a cavity, for example, a heating chamber of the aerosol generator. When the cartridge is inserted into the heating chamber of the aerosol generator, a heating element may be arranged in or around the heating chamber to heat the aerosol-forming substrate. The aerosol generator may include a mouthpiece for closing the cavity when the cartridge is inserted into the cavity. During operation, the aerosol may condense downstream of the cartridge. The formation of condensate may occur particularly when the generated aerosol is warmer than the ambient air and the device structure downstream of the heating chamber. Aerosols passing through the mouthpiece may experience a temperature gradient on the cooler inner surface, which can lead to condensation. The condensed aerosols can travel along the inner sides of the mouthpiece's periphery walls toward the mouthpiece outlet. This can result in unwanted contamination or leakage.

[0003] It would be desirable to have an aerosol generator configured to prevent excessive accumulation of condensate and residue within the mouthpiece. It would be desirable to have an aerosol generator that provides an enhanced user experience. It would be desirable to have an aerosol generator that provides a clean and pleasant user experience.

[0004] According to an embodiment of the present invention, an aerosol generating device may be provided comprising a main body, a mouthpiece having a peripheral wall defining an airflow passage, and a cavity for receiving a cartridge. The cavity may be arranged between the main body and the mouthpiece. The peripheral wall of the mouthpiece may include a surface heater.

[0005] According to an embodiment of the present invention, an aerosol generating device is provided comprising a main body, a mouthpiece having a peripheral wall defining an airflow passage, and a cavity for receiving a cartridge. The cavity is arranged between the main body and the mouthpiece. The peripheral wall of the mouthpiece includes a surface heater.

[0006] By providing surface heaters on the peripheral walls of the mouthpiece, aerosol condensation can be reduced or prevented. The surface heaters aim to increase the temperature of the areas of the mouthpiece corresponding to zones prone to condensation accumulation during the operation of the aerosol generator. Thus, by incorporating surface heaters within the mouthpiece, the present invention addresses the problem posed by the temperature gradient between the warmer aerosol and the colder inner surface of the aerosol generator. The proposed design effectively minimizes condensation on the inner walls of the mouthpiece, thereby reducing the possibility of liquid accumulation and subsequent solute deposition. Consequently, the device maintains optimal efficiency, ensures unhindered aerosol flow, and improves the overall user experience by preventing unpleasant odors caused by residue accumulation.

[0007] The aerosol generating device may include a main body and a mouthpiece.

[0008] The main body of the aerosol generator may include a power supply unit, preferably a battery, for supplying power to a heating element of the aerosol generation system.

[0009] The main body of the aerosol generating device may include an electrical circuit, preferably including a controller, for controlling the supply of electrical energy from a power supply unit to a heating element.

[0010] The cavity of the aerosol generator may be arranged at the proximal end of the main body. The cavity may have a hollow cylindrical shape. The cavity may have a circular cross-section. Alternatively, the cavity may have a rectangular or egg-shaped cross-section.

[0011] The main body may include an air inlet. The air inlet may be fluidly connected to the base of the cavity. When a user inhales through the mouthpiece, ambient air may be drawn into the airflow channel of the aerosol generator through the air inlet. From the airflow channel extending through the main body, air may be drawn into the cavity through one or more perforations located at the bottom of the cavity. This section of the cavity may be referred to as the main body outlet. When a cartridge is received within the cavity, air may then be drawn into the cartridge through the cartridge inlet. The cartridge may be positioned at the distal end of the cartridge. Then, air may be drawn out of the cartridge through the cartridge, specifically through the material storage portion of the cartridge, and then through the cartridge outlet. Then, air enters the mouthpiece, specifically through the mouthpiece inlet. The airflow channel may continue through the mouthpiece toward the mouthpiece outlet. The user may place their lips against the mouthpiece outlet to inhale the generated aerosol.

[0012] The mouthpiece of the aerosol generator can be positioned so that the mouthpiece can close the cavity. Closing the cavity can be performed after inserting a cartridge into the cavity. That is, after inserting the cartridge into the cavity, the cartridge can be sandwiched between the main body of the aerosol generator and the closed mouthpiece of the aerosol generator.

[0013] The mouthpiece can be connected to the main body. The mouthpiece can be connected to the main body by a hinge. The mouthpiece can be opened to allow insertion of a cartridge into the cavity. The mouthpiece can be closed to lock the cartridge in place.

[0014] The mouthpiece can define a mouthpiece inlet and a mouthpiece outlet. The mouthpiece inlet may be fluidly connected to a cavity. The mouthpiece outlet may be configured to release an aerosol.

[0015] The cavity of the aerosol generator is configured to accommodate a cartridge during use. The cartridge may include a cartridge inlet, and the main body may include a main body outlet. The cartridge inlet may be fluidly connected to the main body outlet. The cartridge inlet may be formed by one or both of a proximal air opening and a distal air opening.

[0016] The cartridge may include a cartridge outlet. The cartridge outlet may be fluidically connected to the mouthpiece inlet. The cartridge outlet may be formed by one or both of a proximal air opening and a distal air opening.

[0017] The periphery wall of the mouthpiece may be configured to surround the mouthpiece. The periphery wall of the mouthpiece may include the outer surface of the mouthpiece.

[0018] A surface heater can be placed within the peripheral wall of the mouthpiece. More specifically, the surface heater can be placed on the inner side of the peripheral wall of the mouthpiece. By providing a surface heater on the inner side of the peripheral wall of the mouthpiece, the portion of the mouthpiece that comes into contact with the aerosol during use can be efficiently heated.

[0019] The surface heater may be part of the surrounding wall. The surface heater may be formed by being embedded within the surrounding wall. The surface heater may be placed on the inner side of the surrounding wall.

[0020] A surface heater may include a heated element. The heated element may have different shapes depending on the specific heating method used.

[0021] The surface heater of the mouthpiece may be a resistive heater. The resistive heater may include resistive heating elements. The resistive heater may include multiple resistive heating elements. In this case, the heating element is formed by one or more resistive heating elements. One or more resistive heating elements may be designed in a serpentine pattern. One or more resistive heating elements may extend uniformly across the heating area of ​​the peripheral wall of the mouthpiece. By configuring one or more resistive heating elements to extend uniformly across the heating area of ​​the peripheral wall of the mouthpiece, the mouthpiece can be heated uniformly. In particular, the formation of cold spots that are not sufficiently heated can be avoided. Such cold spots are undesirable because they can lead to the condensation of warm aerosols.

[0022] One or more resistance heating elements may consist of thin filaments, strips, layers, or wires. The controller may be configured to provide power from the power source of an aerosol generator to power one or more resistance heating elements.

[0023] The resistance heater may include a contact portion for connecting the resistance heater to a power source within the main body. The contact portion of the resistance heater may be configured to be coupled to a corresponding contact portion of the main device. The main device contact portion may be electrically connected to the power source of the main device. When the mouthpiece is attached to the main device and the mouthpiece is closed so that the cartridge is secured in place, the contact portion of the resistance heater may be coupled to a corresponding contact portion of the main device to connect the resistance heater of the mouthpiece to the power source of the main device.

[0024] The surface heater may also be configured as an inductive heater. The inductive heater may include an induction coil and a susceptor provided on the peripheral wall of the mouthpiece.

[0025] In an induction heater, the susceptor surface represents a heating element where heat is generated. Accordingly, the susceptor can preferably be positioned on the inner side of the peripheral wall of the mouthpiece. By providing the susceptor on the inner side of the peripheral wall of the mouthpiece, efficient heating of the portion of the mouthpiece that comes into contact with the aerosol during use can be achieved. The susceptor may include one or more susceptor elements. The heated element of the induction heater is formed by one or more susceptor elements.

[0026] The induction coil may be located near the susceptor. Preferably, the induction coil is located radially outward from the susceptor within the peripheral wall of the mouthpiece.

[0027] The induction heater may include a contact portion for connecting the induction coil of the induction heater to a power source within the main body. The contact portion of the induction heater may be configured to engage with a corresponding contact portion of the main device. The main device contact portion may be electrically connected to the power source of the main device. When the mouthpiece is attached to the main device and when the mouthpiece is closed to lock the cartridge in place, the contact portion of the induction heater may be coupled with a corresponding contact portion of the main device to connect the induction coil of the induction heater of the mouthpiece to the power source of the main device.

[0028] In an embodiment, the aerosol generator may be configured to operate with a heated cartridge. The aerosol generator may be further configured to include a surface heater configured as a conductive heater. The conductive heater may be configured to receive heat from the heated cartridge. In this embodiment, heat generated within or from the cartridge may be thermally conducted to the mouthpiece.

[0029] The conductive heater includes a heat-conducting material. The heat-conducting element can be configured to capture residual heat emitted from a heated cartridge.

[0030] The conductive heater may include a thermal bridge. The thermal bridge may extend between a heat-conducting element within the peripheral wall of the mouthpiece and the cavity of the main device where the cartridge is heated.

[0031] The thermal bridge may include a plurality of thermally conductive components extending between the thermal conductive element and the cartridge. The conductive components may be configured as a metal coating or as a set of metal plates. The conductive components may extend along the wall portion of the cavity of the aerosol generator.

[0032] The conductive component can be configured to absorb heat emitted from the cartridge. The thermal conductive components of the thermal conductive element and the thermal bridge can be manufactured from materials having high thermal conductivity. The thermal conductive components of the thermal conductive element and the thermal bridge can be configured to include additional insulating shielding materials to achieve more efficient heat transfer.

[0033] A heat-conducting element within the peripheral wall of the mouthpiece can be configured to function as a heat sink. The temperature of the heat-conducting element may be lower than the temperature in the cavity containing the heated cartridge. Therefore, thermal energy can flow from the heated cartridge toward the heat-conducting element through a thermal bridge.

[0034] The heating element of a conductive heater is formed by one or more heat-conducting elements.

[0035] An aerosol generating device comprising a mouthpiece exclusively heated by a conductive heater as described above can have a reliable and simple mechanical structure. In particular, such an aerosol generating device does not require any releaseable electrical contact between the mouthpiece and the main body.

[0036] Conductive heaters can be used in addition to or alternative to resistive or inductive heaters.

[0037] The mouthpiece may be manufactured from suitable materials. The mouthpiece may be manufactured from materials such as metal, alloy, plastic, composite materials containing one or more of these materials, or ceramic. Plastic materials may include thermoplastic plastics suitable for food or pharmacological applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene.

[0038] The peripheral walls of the mouthpiece may have a layered structure. The individual layers of the mouthpiece may be configured to achieve different technical purposes.

[0039] These layers may include an outermost structural layer. The outermost structural layer may be a layer that comes into contact with the user's lips. The outermost structural layer may be made of a material such as a metal, an alloy, a plastic, a composite material containing one or more of these materials, or a ceramic. Plastic materials may include thermoplastic plastics suitable for food or pharmacological applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene.

[0040] The layers of the mouthpiece may include an insulating layer. The insulating layer may be useful for protecting the user from excessive heat generated by the surface heater of the mouthpiece. Suitable materials for the insulating layer are not limited to these materials but include, for example, polyurethane, polyethylene (PE), polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE), glass, ceramics, and metal alloys.

[0041] The insulation layer of the periphery wall of the mouthpiece may include a chamber-type structure that forms an insulating air gap. Since air is a good insulator, this structure can improve the insulation capacity of the insulation layer. In particular, the insulation layer of the periphery wall of the mouthpiece may be configured to reduce heat transfer from the heated element to the outermost structural layer.

[0042] The mouthpiece may additionally include a support layer. The support layer may be used to support the heated element of the mouthpiece. Materials suitable for the support layer include, but are not limited to, polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), fluoroethylene propylene (FEP), ethylene tetrafluoroethylene (ETFE), polychlorotrifluoroethylene (PCTFE or PTFCE), and dielectric materials such as polyetheretherketone.

[0043] The mouthpiece may further include an interface layer. The interface layer may have heat dissipation properties to enhance heat transfer from the heated element. The interface layer may be made of a dielectric material. Such dielectric materials may be useful for electrically insulating the heated element from the environment. In particular, the interface layer may be used to electrically insulate the heated element from the airflow passage defined in the mouthpiece. Materials suitable for the interface layer include, but are not limited to, dielectric materials such as polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), fluoroethylene propylene (FEP), ethylene tetrafluoroethylene (ETFE), polychlorotrifluoroethylene (PCTFE or PTFCE), and polyetheretherketone.

[0044] The support layer and the interface layer can be manufactured from a dielectric material to encapsulate the heated element. This design can generally be manufactured by depositing a metal layer on a dielectric thin film support, etching the metal layer into a desired pattern, applying another layer of the dielectric thin film over the etched heated element, and then applying heat pressurization to seal the heated element within the dielectric layer.

[0045] The layered structure of the mouthpiece may include an outermost structural layer, an insulating layer, a supporting layer holding a heated element, and an innermost layer interlocking with an airflow passage.

[0046] The periphery wall of the mouthpiece may additionally include a temperature sensor. The temperature sensor may be connected to the controller of the aerosol generator. The temperature sensor may be configured to detect the temperature of the inner side of the periphery wall of the mouthpiece.

[0047] Upon detection, the temperature sensor can generate an electrical signal that can be transmitted to a controller through an appropriate electrical terminal. The controller can process the received electrical signal to determine the current temperature of the inner side of the peripheral wall of the mouthpiece.

[0048] The controller can be configured to adjust the power output to the surface heater of the mouthpiece based on the temperature detected by the temperature sensor. If the detected temperature is lower than a predetermined threshold temperature, the controller can increase the power supply to the surface heater. Conversely, if the temperature exceeds a desired upper temperature threshold, the controller can be configured to reduce the power supply to the surface heater. Therefore, providing a temperature sensor inside or on the periphery wall of the mouthpiece enables the mouthpiece temperature to be maintained within a temperature range where condensation accumulated along the inner side of the mouthpiece is reduced or even prevented. By including a temperature sensor in communication with the controller, the temperature of the mouthpiece can be adjusted in real time. If the detected temperature deviates from the desired range, the controller can adjust the power output to the surface heater to ensure optimal conditions within the mouthpiece.

[0049] The cartridge may have a length. The length can be measured along the longitudinal central axis of the cartridge. The length can be measured from the proximal end of the cartridge to the distal end of the cartridge.

[0050] The cartridge can have a width. The width of the cartridge can be measured perpendicular to the length of the cartridge.

[0051] The cartridge can have thickness. The thickness of the cartridge can be measured perpendicular to the length of the cartridge and perpendicular to the width of the cartridge.

[0052] The width of the cartridge can be greater than the thickness of the cartridge.

[0053] The cartridge may be configured as a replaceable cartridge. That is, the cartridge may be provided outside the aerosol generator so that the cartridge can be received by the aerosol generator, more specifically, by the cavity of the aerosol generator. After the cartridge is consumed, the consumed cartridge may be removed from the cavity of the aerosol generator, and a new cartridge may be inserted into the cavity of the aerosol generator.

[0054] The cartridge may include a material storage unit. The material storage unit may be fluidly connected to the cartridge outlet.

[0055] A heating element may be arranged in a cartridge. A heating element may also be arranged in a cartridge to heat an aerosol-forming substrate arranged within the cartridge.

[0056] The electrical contact of the cartridge may be electrically connected to a heating element. The electrical contact may be arranged on the housing of the cartridge. When the cartridge is received within the cavity of an aerosol generator, the electrical contact of the cartridge may be electrically connected to a corresponding electrical contact of the aerosol generator, preferably the body of the aerosol generator. The electrical contact of the aerosol generator may be arranged to be electrically connected to a power supply of the aerosol generating article. In this way, when the cartridge is received within the cavity, the power supply of the aerosol generator may supply power to the heating element of the cartridge.

[0057] The heating element may be configured as a resistance heating element. The heater may include a heating track. The heating track may be arranged in a wound, coiled, zigzag, or spiral pattern.

[0058] Alternatively, the heating element may be configured as an induction heating element. In the case of an induction heating element, the heating element may include an induction coil. Additionally, the heating element may further include a susceptor element that can be heated by eddy currents induced by alternating current flowing through the induction coil. In this case, the susceptor element may be arranged inside the induction coil. The susceptor element may be provided in a cartridge, while the induction coil may be provided in an aerosol generator, particularly in the main body of the aerosol generator. Alternatively, both the susceptor element and the induction coil may be provided within the cartridge.

[0059] The cartridge may be configured as described in any one of WO2022154863, WO2022154869, and WO2021262266, which is incorporated herein by reference. Specifically, the cartridge dimensions and internal volumes described in any one of WO2022154863, WO2022154869, and WO2021262266 are incorporated herein by reference.

[0060] The cartridge may be configured as a replaceable cartridge. The cartridge may include a substrate storage portion for holding an aerosol-forming substrate.

[0061] The aerosol-forming material may be as described in any one of WO2022154863, WO2022154869 and WO2021262266, which is incorporated herein by reference.

[0062] The aerosol-forming substrate may be a solid. The aerosol-forming substrate may include tobacco, or preferably be composed of tobacco. The aerosol-forming substrate may include nicotine. The aerosol-forming substrate may include an aerosol-forming agent, preferably glycerol.

[0063] Alternatively, the aerosol-forming substrate may be in the form of a liquid or a gel. In addition, in this case, the aerosol-forming substrate may include one or more of tobacco, nicotine, and an aerosol-forming agent, preferably glycerin.

[0064] The aerosol-forming substrate may be maintained within a matrix. The matrix may be placed within a substrate storage unit. The matrix may include a capillary material, and preferably may be composed of a capillary material.

[0065] As used herein, the terms 'proximal', 'distal', 'downstream', and 'upstream' are used to describe the relative positions of a component of an aerosol generator, or a part of a component, with respect to the direction in which the user inhales the aerosol generator during use.

[0066] The aerosol generator may include a mouse end through which the aerosol exits the aerosol generator and is delivered to the user upon use. The mouse end may also be referred to as the proximal end. To inhale the aerosol generated by the aerosol generator upon use, the user inhales from the proximal end of the aerosol generator or the mouse end. The mouse end may be part of a mouthpiece. The aerosol generator includes a distal end located opposite the proximal or mouse end. The proximal or mouse end of the aerosol generator may also be referred to as the downstream end, and the distal end of the aerosol generator may also be referred to as the upstream end. Components of the aerosol generator, or parts of components, may be described as being upstream or downstream of each other based on their relative position between the proximal end, downstream end, or mouse end of the aerosol generator and the distal end or upstream end.

[0067] As used herein, the term "aerosol generating device" relates to a device that generates an aerosol by interacting with an aerosol-forming substrate. The aerosol-forming substrate may be part of a cartridge. The aerosol generating device may be a smoking device that generates an aerosol that can be inhaled directly into the user's lungs through the user's mouth by interacting with the aerosol-forming substrate of the cartridge. The aerosol generating device may be a holder. The device may be an electric heating smoking device. The aerosol generating device may include a housing, an electrical circuit, a power supply, and a heating chamber.

[0068] As used herein with reference to the present invention, the term "smoking" does not refer to conventional smoking in which a device, article, system, substrate, or otherwise an aerosol-forming substrate is completely or at least partially combusted. The aerosol generating device of the present invention is configured to heat an aerosol-forming substrate to a temperature below the combustion temperature of the aerosol-forming substrate, but above a temperature at which one or more volatile compounds of the aerosol-forming substrate are released to form an inhalable aerosol.

[0069] The aerosol generator may include an electrical circuit. The electrical circuit may include a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of a controller. The electrical circuit may include additional electronic components. The electrical circuit may be configured to regulate the power supply to a heating element. The heating element may be part of a cartridge. Power may be supplied to the heating element continuously after activation of the aerosol generator, or intermittently, for example, whenever puffing occurs. 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, to control the supply of power to the heating element according to the electrical resistance of the heating element.

[0070] The aerosol generator may include a power supply unit, typically a battery, within the main body of the aerosol generator. In one embodiment, the power supply unit is a lithium-ion battery. Alternatively, the power supply unit may be a nickel-hydrogen alloy battery, a nickel-cadmium battery, or a lithium-based battery, for example, a lithium-cobalt, lithium-iron-phosphate, lithium titanate, or lithium-polymer battery. Alternatively, the power supply unit may be another form of charge storage device, such as a capacitor. The power supply unit may require recharging and may have a capacity to store sufficient energy for one or more usage experiences; for example, the power supply unit may have a capacity sufficient to continuously generate aerosols for a period of about 6 minutes, or for a period that is a multiple of 6 minutes. In another example, the power supply unit may have a capacity sufficient to provide individual activation of a predetermined number of puffs or heating elements.

[0071] The cavity of the aerosol generator may have an open end into which a cartridge is inserted. The open end may be a proximal end. The cavity may have a closed end opposite to the open end. The closed end may be the base of the cavity. The closed end may be closed except for the provision of air perforations arranged at the base. The base of the cavity may be flat. The base of the cavity may be circular. The base of the cavity may be arranged upstream of the cavity. The open end may be arranged downstream of the cavity. The cavity may have an elongated extension. The cavity may have a longitudinal central axis. The longitudinal direction may be a direction extending between the open end and the closed end along the longitudinal central axis. The longitudinal central axis of the cavity may be parallel to the longitudinal axis of the aerosol generator.

[0072] The cavity 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 to be accommodated within the cavity. 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.

[0073] The airflow channel can be extended through the cavity. Ambient air can be drawn through the airflow channel into the aerosol generator, into the cavity, and toward the user. A mouthpiece can be positioned downstream of the cavity. The airflow channel can be extended through the mouthpiece.

[0074] In all aspects of the present disclosure, the heating element of the cartridge and / or the heating element of the mouthpiece may comprise an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, electrically "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials composed of ceramic materials and metal materials. Such composite materials may comprise doped ceramics or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, platinum, gold, and silver. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, gold-, and iron-containing alloys, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, and iron-manganese-aluminum alloys. In the composite material, the electrically resistive material may be optionally embedded in an insulating material, encapsulated or coated with an insulating material, or vice versa, depending on energy transfer dynamics and required external physicochemical properties.

[0075] As described, in any one of the aspects of the present invention, the heating element may be part of a cartridge. The cartridge may include an internal heating element or an external heating element, or both internal and external heating elements, wherein “internal” and “external” refer to an aerosol-forming substrate. The internal heating element may take any suitable form. For example, the internal heating element may take the form of a heating blade. Alternatively, the internal heater may take the form of a casing or substrate having different electrically conductive parts, or an electrically resistive metal tube. Alternatively, the internal heating element may be one or more heating needles or rods passing through the center of the aerosol-forming substrate. Other alternatives include heating wires or filaments, for example, Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wires, or heating plates. Optionally, the internal heating element may be deposited in or on a rigid carrier material. In one such embodiment, the electrically resistive heating element may be formed using a metal having a defined relationship between temperature and resistivity. In such an exemplary device, metal can be formed as a track on a suitable insulating material, such as ceramic material, and then interposed within another insulating material, such as glass. A heater formed in this manner can be used to perform both heating a heating element and monitoring the temperature of the heating element during operation.

[0076] The external heating element, which is particularly desirable, may take any suitable form. For example, the external heating element may take the form of one or more flexible heating foils or tracks on a dielectric substrate such as polyimide. The flexible heating foils or tracks may be shaped to correspond to the outer periphery of the substrate receiving cavity. Alternatively, the external heating element may take the form of a metal grid or grids, a flexible printed circuit substrate, a molded interconnect device (MID), a ceramic heater, or a flexible carbon fiber heater, or may be formed using a coating technique such as plasma vapor deposition on a substrate of a suitable shape. Additionally, the external heating element may be formed using a metal having a defined relationship between temperature and resistivity. In such an exemplary device, the metal may be formed as a track between two layers of a suitable insulating material. The external heating element formed in this manner may be used for both heating the external heating element during operation and monitoring the temperature of the external heating element.

[0077] As an alternative to electric resistance heating elements, the heating element of a mouthpiece or cartridge may be configured as an induction heating element. An induction heating element may include an induction coil and a susceptor. Generally, a susceptor is a material capable of generating heat when penetrated by an alternating magnetic field. If the susceptor is conductive, eddy currents are typically induced by an alternating magnetic field. If the susceptor is magnetic, other effects that typically contribute to heating are generally referred to as hysteresis loss. Hysteresis loss occurs primarily due to the displacement of blocks of magnetic domains within the susceptor, because their magnetic orientation aligns with the alternating magnetic induction field. Other effects contributing to hysteresis loss are when magnetic domains grow or contract within the susceptor. Generally, all these changes occurring in the susceptor at the nanoscale or smaller are referred to as "hysteresis loss" because they generate heat within the susceptor. Therefore, if the susceptor is both magnetic and electrically conductive, both hysteresis loss and the generation of eddy currents will contribute to the heating of the susceptor. If the susceptor is magnetic but not conductive, hysteresis loss will be the only means by which the susceptor is heated when penetrated by an alternating magnetic field. According to the present invention, the susceptor may be electrically conductive or magnetic, or both electrically conductive and magnetic. An alternating magnetic field generated by one or more induction coils heats the susceptor, and subsequently, the susceptor transfers heat to an aerosol-forming substrate, thereby causing an aerosol to be formed. The heat transfer may be primarily by conduction of heat. Such heat transfer is best when the susceptor is in close thermal contact with the aerosol-forming substrate.

[0078] As used herein, the term "cartridge" refers to an element comprising an aerosol-forming substrate capable of releasing a volatile compound capable of forming an aerosol. For example, the cartridge may be a smoking cartridge that generates an aerosol that can be inhaled directly into the user's lungs through the user's mouth. The cartridge may be disposable.

[0079] As used herein, the term 'aerosol-forming substrate' relates to a substrate capable of releasing one or more volatile compounds capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. For convenience, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.

[0080] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may include both a solid component and a liquid component. The aerosol-forming substrate may include a tobacco-containing material containing volatile tobacco flavor compounds released from the substrate upon heating. The aerosol-forming substrate may include a non-tobacco material. The aerosol-forming substrate may include an aerosol-forming agent that facilitates the formation of a dense and stable aerosol. Examples of suitable aerosol-forming agents are glycerin and propylene glycol.

[0081] The aerosol generating material preferably comprises a homogenized tobacco material, an aerosol forming agent, and water. Providing a homogenized tobacco material can improve aerosol generation, nicotine content, and the flavor profile of the aerosol generated during heating of the aerosol generating article. Specifically, the process of manufacturing homogenized tobacco involves a step of grinding tobacco leaves, which enables more effective release of nicotine and flavor upon heating.

[0082] The present invention also relates to an aerosol generating system comprising an aerosol generating device described herein and a cartridge configured to be accommodated in a cavity of the aerosol generating device.

[0083] The cartridge may include an aerosol-forming substrate. The cartridge may include a heating element. The heating element of the cartridge may be configured to heat the aerosol-forming substrate of the cartridge. The heating element of the cartridge may be provided in addition to a surface heater on the peripheral wall of the mouthpiece.

[0084] A non-limiting, non-comprehensive list of examples is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0085] Example 1. As an aerosol generating device,

[0086] entity,

[0087] A mouthpiece having peripheral walls defining an airflow passage and

[0088] It includes a cavity for receiving a cartridge, wherein the cavity is arranged between the main body and the mouthpiece, and

[0089] The peripheral wall of the above mouthpiece is an aerosol generating device comprising a surface heater.

[0090] Example 2. In Example 1, the mouthpiece is an aerosol generating device defining a mouthpiece inlet and a mouthpiece outlet.

[0091] Example 3. In Example 2, the aerosol generating device wherein the mouthpiece inlet is in fluid communication with the cavity.

[0092] Example 4. An aerosol generating device, wherein in either Example 2 or 3, the mouthpiece outlet is configured to emit an aerosol.

[0093] Example 5. In any one of the previous embodiments, the surface heater is disposed within the peripheral wall of the mouthpiece, an aerosol generating device.

[0094] Example 6. In any one of the previous embodiments, the surface heater is positioned on the inner side of the peripheral wall of the mouthpiece, an aerosol generating device.

[0095] Example 7. An aerosol generating device in which, in any one of the previous embodiments, the surface heater is a resistive heater.

[0096] Example 8. In any one of the previous embodiments, the aerosol generating device, wherein the resistive heater comprises a resistive heating element.

[0097] Example 9. In any one of the prior embodiments, the resistance heating element extends uniformly across a heated zone of the peripheral wall of the mouthpiece, an aerosol generating device.

[0098] Example 10. An aerosol generating device in which, in any one of the previous embodiments, the resistance heating element is designed in a wavy pattern.

[0099] Example 11. In any one of the previous embodiments, the resistance heating heater comprises a plurality of resistance heating elements, an aerosol generating device.

[0100] Example 12. In Example 11, the resistance heating element is composed of a thin filament, strip, layer, or wire, in an aerosol generating device.

[0101] Example 13. In any one of the prior embodiments, the aerosol generating device comprises a resistive heater including a contact portion for connecting the resistive heater to a power source within the main body.

[0102] Example 14. An aerosol generating device in which, in any one of the prior embodiments, the surface heater is configured as an inductive heater.

[0103] Example 15. In Example 14, the aerosol generating device comprises an induction heater including an induction coil and a susceptor provided on the peripheral wall of the mouthpiece.

[0104] Example 16. In Example 15, the aerosol generating device, wherein the induction coil is located radially outward from the susceptor on the peripheral wall of the mouthpiece.

[0105] Example 17. In any one of the prior embodiments, the aerosol generating device is configured to operate with a heated cartridge, and the surface heater is configured as a conductive heater.

[0106] Example 18. An aerosol generating device in Example 17, wherein the conductive heater comprises a heat-conducting element, and the heat-conducting element is configured to capture residual heat emitted from the heated cartridge.

[0107] Example 19. An aerosol generating device in Example 18, wherein the conductive heater comprises a thermal bridge extending between a thermally conductive element within the peripheral wall of the mouthpiece and a cavity of the main device in which the cartridge is heated.

[0108] Example 20. An aerosol generating device in any one of Examples 17 to 19, wherein a heat-conducting element within the peripheral wall of the mouthpiece functions as a heat sink.

[0109] Example 21. An aerosol generating device in which, in any one of the previous embodiments, the peripheral wall of the mouthpiece has a layered structure.

[0110] Example 22. An aerosol generating device in Example 21, wherein the layered structure comprises an outermost structural layer, an insulating layer, a supporting layer that holds the heated element, and an innermost layer that interfaces with the airflow passage.

[0111] Example 23. An aerosol generating device in Example 22, wherein the insulating layer of the peripheral wall of the mouthpiece is configured to reduce heat transfer from the heating element to the outermost structural layer.

[0112] Example 24. An aerosol generating device according to Example 22 or 23, wherein the insulating layer of the peripheral wall of the mouthpiece comprises a chamber-type structure forming a thermally insulated air gap.

[0113] Example 25. An aerosol generating device according to Examples 21 to 24, wherein the innermost layer of the mouthpiece comprises a dielectric material that encapsulates the heating element.

[0114] Example 26. In any one of the previous embodiments, the peripheral wall of the mouthpiece comprises a temperature sensor, an aerosol generating device.

[0115] Example 27. In any one of the previous embodiments, the aerosol generating device, wherein the temperature sensor is connected to the controller of the aerosol generating device.

[0116] Example 28. An aerosol generating device, wherein in any one of the prior embodiments, the controller is configured to adjust the power output to the surface heater of the mouthpiece based on the temperature detected by the temperature sensor.

[0117] Example 29. An aerosol generating device, wherein in any one of the prior embodiments, the mouthpiece is configured to be arranged to cover the cavity and surround the cartridge when the cartridge is received within the cavity.

[0118] Example 30. In any one of the previous embodiments, the aerosol generating device, wherein the mouthpiece is connected to the main body by a hinge.

[0119] Example 31. An aerosol generating device, wherein, in any one of the prior embodiments, the mouthpiece is configured to be removablely attached to the main body.

[0120] Example 32. An aerosol generating system comprising an aerosol generating device according to any one of the prior embodiments, and a cartridge configured to be accommodated within the cavity of the aerosol generating device.

[0121] The features described in relation to one embodiment may be equally applied to other embodiments of the present invention. Brief explanation of the drawing

[0122] The present invention will be further explained with reference to the accompanying drawings merely as an example: Fig. 1 ... shows a side cross-sectional view of an aerosol generating system including an aerosol generating device and a removable cartridge; Fig. 2 shows the proximal part of an aerosol generator having a closed mouthpiece; Fig. 3 ... shows a side cross-sectional view of an aerosol generator having a mouthpiece including a resistance heating element; Fig. 4 shows a planar cross-sectional view through the mouthpiece of FIG. 3; Fig. 5 shows a side cross-sectional view of an aerosol generator having a mouthpiece including an induction heating element; Fig. 6 It shows a side cross-sectional view of an aerosol generator having a mouthpiece containing a conductive heating element. Specific details for implementing the invention

[0123] FIG. 1 illustrates an aerosol generating system (10) having an aerosol generating device. The aerosol generating device includes a main body (12) and a mouthpiece (14). The aerosol generating system (10) includes a cartridge (16).

[0124] The main body (12) of the aerosol generating device includes a battery-type power supply unit (18) and a controller (20) for controlling the supply of electrical energy from the power supply unit (18) to the cartridge (16). More specifically, power supplied from the power supply unit (18) to a heating element (not shown in FIG. 1) of the cartridge (16).

[0125] The cartridge (16) can be inserted into the cavity (22) of the main body (12) of the aerosol generating device. The cavity (22) is located at the proximal end of the main body (12).

[0126] The mouthpiece (14) is connected to the main body (12) by a hinge. When the cartridge (16) is inserted into the cavity (22) of the main body (12), the mouthpiece (14) can be closed so that the cartridge (16) is fitted between the main body (12) and the mouthpiece (14).

[0127] The closed configuration of the mouthpiece (14) is illustrated in FIG. 2. The cartridge (16) is received within the cavity (22) of the main body (12). Additionally, the mouthpiece (14) closes the proximal end of the cartridge (16).

[0128] A main body outlet (26) is positioned at the base (24) of the cavity (22). The main body outlet (26) allows airflow into the cavity (22). The main body outlet (26) is fluidly connected to an airflow channel (not shown) of the main body (12), which is then fluidly connected to an air inlet (not shown) of the main body (12) that allows ambient air to be drawn into the main body (12) and into the cavity (22).

[0129] The main body outlet (26) is fluidly connected to the cartridge inlet (28). Thus, ambient air can be drawn into the cartridge (16) through the cartridge inlet (28). The cartridge inlet (28) is positioned at the distal end of the cartridge (16).

[0130] The cartridge (16) includes an aerosol-forming substrate. The aerosol-forming substrate is arranged within the cartridge chamber.

[0131] After moving through the cartridge (16), the vaporized aerosol-forming material entrained by the airflow exits the cartridge (16) through the cartridge outlet (30). The cartridge outlet (30) is positioned at the proximal end of the cartridge (16).

[0132] The cartridge (16) further includes a heating element (not shown) for heating the aerosol-forming substrate of the cartridge (16) so that the aerosol-forming substrate can be vaporized.

[0133] Downstream of the cartridge outlet (30), air (32) enters the mouthpiece inlet (34) and travels through the mouthpiece (14). At the proximal end of the mouthpiece (14), the aerosol exits the mouthpiece (14) at the mouthpiece outlet (36) for inhalation by the user. An air passage (38) is defined in the mouthpiece (14) between the mouthpiece inlet (34) and the mouthpiece outlet (36).

[0134] FIG. 3 illustrates a cross-sectional view of an aerosol generator having a mouthpiece (14) comprising a resistive heater (40). The resistive heater comprises a heating element in the form of a resistive heating element (42) positioned within the inner side (46) of the periphery wall (44) of the mouthpiece (14). The resistive heating element (42) is designed in a serpentine pattern that is traced to surround the inner side (46) of the periphery wall (44) of the mouthpiece (14). Forming a consistent gap between adjacent sections of the serpentine pattern prevents excessive heating in a specific area of ​​the mouthpiece (14). Additionally, the regular serpentine pattern allows for homogeneous heating of the inner side (46) of the periphery wall (44) of the mouthpiece (14).

[0135] Electrical wiring (48) connects the resistive heater (40) to the electrical contact (50) of the mouthpiece (14). In the closed configuration shown in FIG. 3, the electrical contact (50) of the mouthpiece (14) is coupled with a corresponding electrical connection (52) on the main housing (12). In this way, an electrical connection is established between the power supply (18) and control unit (20) of the main device (12) and the resistive heater (40).

[0136] FIG. 4 illustrates a planar cross-sectional view through the mouthpiece along the line (AA) of FIG. 3. As shown in FIG. 4, the peripheral wall (44) of the mouthpiece (14) is formed in a plurality of individual layers. A resistive heater (40) is formed by being embedded within the layered structure of the peripheral wall (44) of the mouthpiece (14).

[0137] In the exemplary configuration of the mouthpiece illustrated in FIG. 4, the peripheral wall (44) comprises a total of four layers, namely, an outermost structural layer (60), an insulating layer (62), a supporting layer (64) that maintains the resistive heater (40), and an innermost layer (66) that engages with the aerosol moving through the air passage (38) defined by the mouthpiece (14).

[0138] The outermost structural layer (60) is formed of food-grade polyetheretherketone (PEEK).

[0139] The insulating layer (62) is formed of polyethylene terephthalate (PET) and prevents heat generated by the resistive heater (40) from being transferred to the outer structural layer (60) that typically comes into contact with the user's lips.

[0140] The support layer (64) is formed of polytetrafluoroethylene (PTFE). The resistive heater includes a resistive heating element (42) in the form of a serpentine metal track deposited on the support layer (64).

[0141] The interface layer (66) is formed of a dielectric thin film applied on a support layer (64) that holds the resistive heater (40). The interface layer (66) prevents the resistive heater (40) from coming into contact with the aerosol flowing through the aerosol passage (38) formed by the mouthpiece 14.

[0142] FIG. 5 illustrates an alternative embodiment of a heated mouthpiece (14) for an aerosol generator. The mouthpiece (14) of such an aerosol generator also includes a layered structure. The surface heater of the mouthpiece (14) is formed as an inductive heater (70). The structure of the mouthpiece (14) is similar to the structure described in FIG. 4. However, instead of a resistance heating element (42), the heated element is formed as an array of susceptors (72) made of a metal material provided in the layered structure of the mouthpiece (14). An inductive coil (74) is provided to generate an alternating magnetic field, embedded within the mouthpiece (14) and positioned radially outward from the array of susceptors (72). The inductive coil (74) is connected to electrical contacts (50, 52) via electrical wiring (48) to establish electrical communication between the power supply (18) and controller (20) of the main device (12) and the inductive heater (70).

[0143] The mouthpiece (14) illustrated in FIG. 5 is also provided with a temperature sensor (76). The temperature sensor (76) is connected to a controller (76) and enables monitoring and control of the temperature of the inner side (46) of the surrounding wall (44) of the mouthpiece (14).

[0144] FIG. 6 shows a side cross-sectional view of an aerosol generating device having a mouthpiece (14) including a surface heater formed as a conductive heater (80).

[0145] The mouthpiece (14) of FIG. 6 also includes a layered structure. The structure of the mouthpiece (14) is similar to the structure described in FIG. 4. However, instead of a resistance heating element (42), the heated element is formed by a heat-conducting element (82) provided in the layered structure of the mouthpiece (14).

[0146] The heat conduction element (82) is positioned in close proximity to the inner side (46) of the peripheral wall (44) of the mouthpiece (14). As shown in FIG. 6, the heat conduction element (82) is designed in a wavy pattern that follows a pattern similar to the pattern previously described for the resistance heating element (42) shown in FIG. 3.

[0147] In the embodiment illustrated in FIG. 6, the cartridge (16) includes a heating element (not shown) used to evaporate the volatile components of the aerosol-forming substrate to form an inhalable aerosol. Residual heat from the heated cartridge (16) is thermally transferred from the cartridge (16) to a heat-conducting element (82). To this end, upper corner portions (84) of the cavity (22) wall of the aerosol generator holding the cartridge (16) are formed of a high thermal conductivity material. These corner portions (84) are thermally connected to the heat-conducting element (82) of the conductive heater (80) of the mouthpiece (14) through a thermal bridge (86).

[0148] In this embodiment, the thermally conductive component is configured to collect residual heat during the heating phase of the cartridge (16). The thermally conductive element (82) of the mouthpiece (14) functions as a heat sink for the heat generated by the heated cartridge (16). In this way, the excess heat generated from the cartridge (16) can be used passively by the thermally conductive component of the mouthpiece (14). No additional electrical energy is consumed to heat the inner surface (46) of the peripheral wall (44) of the mouthpiece (14). Additionally, in this embodiment, an electrical contact between the mouthpiece (14) and the main device (12) is not required.

Claims

Claim 1 An aerosol generating device comprising a main body, a mouthpiece having a peripheral wall defining an airflow passage, and a cavity for receiving a cartridge, wherein the cavity is arranged between the main body and the mouthpiece, and the peripheral wall of the mouthpiece comprises a surface heater. Claim 2 In claim 1, the surface heater is disposed within the peripheral wall of the mouthpiece, an aerosol generating device. Claim 3 An aerosol generating device according to claim 1 or 2, wherein the surface heater is disposed on the inner side of the peripheral wall of the mouthpiece. Claim 4 An aerosol generating device according to any one of claims 1 to 3, wherein the surface heater is a resistive heater. Claim 5 In paragraph 4, the aerosol generating device wherein the resistive heater comprises one or more resistive heating elements. Claim 6 An aerosol generating device according to any one of claims 1 to 5, wherein the surface heater is configured as an inductive heater. Claim 7 In claim 6, the aerosol generating device comprises an induction heater including an induction coil and a susceptor provided on the peripheral wall of the mouthpiece. Claim 8 An aerosol generating device according to any one of claims 1 to 7, wherein the aerosol generating device is configured to operate with a heated cartridge, and the surface heater is configured as a conductive heater. Claim 9 In claim 8, the aerosol generating device wherein the conductive heater comprises a heat-conducting element, and the heat-conducting element is configured to capture residual heat emitted from the heated cartridge. Claim 10 In claim 9, the aerosol generating device comprises a conductive heater including a thermal bridge extending between a thermally conductive element within the peripheral wall of the mouthpiece and a cavity of the main device in which the cartridge is heated. Claim 11 An aerosol generating device according to any one of claims 1 to 10, wherein the peripheral wall of the mouthpiece has a layered structure. Claim 12 An aerosol generating device according to claim 11, wherein the layered structure comprises an outermost structural layer, an insulating layer, a supporting layer that maintains the heated element, and an innermost layer that interfaces with the airflow passage. Claim 13 An aerosol generating device according to any one of claims 1 to 12, wherein the peripheral wall of the mouthpiece comprises a temperature sensor. Claim 14 An aerosol generating device according to any one of claims 1 to 13, comprising a controller, wherein the controller is configured to adjust the power output to the surface heater of the mouthpiece based on the temperature detected by the temperature sensor. Claim 15 An aerosol generating system comprising an aerosol generating device according to any one of claims 1 to 14, and a cartridge configured to be accommodated within the cavity of said aerosol generating device.

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