Aerosol-generating system comprising a heated gel container

Abstract

An aerosol generating system comprising: an electric power supply, an electric heater connected to the electric power supply, and a substrate container comprising a blind cavity containing an aerosol-forming substrate in the form of a gel that is solid at room temperature, wherein the electric heater is located outside the substrate container and is configured to heat the substrate container without contacting the aerosol-forming substrate to generate vapor from the aerosol-forming substrate. Providing a gel rather than a liquid is advantageous during storage and transport, as well as during use. The gel can also provide a dense and stable aerosol. Heating the gel without requiring the gel to come into contact with the heater is advantageous because it reduces the possibility of unwanted material accumulating on the heater. When the heater is separated from the gel, the heater can be kept clean, requiring less maintenance, and the performance of the system can be more reliable and consistent.

Description

Technology Field

[0001] The present invention relates to an aerosol generating system that generates an aerosol by heating an aerosol forming substrate. In particular, the present invention relates to an aerosol generating system that forms an aerosol by heating a gel. Background Technology

[0002] Aerosol generating systems, such as electronic cigarettes, that operate by heating a liquid formulation to produce an aerosol for inhalation by the user are widely used. Typically, these include a device section and a cartridge. In some systems, the device section includes a power supply and control electronics, while the cartridge includes a liquid reservoir that holds the liquid formulation, a heater that vaporizes the liquid formulation, and a wick that transfers the liquid from the reservoir to the heater. Although this type of system is gaining popularity, it has disadvantages. One disadvantage is the possibility of liquid leakage from the reservoir during transfer and storage, and when the cartridge is connected to the device section. The use of a wick to transfer liquid from the reservoir to the heater can add complexity to the system. means of solving the problem

[0003] In a first aspect of the present invention, an aerosol generating system is provided, and the aerosol generating system is:

[0004] Electric power supply unit;

[0005] An electric heater connected to an electric power supply; and

[0006] It includes a substrate container comprising a blind cavity containing an aerosol-forming substrate in the form of a gel that is solid at room temperature;

[0007] The electric heater is located on the outside of the substrate container and is configured to heat the substrate container without contacting the aerosol-forming substrate to generate steam from the aerosol-forming substrate.

[0008] In this context, an aerosol-forming substrate is a material or a mixture of materials capable of releasing a volatile compound capable of forming an aerosol. Providing the aerosol-forming substrate in the form of a gel may be advantageous during storage, transport, or use. By providing the aerosol-forming substrate in the form of a gel, the risk of leakage from the device may be reduced. Replenishing the aerosol-forming substrate to the device when it is depleted or exhausted may also be improved, for example, by reducing the risk of leakage or spillage.

[0009] In this context, "blind" means that one end is closed. Preferably, there is only one aperture for entry into the cavity and for exit from it.

[0010] Heating the gel without requiring the gel to come into contact with the heater is advantageous because it reduces the likelihood of unwanted material accumulating on the heater. When the heater is separated from the gel, the heater can be kept clean, which may require less maintenance and allow for more reliable and consistent system performance.

[0011] The container may contain materials other than gel.

[0012] Advantageously, the gel is a solid at room temperature. In this context, "solid" means that the gel has a stable size and shape and does not flow. In this context, room temperature means 25 degrees Celsius.

[0013] The gel may contain an aerosol-forming agent. As used herein, the term “aerosol-forming agent” refers to any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol upon use. The aerosol-forming agent is substantially resistant to thermal degradation at the operating temperature of the cartridge. Suitable aerosol-forming agents are well known in the art but are not limited thereto, but include polyhydric alcohols such as triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Preferred aerosol-forming agents are polyhydric alcohols or mixtures thereof, such as triethylene glycol and 1,3-butanediol, and most preferably glycerin or polyethylene glycol.

[0014] Advantageously, the gel comprises a thermoreversible gel. This means that when heated to the melting temperature, the gel becomes a fluid and reverts to a gel at the gelation temperature. The gelation temperature is preferably above room temperature and atmospheric pressure. Atmospheric pressure refers to a pressure of 1 atmosphere. The melting temperature is preferably higher than the gelation temperature. Preferably, the melting temperature of the gel is 50 degrees Celsius, or 60 degrees Celsius, or above 70 degrees Celsius, more preferably above 80 degrees Celsius. In this context, the melting temperature refers to the temperature at which the gel is no longer a solid and begins to flow. The gel may comprise a gelling agent. Preferably, the gel comprises agar or agarose or sodium alginate. The gel may comprise gellan gum. The gel may comprise a mixture of materials. The gel may comprise water.

[0015] The gel may be provided as a single block or as multiple gel elements, e.g., beads or capsules. The use of beads or capsules may allow for simple refilling of the first (or second) chamber by the end user. The use of capsules or beads may also allow the user to know when the cartridge has already been used, because the gel does not form the same capsule or bead upon gelation after heating and subsequent cooling.

[0016] The gel may contain nicotine, tobacco products, or other target compounds to be delivered to the user. When the resulting aerosol contains nicotine, it is advantageous for the nicotine to be contained in a gel or other solid form in the base container rather than in liquid form. Nicotine may be included in the gel along with an aerosol-forming agent. Nicotine is irritating to the skin and can be toxic. Therefore, it is desirable to prevent any possibility of nicotine leakage by fixing the nicotine in the gel at room temperature.

[0017] The flavor compound may be contained in the second chamber in the form of a gel. Alternatively or additionally, the flavor compound may be provided in other forms. For example, the second chamber may contain a solid tobacco material that releases the flavor compound when heated. The second chamber may contain one or more of powders, granules, pellets, shreds, spaghetti, strips, or sheets, containing, for example, one or more of herbal leaves, tobacco leaves, pieces of tobacco ribs, regenerated tobacco, homogenized tobacco, extruded tobacco, and puffed tobacco. The solid tobacco material in the second chamber may be in a loose form. The tobacco may be contained as a gel or liquid. The second chamber may contain additional tobacco or non-tobacco volatile flavor compounds that are released upon heating.

[0018] When agar is used as a gelling agent, the gel preferably comprises 0.5 to 5 weight% (more preferably 0.8 to 1 weight%) of agar. The gel may further comprise 0.1 to 2 weight% of nicotine. The gel may further comprise 30 to 90 weight% (more preferably 70 to 90 weight%) of glycerin. The remainder of the gel may comprise water and any flavoring agent.

[0019] When gellan gum is used as a gelling agent, the gel preferably comprises 0.5 to 5 weight percent of gellan gum. The gel may further comprise 0.1 to 2 weight percent of nicotine. The gel may further comprise 30 to 99.4 weight percent of glycerin. The remainder of the gel may comprise water and an optional flavoring agent.

[0020] In one embodiment, the gel comprises 2 wt% nicotine, 70 wt% glycerol, 27 wt% water, and 1 wt% agar. In another embodiment, the gel comprises 65 wt% glycerol, 20 wt% water, 14.3 wt% tobacco, and 0.7 wt% agar.

[0021] Advantageously, the system does not include a transfer mechanism for transferring the gel to an electric heater. The contents of the substrate container are advantageously Original position It is heated to generate the desired aerosol. In this context, Original position refers to the same location inside the substrate container where the contents are maintained before use. There is no requirement for a capillary wick or pump. Advantageously, the system does not include additional non-volatile structures inside the substrate container to maintain or hold the liquid or gel in close proximity to the heater.

[0022] The system may include a device and a separate consumable part, the consumable part being configured to be housed within or connected to the device, the device including an electric power supply, and the consumable part including a material container. The consumable part may conveniently be referred to as a cartridge.

[0023] The cartridge can be easily discarded and replaced when the gel is consumed. The device advantageously includes at least a portion of an electric heater. By providing a heater within the device, the cartridge can be manufactured simply and inexpensively. The electric heater can be configured to heat the cartridge to generate steam from the gel inside the cartridge.

[0024] The device may include a device housing having a cavity for receiving a cartridge. The cavity of the device may be substantially cylindrical. Preferably, the cavity has a diameter substantially equal to or slightly larger than the diameter of the cartridge.

[0025] The aerosol generating device may include a device body and may further include a mouthpiece separate from the device body. The mouthpiece may be configured to engage with the device body. The device body may be configured to accommodate a consumable part within a cavity of the device body. By providing a reusable mouthpiece separate from the consumable part, the configuration of the consumable part can be simplified and made inexpensive.

[0026] Advantageously, at least one wall of the substrate container is in thermal contact with a heater. At least one wall of the substrate container may be located between the heater and the aerosol-forming substrate. At least one wall of the substrate container may advantageously be in direct contact with the heater. The gel inside the substrate container may subsequently be heated by conduction through the outer wall. Advantageously, the substrate container comprises at least one liquid-impermeable and vapor-impermeable outer wall defining a blind cavity.

[0027] The cartridge can have any suitable shape.

[0028] Preferably, the cartridge is substantially cylindrical. As used herein with reference to the invention, the terms “cylindrical” and “cylindrical” refer to a substantially straight column having a pair of opposing substantially planar end faces.

[0029] The cartridge can have any appropriate size.

[0030] The cartridge may have a length of, for example, about 5 mm to about 30 mm. In a specific embodiment, the cartridge may have a length of about 12 mm.

[0031] The cartridge may have a diameter of, for example, about 4 mm to about 10 mm. In a specific embodiment, the cartridge may have a diameter of about 7 mm.

[0032] The container or cartridge may include a housing. The housing of the cartridge may be formed from one or more materials. Suitable materials include, but are not limited to, metals, aluminum, polymers, polyether ether ketones (PEEK), polyimides such as Kapton®, polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), polystyrene (PS), fluoroethylene propylene (FEP), polytetrafluoroethylene (PTFE), epoxy resins, polyurethane resins, and vinyl resins.

[0033] The housing of the cartridge may be formed from one or more thermally conductive materials. The interior of the cartridge may be coated or treated to include one or more thermally conductive materials. By using one or more thermally conductive materials to form the cartridge or to coat the interior of the cartridge, heat transfer from the heater to the gel can be advantageously increased. Suitable thermally conductive materials include, for example, metals such as aluminum, chromium, copper, gold, iron, nickel, and silver; alloys such as brass and steel; and ceramics, or combinations thereof. Advantageously, at least one wall of the housing has a thermal conductivity greater than 10 W / (m·K) at room temperature. In a preferred embodiment, the housing comprises at least one wall formed of aluminum.

[0034] In an embodiment configured such that the cartridge is induction heated, the housing of the cartridge may include a susceptor, for example, a susceptor layer. The susceptor layer may, for example, form a wall of the housing or be a coating applied to the inside or outside of the housing. The susceptor may be located inside a chamber within the cartridge. For example, a gel may include a susceptor material.

[0035] A cartridge for use in an aerosol generating system according to the present invention may be formed by any suitable method. Suitable methods include, but are not limited to, deep drawing, injection molding, blistering, blow forming, and extrusion.

[0036] The cartridge may include a mouthpiece configured to allow a user to puff the mouthpiece to inhale an aerosol into their mouth or lungs. If the cartridge includes a mouthpiece, the mouthpiece may include a filter. The filter may have low particulate filtration efficiency or very low particulate filtration efficiency. Alternatively, the mouthpiece may include a hollow tube. The mouthpiece may include an airflow regulator, for example, a limiter.

[0037] A cartridge may be provided inside a mouthpiece tube. The mouthpiece tube may include an aerosol forming chamber. The mouthpiece tube may include an airflow restrictor. The mouthpiece tube may include a filter. The mouthpiece tube may include a cardboard housing. The mouthpiece tube may include one or more vapor-impermeable elements inside the cardboard tube. The mouthpiece tube may have a diameter similar to that of a conventional cigarette, for example, about 7 mm. The mouthpiece tube may have a mouth end configured to be placed in the user's mouth for inhalation of an aerosol through it. A cartridge may be retained inside the mouthpiece tube, for example, at the opposite end of the mouth end.

[0038] The open end of the substrate container can be sealed by one or more brittle barriers.

[0039] One or more brittle barriers may be formed of any suitable material. For example, one or more brittle barriers may be formed of, for example, a foil or film containing a metal. If the cartridge comprises one or more brittle barriers that seal one or both of the first chamber and the second chamber, the device body preferably further comprises a perforating member configured to rupture one or more brittle barriers.

[0040] Alternatively or additionally, the substrate container may be sealed by one or more removable barriers. For example, the substrate container may be sealed by one or more release seals.

[0041] One or more removable barriers may be formed of any suitable material. For example, one or more removable barriers may be formed of a foil or film containing, for example, metal.

[0042] The open end of the substrate container may be sealed by a vapor-permeable element, for example, a thin film or mesh, configured to allow the escape of vapor from the substrate container through a thin film or mesh. Alternatively, the substrate container may be sealed by a pressure-activated valve that allows the release of vapor through the valve when the pressure difference across the valve exceeds a critical pressure difference.

[0043] The substrate container may include a first chamber containing a gel and a second chamber separate from the first chamber. The second chamber may contain the same gel as the first chamber, or may contain a gel or a different material different from the first chamber.

[0044] The first and second chambers may be permanently fixed together or separated from each other. The first and second chambers may be provided separately and may be fixed together by the user using a suitable mechanical interlock, such as a snap fitting or a screw fitting. Alternatively, the first and second chambers may remain separated during use.

[0045] By providing the first and second chambers separately, a "mix and match" type set of selections may be made available to the user. The contents of the first chamber may provide a specific dosage of a target compound to be delivered to the user, such as nicotine, and may provide an aerosol of a specific density, and various options may be available to the user. The contents of the second chamber may primarily provide a flavor compound, and various options for the second chamber may be available to the user. The user may select one chamber from various first chambers and one chamber from various second chambers and fit them together to form a complete cartridge.

[0046] Even if the first and second chambers are provided together and permanently fixed to each other, the same mixing and matching approach may be taken by the manufacturer to provide various different cartridges.

[0047] The first and second chambers may have the same size and shape as each other, or they may have different sizes or shapes. The size and shape of the first and second chambers may be selected to suit their contents and to provide a specific heating rate during use.

[0048] It may also be possible to have more than two chambers. It may be desirable to have three or more chambers within the cartridge, wherein at least two chambers have different contents.

[0049] The first and second chambers may advantageously contain different compositions. Both the first and second chambers may contain a gel. Advantageously, the first chamber and the second chamber also do not contain a liquid at room temperature. Advantageously, the first chamber and the second chamber also do not contain a liquid-retaining material or a wick material.

[0050] The first and second chambers may be positioned side by side so that the airflow passes through one chamber first and then through the other chamber, or one chamber may be positioned within another chamber, or arranged in series.

[0051] The cartridge may include a slot between the first and second chambers. The slot may be configured to accommodate a heating element. The heating element may be accommodated within the slot, for example, when the cartridge is installed in an aerosol forming device. Providing a slot in which the heating element is accommodated can provide efficient heating by facilitating that thermal energy from the heating element passes directly into the interior of the substrate container rather than heating, for example, other elements of the system or ambient air. Advantageously, the slot is a blind slot. In this context, "blind" means that one end is closed. Providing a blind slot can help shield the heating element from steam or aerosols generated by the system and prevent condensation from accumulating on the heater.

[0052] If the material comprises a first and a second chamber, a slot may be provided between the first and second chambers. For example, the slot may be provided inside a wall separating the first and second chambers.

[0053] The electric heater may include a resistive heater. The electric heater may include one or more heating elements.

[0054] The electric heating element may include one or more external heating elements, one or more internal heating elements, or one or more external heating elements and one or more internal heating elements. In this context, "external" refers to the outer side of the cavity, and "internal" refers to the inner side of the cavity of the device.

[0055] One or more external heating elements may comprise an array of external heating elements arranged around the inner surface of the cavity. In certain embodiments, the external heating elements extend along the longitudinal direction of the cavity. By this arrangement, the heating elements may extend along the same direction in which the cartridge is inserted into and removed from the cavity. This can reduce interference between the heating elements and the cartridge. In some embodiments, the external heating elements extend along the longitudinal direction of the cavity and are spaced circumferentially. If the heating element comprises one or more internal heating elements, the one or more internal heating elements may comprise any suitable number of heating elements. For example, the heating element may comprise a single internal heating element. The single internal heating element may extend along the longitudinal direction of the cavity.

[0056] The electric heating element may preferably 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 disilide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic 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, and platinum group metals. Examples of suitable metal alloys include stainless steel, Constantan, 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, and stainless steel, Timetal®, iron-aluminum alloys, and iron-manganese-aluminum alloys. Timetal® is a registered trademark of Titanium Metals Corporation, located at Broadway Suite 4300, Denver, Colorado, 1999. In the composite material, the electrically resistive material may optionally be embedded in the insulating material, encapsulated or coated with the insulating material, or vice versa, depending on the kinetics of energy transfer and the required external physicochemical properties. The heating element may comprise a metal etched foil insulated between two layers of inert material. In that case, the inert material may include Kapton®, all-polyimide, or mica foil. Kapton® is a registered trademark of EI du Pont de Nemours and Company, located at 1007 Market Street, Wilmington, Delaware, United States of America, 19898. This type of flexible heating element follows the shape of the cavity and can extend around the circumference of the cavity.

[0057] An electric heating element can be formed using a metal having a defined relationship between temperature and resistance. In this embodiment, the metal can be formed as a track between two layers of a suitable insulating material. An electric heating element formed in this way can be used as both a heater and a temperature sensor.

[0058] Where the electric heating element includes a susceptor, the aerosol generator body preferably includes an inductor arranged to generate a fluctuating electromagnetic field within a cavity and an electric power supply connected to the inductor. The inductor may include one or more coils that generate a fluctuating electromagnetic field. The coil or coils may surround the cavity.

[0059] Preferably, the device body can generate a fluctuating electromagnetic field of 1 to 30 MHz, for example, 2 to 10 MHz, for example, 5 to 7 MHz. Preferably, the device body can generate a fluctuating electromagnetic field having a field strength (H-field) of 1 to 5 kA / m, for example, 2 to 3 kA / m, for example, about 2.5 kA / m.

[0060] The aerosol generating system according to the present invention may include a single heater. This advantageously provides a simple device configuration. The single heater may be configured as an external heater located outside the cavity when in use. Alternatively, the single heater may be configured as an internal heater located inside the cavity when in use and accommodated within a slot of a cartridge. Preferably, the single heater is configured as an internal heater.

[0061] When a single heater is configured as an internal heater, the aerosol generating device may advantageously include a guide means to facilitate proper alignment of the cartridge and the internal heater.

[0062] Preferably, a single heater is an electric heating element comprising an electric resistive material. The electric heating element may comprise a non-elastic material, for example, glass, ceramic sintered material such as alumina (Al2O3) and silicon nitride (Si3N4), or a printed circuit board or silicone rubber. Alternatively, the electric heating element may comprise an elastic metallic material, for example, an iron alloy or a nickel-chromium alloy.

[0063] A single heater may have a shape suitable for heating the cartridge. The electric heater may be positioned between the first and second chambers of the cartridge when the cartridge is connected to or housed within the device body. Preferably, the heater does not protrude from the aerosol generator.

[0064] Preferably, the electric heater surrounds the substrate container. Preferably, the electric heater includes one or more electric resistive tracks in the flexible insulating substrate.

[0065] The aerosol generating system of the present invention may further include one or more temperature sensors configured to detect the temperature of at least one electric heating element. In such an embodiment, the system may include a controller, and the controller may be configured to control the power supply to the electric heater based on the detected temperature. Advantageously, the controller is configured to continuously supply power to the heater after activation of the system rather than in response to a detected user puff. Alternatively, the controller may be configured to supply power to the heater in response to a user puff.

[0066] The system may include an electronic circuit that controls the power supply to the electric heater. The electronic circuit may be a simple switch. Alternatively, the electronic circuit may include one or more microprocessors or microcontrollers. The electronic circuit may be programmable.

[0067] The electric power supply may be a DC voltage source. In a preferred embodiment, the power supply is a battery. For example, the power supply may be a nickel-hydrogen battery, a nickel-cadmium battery, or a lithium-based battery, such as a lithium-cobalt, lithium-iron-phosphate, or lithium-polymer battery. Alternatively, the power supply may be another type of charge storage device, such as a capacitor. The power supply may require recharging and may have a capacity to store sufficient energy to use an aerosol generator having one or more aerosol generating articles.

[0068] Preferably, the aerosol generating system is configured to generate an aerosol for inhalation by a user. The aerosol generating system may be a portable system and may include a mouthpiece that the user sucks in or inhales when using it.

[0069] Advantageously, the system does not include a transfer mechanism for transferring the aerosol-forming agent to the heater. The contents of the cartridge are advantageously Original position It is heated to generate the desired aerosol. In this context in situ This means that the contents are in the same location inside the first and second chambers where they are maintained before use. There are no requirements for a capillary wick or pump.

[0070] Preferably, the aerosol generator is a portable or handheld aerosol generator that is comfortable for a user to hold between the fingers of one hand.

[0071] The aerosol generating device may have a substantially cylindrical shape. The aerosol generating device may have a length of approximately 70 mm to approximately 120 mm.

[0072] In another aspect of the present invention, a cartridge for an aerosol generating system comprising an electric heater is provided, said cartridge being:

[0073] It includes a substrate container comprising a blind cavity containing an aerosol-forming substrate in the form of a gel that is solid at room temperature, and the cartridge is configured to be removablely connected to or received in the main body of an aerosol generating system.

[0074] The features of the substrate container and cartridge described in relation to the first aspect of the present invention may be applied to the cartridge of the second aspect of the present invention. In particular, the substrate container may include at least one liquid and vapor impermeable outer wall defining a blind cavity. The blind cavity may be sealed by a brittle, removable, or vapor-permeable sealing element. Brief explanation of the drawing

[0075] The present invention will now be further described with reference to the accompanying drawings, which further illustrate embodiments according to the present invention: FIG. 1a is a schematic diagram of an aerosol generating device according to a first embodiment of the present invention; FIG. 1b illustrates the device of FIG. 1a having a cartridge accommodated within the cavity of the device; FIG. 2 illustrates the cartridge of FIG. 1b in detail; FIG. 3 is a schematic diagram of an aerosol generating system according to a second embodiment of the present invention; FIG. 4 is a schematic diagram of an aerosol generating system according to a third embodiment of the present invention; FIG. 5 illustrates the mouthpiece of the system of FIG. 4; FIGS. 6A and 6B illustrate the cartridge of the system of FIG. 4; FIGS. 7a and 7b are schematic diagrams of a fourth embodiment of the present invention; and Figure 8 illustrates the airflow in the embodiment of Figure 7. Specific details for implementing the invention

[0076] FIG. 1a is a schematic diagram of an aerosol generator according to a first embodiment of the present invention. FIG. 1a shows a cross-sectional view of an aerosol generator (100) for use with a container (200) as shown in FIG. 2. The aerosol generator comprises an outer housing (102) containing a power supply (104), such as a rechargeable battery, and a control circuit (106). The housing (102) further comprises a cavity (108) configured to accommodate the container (200). A heater (110) extends around the perimeter of the cavity (108). The control circuit is connected to the heater (110). The heater is formed by one or more metal heating tracks sandwiched between two layers of a flexible thermally stable substrate material, such as polyimide. The aerosol generator (100) further comprises a mouthpiece (112) attachable to the proximal end of the aerosol generator housing (102) by a push fitting or a screw fitting. The mouthpiece includes a perforated portion (114), an air inlet (118), and an air outlet (116).

[0077] A container or cartridge (200) that a user places within the cavity (108) of the device is illustrated in FIG. 2. The container has a housing (210) formed of aluminum, which is a good thermal conductor. The housing of the container is in the form of a cup that defines a blind cavity. The housing (210) may be manufactured using a suitable known technique, such as deep drawing. The container contains a gel (10). In this embodiment, the gel comprises 2 wt% nicotine, 70 wt% glycerol, 27 wt% water, and 1 wt% agar. In another embodiment, the gel comprises 65 wt% glycerol, 20 wt% water, 14.3 wt% solid powder tobacco, and 0.7 wt% agar. The gel is sealed within the cavity of the container by a brittle sealing foil (214). The sealing foil is welded, heat-sealed, or attached to the lip (212) of the housing (210). This type of container can be made very cheaply.

[0078] FIG. 1b illustrates a cross-sectional view of an aerosol generator (100) having a container (200) housed within a cavity (108) of a housing. When in use, the user inserts the container (200) into the cavity (108) of the aerosol generator (100) and then attaches a mouthpiece (112) to the housing (102). By attaching the mouthpiece, the perforation portion (114) perforates the sealing foil (214) of the container to form an airflow path (115) from the air inlet (118) through the container to the air outlet. Then, the user presses a button (not shown) to activate the device. After activation of the device, the heater is powered by the power supply unit (104) via the control electronic device (106). The heater then directly heats the outer wall of the cartridge. When the temperature of the container (200) reaches an operating temperature of about 250°C, the user is notified by an indicator (not shown) that the user can now inhale the mouthpiece from the outlet (116). When the user inhales the mouthpiece, air enters through the air inlet (118), proceeds through the mouthpiece into the container (200), accompanied by the vaporized gel, and then exits through the air outlet (116) inside the mouthpiece to the user's mouth. The heater can operate for a certain period after activation, say, for 6 minutes, or until the user turns off the system.

[0079] When the gel in the cartridge is depleted, the cartridge can be removed by the user and replaced with a new cartridge.

[0080] FIG. 3 is a schematic diagram of an aerosol generating system according to a second embodiment of the present invention. The embodiment of FIG. 3 is operated by using induction heating rather than resistance heating. Instead of using a resistive heater around a cavity in which a cartridge is received, the device includes an inductor coil (310) surrounding the cavity, and a susceptor is provided within the cavity, in this example, as part of the cartridge.

[0081] The aerosol generator comprises an outer housing (302) containing a power supply (304), such as a rechargeable battery, and a control circuit (306). The housing (302) further comprises a cavity (308) configured to accommodate a container (250). An induction coil is positioned around the perimeter of the cavity (308). The control circuit is connected to the induction coil (310). The control circuit includes components for generating an AC signal provided to the induction coil (224). The aerosol generator (100) further comprises a mouthpiece (312) attachable to the proximal end of the aerosol generator housing (302) by means of a push fitting or a screw fitting. The mouthpiece includes a perforated portion (314), an air inlet (318), and an air outlet (316) in the same manner as in the embodiment of FIG. 1.

[0082] The cartridge (250) of FIG. 3 is similar to the cartridge shown in FIG. 2. The composition of the gel may be the same as in the embodiment of FIG. 1. However, the housing of the cartridge comprises a susceptor material that generates heat in an alternating magnetic field. The susceptor may be provided as a coating on the inside or outside of the housing, or provided inside the housing itself. In this example, the susceptor material is stainless steel provided as part of the cartridge rather than as part of the device body, but it is possible for the susceptor material to be provided as part of the device body or on both the cartridge and the device body. The entire cartridge may be formed of the susceptor material, or the susceptor material may be provided as a coating or layer on one or more surfaces of the cartridge. It is also possible to provide the susceptor material inside the first and second chambers, suspended in the gel or other material contained therein.

[0083] When operating, the system is configured to operate in a continuous heating mode as in the embodiment of FIG. 1. This means that when the user turns on the device, the device supplies an AC signal to an induction coil to generate an alternating magnetic field in the cavity. This induces a current flow within the susceptor, causing the susceptor to heat up. If a ferromagnetic material is used as the susceptor, hysteresis losses may also contribute to the heating. In this context, the induction coil can be described as an induction heater. By controlling the magnitude and frequency of the AC signal, the temperature inside the cartridge (250) can be controlled. A temperature sensor may be provided inside the cavity (308), and a feedback control loop is used. Again, the induction heater may operate for a certain period after activation, say, for 6 minutes, or until the user turns off the system.

[0084] FIG. 4 is a schematic diagram of an aerosol generating system according to a third embodiment of the present invention. The aerosol generating system includes an aerosol generating device (410) and a replaceable cartridge (420). The aerosol generating device includes a device body (412) and a mouthpiece portion (414).

[0085] The device body (412) includes a power supply unit comprising a lithium-ion battery (416) and an electronic control circuit (418). The device body also includes a heater (422) in the form of a blade protruding into a cavity (424) within the housing of the device body. The heater is an electric heater comprising an electric resistive track in a ceramic substrate material. The control circuit is configured to control the power supply from the battery (416) to the electric heater (422).

[0086] Any type of connection, such as a snap fitting or a screw fitting, may be used for the mouthpiece portion (414), but it engages with the device body using a simple push fitting. The mouthpiece portion of this embodiment is a simply tapered hollow tube without any filter elements and is illustrated in more detail in FIG. 5. However, it is possible to include one or more filter elements in the mouthpiece portion. The mouthpiece portion includes an air inlet hole (442) and surrounds an aerosol forming chamber (440) (illustrated in FIG. 4) in which vapor can be condensed in the airflow before entering the user's mouth.

[0087] The cartridge (420) includes a housing that defines a blind chamber. The chamber (430) is open at the mouthpiece end. A thin film (437) (shown in FIG. 4) seals the open end of the chamber. A removable seal may be provided over the thin film, which can be peeled off by the user before use. A blind slot (434) is provided to extend into the chamber to accommodate a heater (422) inside. The blind slot (434) is surrounded by a slot wall (439) and is closed at the mouthpiece end so that the heater does not come into contact with the contents of the chamber. The chamber (430) holds a gel containing nicotine and an aerosol-forming agent, as described with reference to the embodiment of FIG. 2.

[0088] FIG. 6a is a bottom perspective view of the cartridge housing. FIG. 6b is a perspective view of the cartridge housing. The cartridge (420) has a housing having an overall cylindrical shape. A slot wall (439) extends into the chamber. A blind slot (434) is located within the slot wall. A channel (438) is provided in the wall of the cartridge housing to engage with a corresponding rib in the cavity (424). This ensures that the cartridge can be inserted into the cavity (424) only in one direction in which the heater blade is received in the slot (434).

[0089] The gel in the first chamber (430) comprises one or two aerosol-forming agents, such as glycerin, propylene glycol, and polyethylene glycol. The relative concentrations of the aerosol-forming agents may be adjusted to the specific requirements of the system. In this embodiment, the gel in the first chamber (430) comprises, in weight percent: 2% nicotine, 70% glycerin, 27% water, and 1% agar.

[0090] The gelling agent is preferably agar. It has the characteristic of melting at temperatures above 85°C and reverting to a gel at about 40°C. This characteristic makes it suitable for high-temperature environments. The gel will not melt at 50°C, which is useful, for example, when the system is left in a car in the sunlight. The phase transition to liquid at about 85°C means that the gel only needs to be heated to a relatively low temperature to induce aerosolization, which allows for low energy consumption. It may be advantageous to use only agarose, one of the components of agar, instead of agar.

[0091] Additional or other flavors, such as menthol, may be added to the water or aerosol-forming agent before the formation of the gel.

[0092] The amount of gel provided in the cartridge can also be selected to suit specific needs. The cartridge may contain enough gel to provide the user with a single dose or session of use, or it may contain enough gel for multiple doses or sessions of use.

[0093] When operating, the system is configured to operate in a continuous heating mode. This means that the heater (422) heats the cartridge throughout the operation session rather than responding to detected user puffs. The user turns on the system using a simple switch (not shown) and the heater heats the cartridge. A temperature sensor is included in the system to provide the user with an indication when the operating temperature at which the aerosol is generated has been reached. The gel becomes liquid when heated above 85°C. The aerosol containing nicotine and glycerin is generated at a temperature of 180°C to 250°C. During operation, the heater operates at approximately 250°C. The heater can operate for a certain period after activation, say, for 6 minutes, or until the user turns off the system. The operating time may depend on the amount of gel contained inside the cartridge.

[0094] The cartridge housing is formed of aluminum, which is a good heat conductor. The heater does not come into contact with any gel or any generated vapor or aerosol at all. It is kept in a blind slot (434) and thus isolated from generated aerosol. This ensures that there is no accumulation of condensation on the heater, which could lead to the generation of unwanted compounds during operation.

[0095] FIGS. 7A and 7B are schematic diagrams of a cartridge according to a fourth embodiment of the present invention. In the embodiment of FIG. 7A, the cartridge (330) is retained inside a mouthpiece tube (300). A flow restrictor (350) and lining tubes (340, 360, 370) are also retained inside the mouthpiece tube. The components retained inside the mouthpiece tube (330) are shown in an exploded view in FIG. 7B.

[0096] The cartridge (330) is similar to the cartridge shown in FIGS. 6a and 6b. The cartridge (330) is generally cylindrical in shape. However, the cartridge (330) includes a housing that defines two blind chambers. The first and second chambers are of the same size and shape and are separated by a dividing wall (336). The two chambers (331, 332) are open at the mouthpiece end. A blind slot is provided within the dividing wall (336) between the two chambers to accommodate a heater. The blind slot is closed at the mouthpiece end. The first chamber (331) holds a first gel containing nicotine and an aerosol-forming agent, and the second chamber (332) holds a second gel containing crushed tobacco leaves.

[0097] The cartridge (330) does not have a thin film or sealing element but includes an airflow channel (335) formed in the wall of the cartridge and an air inlet (334) that allows air from the top of the airflow channel to the open ends of the first and second chambers.

[0098] The mouthpiece tube is formed of cardboard and has a diameter of 6.6 mm and a length of 45 mm. The lining tube (340) is formed of polyether ether ketone (PEEK) and is provided to prevent the cardboard mouthpiece tube from absorbing moisture from inside the mouthpiece tube. In this embodiment, the lining tube can be made very thin, having a thickness of 0.3 mm. A restrictor (350) is provided to restrict airflow to ensure the mixing of vapor and air from the cartridge and to ensure the generation of aerosols within the space following the restrictor of the lining tube (360).

[0099] FIG. 7 illustrates the airflow inside the mouthpiece tube of FIG. 6a during operation. The mouthpiece tube is illustrated inside the cavity (24) of the type of device (12) illustrated in FIG. 1. However, the device of FIG. 7 does not have a mouthpiece. FIG. 7 illustrates only the end of the device that accommodates the mouthpiece tube. The battery and control circuit are not illustrated. The device includes a device air inlet (355) that allows air into an internal airflow passage (365) formed in the device around the circumference of the cavity (24). A spacer element (352) is positioned at the base of the cavity to allow air flow from the internal airflow passage (365) into the cavity (24), then into the airflow channel (335) within the cartridge (330), and then into the mouthpiece tube through the air inlet (334).

[0100] The cartridges shown in FIGS. 7a and 7b can be heated by a heater of the type shown in FIG. 4 or a heater of the type shown in FIG. 1 or FIG. 3. When operated, the system is configured to operate in a continuous heating mode. This means that the heater heats the cartridge throughout the operation session rather than responding to detected user puffs. The user turns on the system using a simple switch (not shown) and the heater heats the cartridge. The gel in the first and second chambers becomes liquid upon heating, and a vapor containing nicotine and glycerin is generated at a temperature of 180°C to 250°C.

[0101] When the system is at operating temperature, the user sucks in the mouth end of the mouthpiece tube to draw air through the mouthpiece tube. Air is drawn from the internal passage (365) to the distal end of the mouthpiece tube opposite the mouthpiece end. The air travels over the airflow channel (335) and through the air inlet (334) into the space (345). In the space (345), the air mixes with steam from the first and second chambers. The mixed air and steam then pass through the limiter (350), where they are cooled and continue to form an aerosol before being drawn into the user's mouth. After operation, the mouthpiece tube, including the cartridge, can be retrieved from the device and disposed of. This type of mouthpiece tube is sold in packs to provide multiple operations of the system.

[0102] Each described embodiment is described as being configured to operate a continuous heating system in which the heater is activated for a predetermined period during which the user can take multiple puffs. However, the described system may be configured to operate in a different way. For example, based on a signal from an airflow sensor inside the system, power may be supplied to the heater or induction coil only during the duration of each user puff. Alternatively or additionally, power to the heater or induction coil may be turned on or off in response to the user activating a button or switch.

[0103] The drawings illustrate specific embodiments of the present invention. However, it should be apparent that modifications to the described embodiments may be made within the scope of the present invention. In particular, different devices for airflow passing through the system may be provided, and different heating devices, such as non-electric heaters, may be conceived.

Claims

Claim 1 An aerosol generating system comprising: a device body including an electric power supply unit and an electric heater connected to the electric power supply unit; and a consumable part comprising a substrate container including a first chamber and a second chamber separate from the first chamber, wherein the first chamber and the second chamber each comprise a blind cavity containing an aerosol-forming substrate in the form of a gel that is solid at room temperature, said gel comprising an aerosol-forming agent, and said first chamber comprising a gel different from that of the second chamber; said consumable part configured to be received within or connected to the device body, and said electric heater configured to be outside of the substrate container and to heat the substrate container without contacting the aerosol-forming substrate to generate vapor from the aerosol-forming substrate. Claim 2 An aerosol generating system according to claim 1, wherein the electric heater is configured to heat an aerosol-forming substrate within a blind cavity. Claim 3 An aerosol generating system according to claim 1 or 2, further comprising a mouthpiece separate from the consumable part. Claim 4 An aerosol generating system according to claim 1 or 2, wherein at least one wall of the above-described container is in thermal contact with the heater. Claim 5 An aerosol generating system according to claim 1 or 2, wherein the above-described container comprises at least one liquid and vapor impermeable outer wall defining a blind cavity. Claim 6 An aerosol generating system according to claim 1 or 2, wherein the aerosol generating system is a portable aerosol generating system configured to generate an aerosol for a user to inhale. Claim 7 An aerosol generating system according to claim 1 or 2, wherein the electric heater comprises a resistive heater. Claim 8 In claim 1 or 2, the electric heater is an aerosol generating system surrounding a substrate container. Claim 9 An aerosol generating system according to claim 1 or 2, wherein the electric heater comprises one or more electric resistive tracks on a flexible insulating substrate. Claim 10 A cartridge for an aerosol generating system including an electric heater, wherein the cartridge comprises: a substrate container including a first chamber and a second chamber separate from the first chamber, wherein the first chamber and the second chamber each comprise a blind cavity containing an aerosol forming substrate in the form of a gel that is solid at room temperature, wherein the gel comprises an aerosol forming agent, and the first chamber comprises a gel different from that of the second chamber, and wherein the cartridge is configured to be removablely connected to or received in a body of the aerosol generating system. Claim 11 In claim 10, the above-described container comprises at least one liquid and vapor impermeable outer wall defining a blind cavity, a cartridge. Claim 12 In claim 10 or 11, the blind cavity is sealed by a brittle, removable or vapor-permeable sealing element, in a cartridge. Claim 13 In claim 10 or 11, the cartridge, wherein the gel has a melting temperature of at least 60 degrees Celsius. Claim 14 A cartridge according to claim 10 or 11, wherein the gel is a thermoreversible gel. Claim 15 In claim 10 or 11, the gel comprises a cartridge containing nicotine or a tobacco product.

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