AEROSOL GENERATING DEVICE WITH ULTRASONIC NOSING PLANT

Abstract

The invention relates to an aerosol-generating device comprising a cavity for receiving aerosol-forming substrate. The aerosol-generating device may further comprise a heating element configured for heating the aerosol-forming substrate received in the cavity for generating an inhalable aerosol. The aerosol-generating device may further comprise an ultrasonic atomizer. The ultrasonic atomizer may be configured to atomize excess water in the aerosol-forming substrate. The aerosol-generating device may further comprise a controller. The controller may be configured to control a heating operation of the heating element. The controller may be configured to control an excess water removal operation of the ultrasonic atomizer. The controller may be configured to perform the excess water removal operation of the ultrasonic atomizer before the heating operation of the heating element. The invention further relates to a method of removing excess water from aerosol-forming substrate in an aerosol-generating device.

Description

[0001] AEROSOL-GENERATING DEVICE WITH ULTRASONIC ATOMIZER

[0002] The present invention relates to an aerosol-generating device. The present invention further relates to a method of removing excess water from aerosol-forming substrate in the aerosol-generating device.

[0003] It is known to provide an aerosol-generating device for generating an inhalable vapor. Such devices may heat aerosol-forming substrate to a temperature at which one or more components of the aerosol-forming substrate are volatilised without burning the aerosol-forming substrate. Aerosol-forming substrate may be provided as part of an aerosol-generating article. The aerosol-generating article may have a rod shape for insertion of the aerosol-generating article into a cavity, such as a heating chamber, of the aerosol-generating device. A heating element may be arranged in or around the heating chamber for heating the aerosol-forming substrate once the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device. In humid climates an undesirable hot aerosol effect may occur in a first puff of a consumer. In more detail, the aerosol-forming substrate of the aerosol-generating article may comprise excess water due to the humid conditions. This excess water may be vaporized by the heating element of the aerosol-generating device before the first puff of the user. In the first puff, the user may inhale this vaporized excess water. This may create the undesired hot aerosol effect in the first puff.

[0004] It would be desirable to have an aerosol-generating device reducing or preventing the hot aerosol effect. It would be desirable to have a method reducing or preventing the hot aerosol effect.

[0005] According to an embodiment of the invention there may be provided an aerosolgenerating device comprising a cavity for receiving aerosol-forming substrate. The aerosolgenerating device may further comprise a heating element configured for heating the aerosolforming substrate received in the cavity for generating an inhalable aerosol. The aerosolgenerating device may further comprise an ultrasonic atomizer. The ultrasonic atomizer may be configured to atomize excess water in the aerosol-forming substrate. The aerosolgenerating device may further comprise a controller. The controller may be configured to control a heating operation of the heating element. The controller may be configured to control an excess water removal operation of the ultrasonic atomizer. The controller may be configured to perform the excess water removal operation of the ultrasonic atomizer before the heating operation of the heating element. According to an embodiment of the invention there is provided an aerosol-generating device comprising a cavity for receiving aerosol-forming substrate. The aerosol-generating device further comprises a heating element configured for heating the aerosol-forming substrate received in the cavity for generating an inhalable aerosol. The aerosol-generating device further comprises an ultrasonic atomizer. The ultrasonic atomizer is configured to atomize excess water in the aerosol-forming substrate. The aerosol-generating device further comprises a controller. The controller is configured to control a heating operation of the heating element. The controller is configured to control an excess water removal operation of the ultrasonic atomizer. The controller is configured to perform the excess water removal operation of the ultrasonic atomizer before the heating operation of the heating element.

[0006] Providing the ultrasonic atomizer and operating the ultrasonic operator by means of the controller in an excess water removal operation enables removal of excess water from the aerosol-forming substrate. The removal of excess water from the aerosol-forming substrate may prevent an undesired hot aerosol effect in case of hot or humid climates. Performing the excess water removal operation before the heating operation of the heating element removes the excess water before a user experience. Particularly, the aerosol-forming substrate may have - in a humid / hot environment - a relatively high moisture content. This relatively high moisture content may lead to the vaporization of a relatively high amount of this moisture during a preheating phase of the aerosol-generating device. A first puff of a user may be unpleasantly affected by this due to the inhalation of the relatively large amount of vaporized water. This may be referred to as hot aerosol effect.

[0007] The excess water removal operation is preferably performed during a preheating mode of the aerosol-generating device. In any case, the excess water removal operation is preferably conducted before a regular usage session of the aerosol-generating device. The regular usage session may start with the heating operation, i.e. with the controller initiating heating of the heating element to heat the aerosol-forming substrate to thereby vaporize the aerosol-forming substrate for aerosol generation.

[0008] The ultrasonic atomizer atomizing the excess water may mean that the ultrasonic atomizer is configured to vaporize water contained in the aerosol-forming substrate. The ultrasonic atomizer may do so by subjecting the water contained in the aerosol-forming substrate to ultrasonic vibrations.

[0009] The ultrasonic atomizer may comprise, preferably may be configured as, a piezoelectric element. The piezoelectric element may be configured to create ultrasonic vibrations. The ultrasonic atomizer may be configured to create ambient temperature piezoelectric vibrations.

[0010] The piezoelectric element may comprise, preferably may be perforated with, a multitude of micro holes. The micro holes may create a capillarity of the ultrasonic atomizer moving the excess water of the aerosol-forming substrate towards the piezoelectric element for vaporization.

[0011] The ultrasonic atomizer may comprise, preferably may be configured as, an ultrasonic element. The ultrasonic element may be configured to create ultrasonic vibrations.

[0012] The ultrasonic atomizer may be configured to create ultrasonic waves.

[0013] The ultrasonic atomizer may be configured to de-humidify the aerosol-forming substrate during the excess water removal operation.

[0014] The ultrasonic atomizer may be configured to operate at ambient temperatures. In other words, the ultrasonic atomizer may not heat the aerosol-forming substrate.

[0015] The ultrasonic atomizer may be disk-shaped or cylindrical.

[0016] In case of the ultrasonic atomizer being disk-shaped, the ultrasonic atomizer is preferably arranged adjacent or forming a base of the cavity of the aerosol-generating device. When an aerosol-generating article comprising the aerosol-forming substrate is inserted into the cavity of the aerosol-generating device, a distal end face of the aerosol-generating article may be arranged adjacent or may come into direct contact with a large surface of the ultrasonic atomizer. The ultrasonic vibrations created by the ultrasonic atomizer may then be optimally transmitted into the aerosol-forming substrate so that water contained in the aerosol-forming substrate can be atomized by the ultrasonic atomizer. The outer diameter of the disk-shaped ultrasonic atomizer may correspond to the outer diameter of the aerosol-generating article to be received in the cavity of the aerosol-generating device.

[0017] In case of the ultrasonic atomizer being cylindrical, the ultrasonic atomizer is preferably arranged at least partly, preferably fully, surrounding the cavity of the aerosol-generating article. Alternatively, the ultrasonic atomizer can this case form a sidewall of the cavity of the aerosol-generating device. When the aerosol-generating article containing the aerosol-forming substrate is inserted into the cavity of the aerosol-generating device, the outer periphery of the aerosol-generating article is closed or directly contacting the inner sidewall of the ultrasonic atomizer. The ultrasonic vibrations created by the ultrasonic atomizer can then be optimally transferred into the aerosol-forming substrate of the aerosol-generating article thereby atomizing the water contained in the aerosol-forming substrate. An inner diameter of the tubular ultrasonic atomizer may correspond to an outer diameter of the aerosol-generating article to be received in the cavity of the aerosol-generating device.

[0018] According to one embodiment, a disk-shaped ultrasonic atomizer may be arranged adjacent or forming the base of the cavity while a further cylindrical atomizer may be arranged at least partly surrounding or forming the sidewall of the cavity of the aerosol-generating device. Providing two separate atomizers may improve the atomizing action of excess water in the aerosol-forming substrate when the aerosol-generating article comprising the aerosolforming substrate is inserted into the cavity.

[0019] The ultrasonic atomizer may be arranged at least partly surrounding the cavity. The ultrasonic atomizer may be arranged fully surrounding the cavity. The ultrasonic atomizer may be arranged at least partly forming a sidewall of the cavity.

[0020] The ultrasonic atomizer may be tubular. The ultrasonic atomizer may be ring-shaped.

[0021] The ultrasonic atomizer may be arranged adjacent a distal end of the cavity. The ultrasonic atomizer may be arranged at a base of the cavity. The ultrasonic atomizer may form the base of the cavity.

[0022] The ultrasonic atomizer may be fluid permeable. Providing a fluid permeable ultrasonic atomizer may allow the ultrasonic atomizer to be arranged in an airflow channel of the aerosolgenerating device. Particularly in the embodiment where the ultrasonic atomizer is arranged at or forming the base of the cavity, this may beneficial as the airflow channel may be arranged such that ambient air can be drawn into the cavity at the base of the cavity. In this case, the air could be drawn through the ultrasonic atomizer.

[0023] The ultrasonic atomizer may comprise a perforated mesh disc. The perforated mesh disc may be fluid permeable. The perforated mesh disc may be arranged at a forming the base of the cavity. The perforated mesh disc may be arranged in the airflow channel of the aerosolgenerating device. The perforated mesh disc may be arranged spanning the airflow channel of the aerosol-generating device. The perforated mesh disc may create a capillarity due to the the interstices of the mesh thereby drawing excess water of the aerosol-forming substrate towards the ultrasonic atomizer for vaporization.

[0024] The ultrasonic atomizer may be configured as or similar to an artificial fog machine.

[0025] The aerosol-generating device may further comprise an airflow channel upstream of the cavity and fluidly connected with the cavity. As described above, the ultrasonic atomizer may be arranged in or spanning the airflow channel. The aerosol-generating device may comprise an air inlet fluidly connected with the airflow channel. Ambient air may be drawn through the air inlet and further through the airflow channel into the cavity. Subsequently, vaporized aerosol-forming substrate may be entrained in the airflow through the cavity and subsequently inhaled as an inhalable aerosol by a user.

[0026] The ultrasonic atomizer may be arranged to channel atomized excess water from the aerosol-forming substrate into the upstream airflow channel.

[0027] This may reduce or prevent the hot aerosol effect in that the hot air is not immediately drawn into the mouth of a user during a first puff but is instead first drawn through the aerosolgenerating article inserted into the cavity. During passage of the upstream airflow channel and the aerosol-generating article, the vaporized air may cool down to prevent the unwanted hot aerosol effect. Further, having the excess water vaporized into the upstream airflow channel by means of the ultrasonic atomizer may mean that, during the heating operation, this water Is not heated. Hence, a user inhaling this water may not experience the hot aerosol effect. This may even beneficial as cooling the aerosol during a first puff in which the atomized cooled water in the upstream airflow channel may be inhaled together with the vaporized aerosolforming substrate that is vaporized during the heating operation by the heating element.

[0028] The fluid permeability of the ultrasonic atomizer may be facilitated for enabling the atomized excess water to move into the upstream airflow channel after being atomized by the ultrasonic atomizer. In other words, the atomized water may move through the ultrasonic atomizer into the upstream airflow channel. This is particularly preferred for the embodiment in which the ultrasonic atomizer is arranged at or forming the base of the cavity.

[0029] The ultrasonic atomizer may comprise a central aperture along a longitudinal central axis of the cavity.

[0030] The central aperture may allow airflow through the ultrasonic atomizer. This may be particularly beneficial if the ultrasonic atomizer is arranged at a forming the base of the cavity. The provisioning of the central aperture may lead to the ultrasonic atomizer not or only negligibly influencing resistance to draw of the aerosol-generating device when drawing ambient air into the cavity.

[0031] The ultrasonic atomizer may comprise multiple perforations parallel to a longitudinal central axis of the cavity.

[0032] The perforations may allow airflow through the ultrasonic atomizer. This may be particularly beneficial if the ultrasonic atomizer is arranged at a forming the base of the cavity. The provisioning of the perforations may lead to the ultrasonic atomizer not or only negligibly influencing resistance to draw of the aerosol-generating device when drawing ambient air into the cavity.

[0033] The ultrasonic atomizer may be arranged to contact the aerosol-forming substrate, when the aerosol-forming substrate is received in the cavity. The ultrasonic atomizer may be arranged to contact a distal end face of the aerosol-forming substrate.

[0034] As used herein, the terms ‘proximal’, ‘distal’, ‘downstream’ and ‘upstream’ are used to describe the relative positions of components, or portions of components, of the aerosolgenerating device in relation to the direction in which a user draws on the aerosol-generating device during use thereof.

[0035] The aerosol-generating device may comprise a mouth end through which in use an aerosol exits the aerosol-generating device and is delivered to a user. The mouth end may also be referred to as the proximal end. In use, a user draws on the proximal or mouth end of the aerosol-generating device in order to inhale an aerosol generated by the aerosolgenerating device. Alternatively, a user may directly draw on an aerosol-generating article inserted into an opening at the proximal end of the aerosol-generating device. The opening at the proximal end may be an opening of the cavity. The cavity may be configured to receive the aerosol-generating article. The aerosol-generating device comprises a distal end opposed to the proximal or mouth end. The proximal or mouth end of the aerosol-generating device may also be referred to as the downstream end and the distal end of the aerosol-generating device may also be referred to as the upstream end. Components, or portions of components, of the aerosol-generating device may be described as being upstream or downstream of one another based on their relative positions between the proximal, downstream or mouth end and the distal or upstream end of the aerosol-generating device.

[0036] As used herein, an ‘aerosol-generating device’ relates to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate may be part of an aerosol-generating article, for example part of a smoking article. An aerosol-generating device may be a smoking device that interacts with an aerosol-forming substrate of an aerosolgenerating article to generate an aerosol that is directly inhalable into a user’s lungs thorough the user's mouth. An aerosol-generating device may be a holder. The device may be an electrically heated smoking device. The aerosol-generating device may comprise a housing, electric circuitry, a power supply, a heating chamber and a heating element.

[0037] As used herein with reference to the present invention, the term ‘smoking’ with reference to a device, article, system, substrate, or otherwise does not refer to conventional smoking in which an aerosol-forming substrate is fully or at least partially combusted. The aerosol-generating device of the present invention is arranged to heat the aerosol-forming substrate to a temperature below a combustion temperature of the aerosol-forming substrate, but at or above a temperature at which one or more volatile compounds of the aerosol-forming substrate are released to form an inhalable aerosol.

[0038] The aerosol-generating device may comprise electric circuitry. The electric circuitry may comprise a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of the controller. The electric circuitry may comprise further electronic components. The electric circuitry may be configured to regulate a supply of power to the heating element. The supply of power to the heating element may be during the heating operation. Power may be supplied to the heating element continuously following activation of the aerosol-generating device or may be supplied intermittently, such as on a puff-by-puff basis. The power may be supplied to the heating element in the form of pulses of electrical current. The electric circuitry may be configured to monitor the electrical resistance of the heating element, and preferably to control the supply of power to the heating element dependent on the electrical resistance of the heating element.

[0039] The aerosol-generating device may comprise a power supply, typically a battery, within a main body of the aerosol-generating device. In one embodiment, the power supply is a Lithium-ion battery. Alternatively, the power supply may be a Nickel-metal hydride battery, a Nickel cadmium battery, or a Lithium based battery, for example a Lithium-Cobalt, a Lithium- Iron-Phosphate, Lithium Titanate or a Lithium-Polymer battery. As an alternative, the power supply may be another form of charge storage device such as a capacitor. The power supply may require recharging and may have a capacity that enables to store enough energy for one or more usage experiences; for example, the power supply may have sufficient capacity to continuously generate aerosol for a period of around six minutes or for a period of a multiple of six minutes. In another example, the power supply may have sufficient capacity to provide a predetermined number of puffs or discrete activations of the heating element.

[0040] The cavity of the aerosol-generating device may have an open end into which the aerosol-generating article is inserted. The open end may be a proximal end. The cavity may have a closed end opposite 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 apertures arranged in 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 elongate extension. The cavity may have a longitudinal central axis. A longitudinal direction may be the direction extending between the open and closed ends along the longitudinal central axis. The longitudinal central axis of the cavity may be parallel to the longitudinal axis of the aerosol-generating device.

[0041] 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 received in the cavity. The cavity may have a circular cross-section. The cavity may have an elliptical or rectangular crosssection. The cavity may have an inner diameter corresponding to the outer diameter of the aerosol-generating article.

[0042] An airflow channel may run through the cavity. Ambient air may be drawn into the aerosol-generating device, into the cavity and towards the user through the airflow channel. Downstream of the cavity, a mouthpiece may be arranged or a user may directly draw on the aerosol-generating article. The airflow channel may extend through the mouthpiece.

[0043] In any of the aspects of the disclosure, the heating element may comprise an electrically resistive material. Suitable electrically resistive materials include but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys and composite materials made of a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum platinum, gold and silver. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminium- titanium- zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, gold- and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, stainless steel, Timetai® and iron-manganese-aluminium based alloys. In composite materials, the electrically resistive material may optionally be embedded in, encapsulated or coated with an insulating material or vice-versa, depending on the kinetics of energy transfer and the external physicochemical properties required.

[0044] As described, in any of the aspects of the disclosure, the heating element may be part of an aerosol-generating device. The aerosol-generating device may comprise an internal heating element or an external heating element, or both internal and external heating elements, where "internal" and "external" refer to the aerosol-forming substrate. An internal heating element may take any suitable form. For example, an 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 electro-conductive portions, or an electrically resistive metallic tube. Alternatively, the internal heating element may be one or more heating needles or rods that run through the center of the aerosol-forming substrate. Other alternatives include a heating wire or filament, for example a Ni-Cr (Nickel-Chromium), platinum, tungsten or alloy wire or a heating plate. 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, the metal may be formed as a track on a suitable insulating material, such as ceramic material, and then sandwiched in another insulating material, such as a glass. Heaters formed in this manner may be used to both heat and monitor the temperature of the heating elements during operation.

[0045] An external heating element may take any suitable form. For example, an external heating element may take the form of one or more flexible heating foils on a dielectric substrate, such as polyimide. The flexible heating foils can be shaped to conform to the perimeter of the substrate receiving cavity. Alternatively, an external heating element may take the form of a metallic grid or grids, a flexible printed circuit board, a molded interconnect device (MID), ceramic heater, flexible carbon fibre heater or may be formed using a coating technique, such as plasma vapour deposition, on a suitable shaped substrate. An external heating element may also 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 suitable insulating materials. An external heating element formed in this manner may be used to both heat and monitor the temperature of the external heating element during operation.

[0046] As an alternative to an electrically resistive heating element, the heating element may be configured as an induction heating element. The induction heating element may comprise an induction coil and a susceptor. In general, a susceptor is a material that is capable of generating heat, when penetrated by an alternating magnetic field. When located in an alternating magnetic field. If the susceptor is conductive, then typically eddy currents are induced by the alternating magnetic field. If the susceptor is magnetic, then typically another effect that contributes to the heating is commonly referred to hysteresis losses. Hysteresis losses occur mainly due to the movement of the magnetic domain blocks within the susceptor, because the magnetic orientation of these will align with the magnetic induction field, which alternates. Another effect contributing to the hysteresis loss is when the magnetic domains will grow or shrink within the susceptor. Commonly all these changes in the susceptor that happen on a nano-scale or below are referred to as “hysteresis losses”, because they produce heat in the susceptor. Hence, if the susceptor is both magnetic and electrically conductive, both hysteresis losses and the generation of eddy currents will contribute to the heating of the susceptor. If the susceptor is magnetic, but not conductive, then hysteresis losses will be the only means by which the susceptor will heat, when penetrated by an alternating magnetic field. According to the invention, the susceptor may be electrically conductive or magnetic or both electrically conductive and magnetic. An alternating magnetic field generated by one or several induction coils heat the susceptor, which then transfers the heat to the aerosol-forming substrate, such that an aerosol is formed. The heat transfer may be mainly by conduction of heat. Such a transfer of heat is best, if the susceptor is in close thermal contact with the aerosol-forming substrate.

[0047] As used herein, the term ‘aerosol-generating article’ refers to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. For example, an aerosol-generating article may be a smoking article that generates an aerosol that is directly inhalable into a user’s lungs through the user's mouth. An aerosolgenerating article may be disposable.

[0048] As used herein, the term ‘aerosol-forming substrate’ relates to a substrate capable of releasing one or more volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.

[0049] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosolforming substrate may comprise both solid and liquid components. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds which are released from the substrate upon heating. The aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise an aerosol former that facilitates the formation of a dense and stable aerosol. Examples of suitable aerosol formers are glycerine and propylene glycol.

[0050] The aerosol-generating substrate preferably comprises homogenised tobacco material, an aerosol-former and water. Providing homogenised tobacco material may improve aerosol generation, the nicotine content and the flavour profile of the aerosol generated during heating of the aerosol-generating article. Specifically, the process of making homogenised tobacco involves grinding tobacco leaf, which more effectively enables the release of nicotine and flavours upon heating.

[0051] The invention further relates to a method of removing excess water from aerosolforming substrate in an aerosol-generating as described herein, wherein the method may comprise: operating, via the controller, the ultrasonic of atomizer in the excess water removal operation of the ultrasonic atomizer operating subsequently, via the controller, the heating operation of the heating element. The invention further relates to a method of removing excess water from aerosolforming substrate in an aerosol-generating as described herein, wherein the method comprises: operating, via the controller, the ultrasonic of atomizer in the excess water removal operation of the ultrasonic atomizer operating subsequently, via the controller, the heating operation of the heating element.

[0052] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0053] Example 1 . An aerosol-generating device comprising: a cavity for receiving aerosol-forming substrate, a heating element configured for heating the aerosol-forming substrate received in the cavity for generating an inhalable aerosol, an ultrasonic atomizer, wherein the ultrasonic atomizer is configured to atomize excess water in the aerosol-forming substrate and a controller, wherein the controller is configured to control a heating operation of the heating element, wherein the controller is configured to control an excess water removal operation of the ultrasonic atomizer, and wherein the controller is configured to perform the excess water removal operation of the ultrasonic atomizer before the heating operation of the heating element.

[0054] Example 2. The aerosol-generating device according to example 1 , wherein the ultrasonic atomizer comprises, preferably is configured as, a piezoelectric element.

[0055] Example 3. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer comprises, preferably is configured as, an ultrasonic element.

[0056] Example 4. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer is disk-shaped or cylindrical.

[0057] Example 5. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer is arranged at least partly surrounding the cavity.

[0058] Example 6. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer is arranged adjacent a distal end of the cavity.

[0059] Example 7. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer is fluid permeable. Example 8. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer comprises a perforated mesh disc.

[0060] Example 9. The aerosol-generating device according to any of the preceding examples, wherein the aerosol-generating device further comprises an airflow channel upstream of the cavity and fluidly connected with the cavity.

[0061] Example 10. The aerosol-generating device according to example 9, wherein the ultrasonic atomizer is arranged to channel atomized excess water from the aerosol-forming substrate into the upstream airflow channel.

[0062] Example 11 . The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer comprises a central aperture along a longitudinal central axis of the cavity.

[0063] Example 12. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer comprises multiple perforations parallel to a longitudinal central axis of the cavity.

[0064] Example 13. The aerosol-generating device according to any of the preceding examples, wherein the ultrasonic atomizer is arranged to contact the aerosol-forming substrate, when the aerosol-forming substrate is received in the cavity, particularly wherein the ultrasonic atomizer is arranged to contact a distal end face of the aerosol-forming substrate.

[0065] Example 14. A method of removing excess water from aerosol-forming substrate in an aerosol-generating device according to any of the preceding examples, comprising:

[0066] - operating, via the controller, the ultrasonic of atomizer in the excess water removal operation of the ultrasonic atomizer

[0067] - operating subsequently, via the controller, the heating operation of the heating element.

[0068] Features described in relation to one embodiment may equally be applied to other embodiments of the invention.

[0069] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0070] Figs. 1A and 1 B show a cross-sectional side view of an aerosol-generating device with an ultrasonic atomizer to remove excess water from aerosol-forming substrate received in a cavity of the aerosol-generating device; and

[0071] Fig. 2 shows a further illustration of the ultrasonic atomizer is arranged at a base of the cavity. Figures 1A and 1 B show a cross-sectional side view of an aerosol-generating device 10. An aerosol-generating article 12 is received in the cavity 14 of the aerosol-generating device 10. The aerosol-generating article 12 comprises aerosol-forming substrate 16. The aerosol-generating article 12 further comprises a front plug 18 arranged at a distal end of the aerosol-generating article 12. The front plug 18 is arranged abutting the aerosol-forming substrate 16. The aerosol-forming substrate 16 is arranged in a substrate portion of the aerosol-generating article 12.

[0072] The aerosol-generating device 10 further comprises an airflow channel 20 which fluidly connects the air inlet 22 of the aerosol-generating device 10 with the cavity 14. The airflow channel 20 is arranged upstream of the cavity 14. The airflow channel 20 is arranged connecting the air inlet 22 with a base of the cavity 14. The base of the cavity 14 is arranged at a distal end of the cavity 14. The cavity 14 is cylindrical. The base of the cavity 14 is circular.

[0073] The aerosol-generating device 10 further comprises a heating element 24. The heating element 24 is arranged surrounding the cavity 14. The heating element 24 may be a resistive heating element 24 or an induction heating element 24. In case of an induction heating element 24 the heating element 24 may comprise a susceptor which is heated by an induction coil surrounding the susceptor. The heating element 24 is configured to heat the aerosol-forming substrate 16 of the aerosol-generating article 12 when the aerosol-generating article 12 is received in the cavity 14. The heating element 24 is controlled by a controller (not shown) which controls the heating operation of the heating element 24. During the heating operation, the heating element 24 is heated to heat the aerosol-forming substrate 16 and to vaporize the aerosol-forming substrate 16. Subsequently, a user may draw on a proximal end of the aerosolgenerating article 12 thereby inhaling the generated aerosol. The aerosol is generated by the vaporized aerosol-forming substrate 16 being drawn through the aerosol-generating article 12 and cooling down during that process. The cooling down of the vaporized aerosol-forming substrate 16 leads to a droplet formation of condensed aerosol-forming substrate 16 which then forms the inhalable aerosol.

[0074] Figure 1 further shows an ultrasonic atomizer 26. The ultrasonic atomizer 26 is arranged adjacent the base of the cavity 14. The ultrasonic atomizer 26 is disk-shaped. The ultrasonic atomizer 26 is flat. The ultrasonic atomizer 26 is circular. The ultrasonic atomizer 26 is arranged to contact a distal end face of the aerosol-generating article 12 when the aerosolgenerating article 12 is received in the cavity 14. The ultrasonic atomizer 26 is configured to contact the front plug 18 of the aerosol-generating article 12 when the aerosol-generating article 12 is received in the cavity 14. The ultrasonic atomizer 26 is configured to be operated by the controller in an excess water removal operation. The excess water removal operation is performed before the heating operation of the heating element 24. During the excess water removal operation, the ultrasonic atomizer 26 is activated. The activation of the ultrasonic atomizer 26 leads to excess water of the aerosol-forming substrate 16 being atomized. The excess water of the aerosol-forming substrate 16 may be a moved towards the ultrasonic atomizer 26 by capillary action through the front plug 18. The ultrasonic atomizer 26 itself may have a capillarity to improve transport of excess water from the aerosol-forming substrate 16 towards the ultrasonic atomizer 26. The ultrasonic atomizer 26 is fluid permeable, preferably by means of an aperture 30 through the ultrasonic atomizer 26, so that the vaporized excess water can move through the ultrasonic atomizer 26 into the upstream airflow channel 20.

[0075] Figure 1 A shows the aerosol-generating device 10 during the excess water removal operation. The excess water of the aerosol-forming substrate 16 is vaporized and moves through the ultrasonic atomizer 26 into the upstream airflow channel 20.

[0076] Figure 1 B shows the aerosol-generating device 10 after the excess water removal operation. The excess water has been vaporized and is moved into the upstream airflow channel 20. Subsequently, the heating operation can start thereby heating the aerosol-forming substrate 16 by means of the heating element 24. After the heating operation, a user can draw on the proximal end of the aerosol-generating article 12 and inhale the vaporized aerosolforming substrate 16 as well as the cold vaporized excess water of the aerosol-forming substrate 16. The cold vaporized excess water may cool the first puff which may lead to a more pleasant experience for the user.

[0077] Figure 2 shows an illustration of the arrangement of the ultrasonic atomizer 26 at the distal end of the cavity 14 which is the base of the cavity 14. Hence, when the aerosolgenerating article 12 is received in the cavity 14, the front plug 18 of the aerosol-generating article 12 comes into direct contact with the atomizer. The fluid permeability of the atomizer enables vaporized excess water to flow through the ultrasonic atomizer 26 so as to remove the excess water from the aerosol-forming substrate 16. Figure 2 further shows contacts 28 of the ultrasonic atomizer 26 for electrically contacting the ultrasonic atomizer 26 with one or both of a power supply (not shown) and that control of the aerosol-generating device 10. Figure 2 finally shows an aperture 30 of the ultrasonic atomizer 26 as well as micro holes 32 through the ultrasonic atomizer 26 improving airflow through the ultrasonic atomizer 26.

Claims

1. An aerosol generating device comprising: a cavity for placing an aerosol-forming substrate, a heating element configured to heat an aerosol-forming substrate located in the cavity to generate an inhalable aerosol, an ultrasonic atomizer configured to atomize excess water in an aerosol-forming substrate, and controller, wherein the controller is configured to control the heating operation of the heating element, to control the operation of removing excess water from the ultrasonic atomizer, and to perform the operation of removing excess water from the ultrasonic atomizer before the heating operation of the heating element.

2. An aerosol generating device according to claim 1, wherein the ultrasonic atomizer comprises, and is preferably made in the form of, a piezoelectric element.

3. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic nebulizer comprises, and is preferably in the form of, an ultrasonic element.

4. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic atomizer has a disc shape or a cylindrical shape.

5. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic nebulizer is arranged so as to at least partially surround said cavity.

6. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic atomizer is located adjacent to the distal end of said cavity.

7. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic nebulizer is permeable to the fluid.

8. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic nebulizer comprises a perforated mesh disc.

9. An aerosol generating device according to any one of the preceding claims, further comprising an air flow channel located upstream of said cavity and fluidly connected to said cavity.

10. The aerosol generating device of claim 9, wherein the ultrasonic atomizer is configured to direct atomized excess water from the aerosol-forming substrate into an upstream air flow channel.

11. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic nebulizer comprises a central opening extending along the longitudinal central axis of said cavity.

12. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic nebulizer comprises a plurality of perforations extending parallel to the longitudinal central axis of said cavity.

13. An aerosol generating device according to any one of the preceding claims, wherein the ultrasonic atomizer is configured to contact the aerosol-forming substrate when the aerosol-forming substrate is placed in the cavity, and in particular the ultrasonic atomizer is configured to contact the distal end surface of the aerosol-forming substrate.

14. A method for removing excess water from an aerosol-forming substrate in an aerosol generating device according to any of the preceding claims, comprising the steps of: the controller controls the ultrasonic treatment of the atomizer during the operation of removing excess water from the ultrasonic atomizer, The controller sequentially controls the heating operation of the heating element.