Aerosol generating system and method of producing an aerosol generating system

Abstract

An aerosol generating system comprises: a first positioning segment (14); a substrate segment (12) adjacent to the first positioning segment (14) or designed to be adjacent to the first positioning segment (14) in use, the substrate segment (12) comprising an aerosol generating substrate and at least one susceptor (10) incorporated in the aerosol generating substrate and adapted to cooperate with at least one induction coil (26) surrounding the substrate segment (12) in use; wherein the first positioning segment (14) comprises a cavity (16) adapted to adjust the position of at least one susceptor (10) inside the aerosol generating substrate, and wherein, in use, a portion of at least one susceptor (10) is accommodated in a cavity (16) formed in the first positioning segment (14) so as to position the susceptor (10).

Description

[0001] Aerosol generating system and method of producing an aerosol generating system

[0002] Technical field

[0003] The present invention relates to an aerosol generating system and a method for producing such a system .

[0004] Background

[0005] Several types of inhalation or aerosol generating devices and systems are known and continuously replace traditional cigarettes . Such devices may have one or more susceptors incorporated in an aerosol generating substrate adapted to cooperate with at least one induction coil surrounding the substrate in use .

[0006] For example , WO 2019 / 224073 Al is related to an aerosol generating system comprising an aerosol generating article having an aerosol generating material , into which a U-shaped susceptor is embedded and adapted to cooperate with an induction coil surrounding the article . According to WO 2021 / 074090 Al , such a susceptor is insertable into an aerosol generating material of an aerosol generating article .

[0007] Summary of the invention

[0008] In view of the above , there still remains a need for an aerosol generating system which allows ef ficient and defined heating of an aerosol generating substrate .

[0009] This is achieved by means of the system of claim 1 .

[0010] Accordingly, the system comprises a substrate segment comprising an aerosol generating substrate and at least one susceptor incorporated therein, as well as a first positioning segment . The first positioning segment can, firstly, be adj acent to the substrate segment and can thus be part of a consumable aerosol generating article . In other words , in this alternative , the article , which i s consumed by inhalation and replaced by a new article after use , comprises both the substrate segment and the first positioning segment .

[0011] However, secondly, the first pos itioning segment can also be part of an aerosol generating device adapted to accommodate the article during use , and the first positioning segment can be designed to be adj acent to the substrate segment in use . In both alternatives , the first positioning segment comprises a cavity adapted to adj ust the position of at least one susceptor inside the aerosol generating substrate . In other words , in use , a portion of at least one susceptor is accommodated in a cavity (presenting for example a recess or slit ) formed in the first positioning segment so as to position the susceptor . Consequently, the susceptor is reliably held in a well-defined position, in particular in a radial direction of the article having a longitudinal axis and typically being cylindrical in shape . Reliably positioning the susceptor in a well-defined redial position will signi ficantly improve coupling between the induction coil and the susceptor . In particular, power trans ferred from the induction coil to the heater can be provided particularly ef ficient and heating can be provided ef ficient as well as in a well-defined manner . In particular, defined heating profiles for di f ferent segments of the consumable can be provided, and vaping quality experienced by the user can be maintained at a high level .

[0012] When the first positioning segment is adj acent to the substrate segment , it can be formed in a filter portion with the substrate segment constituting the end portion of the article . Alternatively, the cavity can be formed in a so- called front plug of the article , which constitutes the end portion of the article and, for example , prevents any parts of the aerosol generating substrate , such as pieces of tobacco leaves , from falling out . When the cavity is formed in the aerosol generating device , it can for example be arranged in the bottom of a chamber adapted to accommodate the aerosol generating article . In this case , the susceptor will be accommodated in and positioned by the cavity formed in the device , but the susceptor as such is , also in this case , incorporated in the article , in particular the aerosol generating substrate thereof . In particular, when the cavity is provided in the device , it can have a circular cross-section . This has the advantage that the article can be inserted into the device in any rotational orientation, and the susceptor will always be pos itioned appropriately in the radial direction, in particular centrally .

[0013] This also applies to the embodiment , when the cavity is provided in a segment of the article itsel f . In particular, when the cavity is formed when manufacturing the article , it can be provided with a cylindrical shape in the positioning segment , and the susceptor proj ecting from the substrate segment also in this case , will be positioned appropriately, in particular centrally . This particularly applies to the step of combining the positioning segment and the substrate segment of the article . However, in particular when the cavity is provided in the article itsel f , it can also be formed as a slit or groove . In can then be ensured during manufacture , that the proj ecting susceptor i s oriented in a rotational orientation of the article allowing insertion of the susceptor into the slit or groove .

[0014] Preferred embodiments are described in the further claims .

[0015] In order to further improve pos itioning of the susceptor, a second positioning segment can be provided, with the substrate segment being arranged or designed to be arranged between the first and the second positioning segments . The second positioning segment comprises a cavity (presenting for example a recess or slit ) in order to adj ust the position of at least one susceptor inside the aerosol generating substrate . In other words , with the first positioning segment being part of the article , the substrate segment is located between two positioning segments , and the susceptor is essentially held from both axial sides in the article . In the alternative of the first positioning segment being part of the device , the susceptor is held in the article by means of the cavity of the second positioning segment adj acent the substrate segment , and is held from the second side , namely the end of the article , as soon as the article is inserted into the device and the susceptor is positioned in the cavity of the first positioning segment .

[0016] In order to provide a particularly stable positioning of the susceptor, the cavity of the first and / or second positioning segment can be angled at least once , and the susceptor then preferably has at least one hooked portion to be positioned in the angled cavity .

[0017] Generally, reliability of the positioning of the susceptor can further be improved, when the first and / or second positioning segment is connected with the susceptor .

[0018] In view of an induction coil typically being positioned in the aerosol generating device in a manner concentric with a receiving chamber for an aerosol generating article and, moreover, the article typically being provided centrally within the receiving chamber, it will provide advantages with regard to ef ficient power trans fer from the coil to the susceptor, i f the cavity of the first and / or second positioning segment is adapted to position at least one susceptor at the centre of the substrate segment .

[0019] Whereas the susceptor can be essentially flat , it may also be bent at least once about its longitudinal axis ( i . e . article axis ) , in order to further improve its positioning .

[0020] This can also be reali zed by the aerosol generating substrate being constituted by a sheet of material wound at least once around the susceptor . In order to ef ficiently have the first and / or second positioning segment ful fil more than one function, this may comprise a filter material such as acetate , in order to filter the aerosol drawn from the substrate segment to a mouthpiece . Also , with a positioning segment in the form of a front plug, filter material has proven an appropriate component thereof .

[0021] The cavity of the first and / or second positioning segment can, on the one hand, be pre-manufactured before assembling the system . In other words , it can be formed in the device , before the article is inserted and / or it can be formed in the article as part of its manufacture .

[0022] In particular, the cavity of the first and / or second positioning segment can be formed by pressure during insertion of the susceptor into the substrate segment and partly inserting it into the first and / or second positioning segment .

[0023] This can be reali zed particularly ef ficiently, when the susceptor is longer than the substrate segment . In other words , the susceptor will proj ect from the substrate segment in a longitudinal direction thereof and can thus be pressed and inserted into the first and / or second positioning segment .

[0024] The invention further provides a method for producing an aerosol generating system essentially formed as described above and hereinafter, and details as well as preferred measures and embodiments thereof essentially correspond to those of the system . In particular, any features mentioned above and below with regard to the system are equally applicable to the method of producing it and vice versa .

[0025] Brief description of the drawings

[0026] Hereinafter, embodiments of the invention will be described with reference to the drawings , in which

[0027] Fig . 1 shows a partial cut view of a first embodiment , Fig . 2 shows a partial cut view of another example of the first embodiment ,

[0028] Fig . 3 schematically shows the aerosol generating article inserted into an oven of an aerosol generating device , according to the first embodiment , and

[0029] Fig . 4 schematically shows the aerosol generating article inserted into an oven of an aerosol generating device , according to a second embodiment .

[0030] Detailed description of preferred embodiments

[0031] First Embodiment

[0032] Figures 1 and 2 show di f ferent examples of an aerosol generating system according to a first embodiment . According to this embodiment , the aerosol generating system is an aerosol generating article 5 extending according to an article axis X and configured to operate with an aerosol generating device 6 , as it will be explained in further detail below . The aerosol generating article 5 has for example a generally cylindrical shape defining for example a circular crosssection . In some examples , the cross-section may be oval .

[0033] According to this embodiment , the aerosol generating article 5 comprises a substrate segment 12 and a first positioning segment 14 adj acent to the substrate segment 12 . These segments 12 , 14 are coaxially adj acent one to the other and form for example the same cross-sectional shape . Particularly, the first positioning segment 14 can be fixed to the substrate segment 12 using for example a common wrapper (not shown) or any other appropriate means . The wrapper can comprise paper .

[0034] The substrate segment 12 comprises an aerosol generating substrate and at least one susceptor 10 adapted to heat the aerosol generating substrate when it is placed into a magnetic field . The aerosol generating substrate is formed for example by a tobacco and / or nicotine containing mixture . Such mixture can further comprise an aerosol forming agent , a flavoring agent and / or a binder . The tobacco can for example be presented in the mixture in a form of compressed tobacco leaves . The aerosol generating substrate can be formed by arranging the mixture around the susceptor 10 or the susceptor 10 can be inserted in the mixture . According to a particular example , the aerosol generating substrate can present a sheet , for example a tobacco sheet , wound around the susceptor 10 to form one or several layers .

[0035] The susceptor 10 can comprise or be made from a metal . The susceptor 10 extends according to , i . e . along the article axis X and defines any appropriate shape optimi zed to heat the aerosol generating substrate when it is placed within a magnetic field . For example , the susceptor 10 forms a plate having a width ( dimension perpendicular to the article axis X ) inferior to the width of the aerosol generating article ( i . e . its diameter in case of a circular cross-sectional shape or its greatest diameter in case of an oval cross-sectional shape ) . The plate can be provided with one or several pairs of transversally extending notches 19 arranged facing each other, as it is shown in Figure 3 . Each pair of notches 19 may be arranged to delimit di f ferent segments 28 , 30 of the plate which are intended to interact with di f ferent magnetic coils as it will be explained in further detail below . Particularly, in the example of Figure 3 , three pairs of notches 19 delimit two large segments 28 and two short end segments 30 . Each short end segment 30 is adj acent to a respective end of the susceptor 10 . The large segments 28 extend according to the article axis X between the short end segments 30 .

[0036] According to some examples , the susceptor 10 can be bent , preferably around the article axis X . It can for example form a bent plate with points of bending formed for example by said pairs of notches . Advantageously, the susceptor 10 presents a symmetrical shape in respect with or with respect to the article axis X in at least one plane comprising this axis X . In the example of Figure 3 , this plane corresponds to the plane of the Figure .

[0037] The susceptor 10 extends substantially according to the whole length of the substrate segment 12 and protrudes from at least one of its ends . According to the example of Figure 1 , a protruding end 15 of the susceptor 10 is received in a cavity 16 formed in the first positioning segment 14 . Advantageously, the cavity 16 is formed at the center of the cross-section of the first positioning segment 14 . For example , in case of a circular cross-sectional shape , the cavity 16 is formed at the center of the corresponding circle . In this way, the first positioning segment 14 is designed to position at least a part of the susceptor 10 at the center of the substrate segment 12 .

[0038] The shape of the cavity 16 is adapted to the shape of the protruding end 15 of the susceptor 10 . For example , as it is shown in Figure 1 , the protruding end 15 can be straight and extend according to the article axis X . According to the example of Figure 2 , the protruding part 15 forms at least one hooked portion 18 in respect with the article axis X . In either case , the cavity 16 has a substantially complementary shape to the shape of the protruding end 15 . Thus , in the example of Figure 1 , the cavity 16 has only a straight portion extending along the article axis X . In other words , in this case , the cavity 16 has an " I" shape . In the example of Figure 2 , the cavity 16 has a straight portion extending along the article axis X and a hooked portion extending transversally . In other words , in this case , the cavity has an "L" shape . In some examples , the protruding end 15 can be bent in respect with a central part of the susceptor 10 .

[0039] According to di f ferent examples of this embodiment , the first positioning segment 14 can form a f iltering / cooling portion or a front plug of the aerosol generating article 5 .

[0040] The f ilter / cooling portion is intended to form a mouthpiece or to be received within an external mouthpiece . When the aerosol generating article 5 is provided with a front plug, it can be arranged opposite to the f iltering / cooling portion so as the substrate segment 12 is arranged between the f iltering / cooling portion and the front plug . The front plug can be used to prevent the aerosol generating substrate ( consumed or not ) from falling out from the substrate segment 12 .

[0041] When the first positioning segment 14 is a f ilter / cooling portion, it comprises a filter material at least in the region forming the cavity 16 . The filter material can comprise acetate or any other material able to withstand temperatures comprised between 200 ° C and 1000 ° C, or preferably at least 230 ° C or 250 ° C or 300 ° C or 350 ° C or 400 ° C . Such a material can be for example glass reinforced / coated polypropylene . Advantageously, this material has a mechanical strength configured to ensure the positioning of the protruding end 15 of the susceptor 10 within the cavity 16 . This mechanical strength can be greater than 60 MPa, advantageously greater than 70 MPa and preferably greater than 80 MPa .

[0042] When the first positioning segment 14 is a front plug, it can be made from a substantially solid material defining for example one or several airflow channels conducting airflow from outside to the substrate segment 12 . Alternatively, the front plug can comprise acetate or any other suitable material as disclosed in relation with the f ilter / cooling portion . For example , the front plug can be made from the same material as the f iltering / cooling portion . In some examples , the front plug can be made from a material presenting an increased density in comparison with the material forming the f ilter / cooling portion .

[0043] In some examples , the aerosol generating article 5 can further comprise a second positioning segment 32 arranged opposite to the first positioning segment 14 in respect with the substrate segment 12 , as it is shown in Figure 3 . The three segments 12 , 14 , 32 can be coaxially adj acent one to the other . Particularly, in this case , the substrate segment 12 is arranged between the first 14 and the second positioning segments 32 . The second positioning segment 32 can be fixed to the substrate segment 12 using a common wrapper . For example , a same wrapper can fix both positioning segments 14 , 32 to the substrate segment 12 . In some other examples , separate wrappers can be provided .

[0044] As the first positioning segment 14 , the second positioning segment 32 defines a cavity similar to the cavity 16 explained above which is designed to receive a protruding end of the susceptor 10 opposite to the protruding end 15 explained above . Particularly, in this case , the susceptor 10 extends between the first positioning segment 14 and the second positioning segment 32 and defines two opposite protruding ends received in the respective cavities of the positioning segments 14 , 32 . The cavity of the second positioning segment 32 is also defined at the center of the cross-section of the second positioning segment 32 so as to position at least a part of the susceptor 10 at the center of the substrate segment 12 . The cavity of the second positioning segment 32 can also be straight or form a hooked portion as explained in relation with the cavity 16 of the first positioning element 14 .

[0045] As the first positioning segment 14 , the second positioning segment 32 can form the f iltering / cooling portion or the front plug, as explained above . In the example of Figure 3 , the second positioning segment 32 corresponds to the f iltering / cooling portion and the first positioning segment 14 corresponds to the front plug .

[0046] Particularly, in the example of Figure 3 , the second positioning segment 32 comprises a positioning part 33 and a filtering part 20 . The positioning part 33 is adj acent to the substrate segment 12 and defines the cavity for receiving the protruding end of the susceptor 10 , as explained above . The filtering part 20 comprises a filtering material . The positioning part 33 can be made from a di f ferent material , for example from a material having an increased strength and / or density .

[0047] As shown in Figure 3 , the aerosol generating article 5 is configured to be inserted in the aerosol generating device 6 which comprises an oven designed to receive the substrate segment 12 of the aerosol generating article 5 . The oven essentially defines a heating chamber 24 for accommodating the substrate segment 12 . To ef fect heating, the heating chamber 24 is surrounded by one or several induction coils 26 which cooperate with the susceptor 10 provided in the substrate segment 12 . In the example of Figure 3 and as explained above , the susceptor 10 is segmented by pairs of notches into two large segments 28 cooperating with two di f ferent induction coils 26 . The short end segments 30 are not arranged within the coils to avoid overheating of the susceptor ends . It is noted that the large segments 28 of the susceptor 10 can be individually heated by the respective coil 26 , in order to heat individual segments of the substrate segment which may have di f ferent contents and / or flavors and / or nicotine contents .

[0048] As regards a segmented susceptor 10 , any details thereof can be taken from the application entitled "Aerosol Generating System" filed by the applicant on July 13 , 2022 .

[0049] To manufacture the aerosol generating article 5 according to the first embodiment , the cavity of the or each positioning segment 14 , 32 can be pre-manufactured before assembling the article 5 .

[0050] The pre-manufacturing can be done using a precision tool such as a laser for example to precisely position a cutting tool or an embossing tool in respect with the first and / or second positioning segment ( s ) 14 , 32 . Then, the cutting tool or the embossing tool can be activated to remove material according to the desired cavity' s shape . Instead of the cutting or embossing tool , a heating tool can be used to form a cavity by heating . Alternatively, the cavity of at least one of the positioning elements 14 , 32 is not pre-manufactured but formed by pressure during insertion the corresponding protruding end 15 of the susceptor 10 in the corresponding segment 14 , 32 . For this purpose , a precision tool can be used to precisely position the susceptor 10 in respect with the corresponding segment 14 , 32 and then, exert pressure at the center to form the cavity . Then, according to some examples , the susceptor 10 can be heated to form a cavity in the corresponding segment 14 , 32 .

[0051] In either case , the susceptor 10 can be provided with or without the aerosol generating substrate , before being assembled with the or each positioning segment 14 , 32 .

[0052] For example , when the susceptor 10 is already incorporated in the aerosol generating substrate , at least one of its ends protrudes axially from the substate so as it can be received in or form the corresponding cavity . Then, one or several wrappers can be used to fix together the substrate segment 12 with the first positioning segment 14 and in some cases , with the second positioning segment 32 .

[0053] When the susceptor 10 is provided without the aerosol generating substate , it can first be for example received in or form the cavity of the or each positioning segment 14 , 32 . Advantageously, the susceptor 10 can connect both positioning segments 14 , 32 between them . Thereafter, the aerosol generating substrate can be formed around the susceptor 10 . When the aerosol generating substrate presents a tobacco sheet , it can be simply wound around the susceptor 10 to form one or several layers . When the aerosol generating substrate presents a mixture comprising for example tobacco leaves , it can be for example be blown around the susceptor 10 and fixed by an appropriate binder . Thereafter, like in the previous case , one or several wrappers can be used to fix together the substrate segment 12 with the first positioning segment 14 and in some cases , with the second positioning segment 32 .

[0054] Second Embodiment Figure 4 shows an aerosol generating system according to a second embodiment of the invention . According to this embodiment , the aerosol generating system comprises an aerosol generating article 5 extending according to an article axis X and an aerosol generating device 6 configured to operate with the aerosol generating article 5 . Both aerosol generating article 5 and aerosol generating device 6 are similar to those explained in relation with the first embodiment , except the features explained below . In the example of Figure 4 , the aerosol generating article 5 is only partially inserted in the aerosol generating device 6 .

[0055] Particularly, according to the second embodiment , the first positioning segment 14 is integrated into the aerosol generating device 6 instead of the aerosol generating article 5 . In this case , the first positioning segment 14 can for example be arranged adj acent to a bottom wall of the heating chamber 24 . The first positioning segment 14 can be made from a substantially solid material or be at least partially flexible , like for example a mousse . The first positioning segment 14 can be permanently fixed to the bottom wall of the heating chamber 24 or can be fixed to this wall in a detachable way . In this last case , it can for example form a replaceable element of the aerosol generating device 6 .

[0056] As in the previous embodiment , the first positioning segment 14 defines a cavity 16 designed to receive a protruding end 15 of the substrate segment 12 of the aerosol generating article 5 . The end 15 can permanently protrude from the aerosol generating article 5 so as while inserting the article 5 in the heating chamber 24 , the user can position this end inside the cavity 16 . In some examples , the protruding end 15 is covered by a detachable plug designed for example to be detached before inserting the aerosol generating article 5 inside the heating chamber 24 .

[0057] According to the second embodiment , the aerosol generating article 5 can be provided with a second positioning segment 32 similar to the one of the first embodiment . In some examples of the second embodiment , the aerosol generating article 5 is provided without the second positioning segment 32 . For example , it can be provided only with a f iltering / cooling part arranged opposite to the first positioning segment 14 when the article 14 is received within the heating chamber 24 .

[0058] The cavity of the or each positioning segment 14 , 32 can be formed or pre-manufactured as explained in relation with the first embodiment . Contrary to the previous embodiment , the cavity 16 of the first positioning segment 14 is always premanufactured . Additionally, the first positioning segment 14 is provided separately from the aerosol generating article 5 and is not af fixed to the aerosol generating article 5 . The first positioning segment 14 can for example be inserted into the heating chamber 24 while assembling the aerosol generating device 6 . In some examples , the first positioning segment 14 can be inserted in the heating chamber 24 by the user before using the aerosol generating article 5 .

Claims

Claims1. An aerosol generating system comprising: a first positioning segment (14) ; a substrate segment (12) adjacent to the first positioning segment (14) or designed to be adjacent to the first positioning segment (14) in use, the substrate segment (12) comprising an aerosol generating substrate and at least one susceptor (10) incorporated in the aerosol generating substrate and adapted to cooperate with at least one induction coil (26) surrounding the substrate segment (12) in use; wherein the first positioning segment (14) comprises a cavity (16) adapted to adjust the position of at least one susceptor (10) inside the aerosol generating substrate, and wherein, in use, a portion of at least one susceptor (10) is accommodated in the cavity (16) formed in the first positioning segment (14) so as to position the susceptor (10) .

2. The aerosol generating system of claim 1, characterized in that the system comprises a second positioning segment (32) , the substrate segment (12) is arranged or designed to be arranged between the first (14) and the second positioning segments ( 32 ) ; the second positioning segment (32) comprising a cavity adapted to adjust the position of at least one susceptor (10) inside the aerosol generating substrate.

3. The aerosol generating system of claim 1 or 2, characterized in that the cavity (16) of the first and / or a second positioning segment (s) (14, 32) is angled at least once ; and preferably the susceptor (10) has at least one hooked portion (18) to be positioned in the angled cavity (16) .

4. The aerosol generating system of one of the preceding claims, characterized in that the first and / or a second positioning segment (14, 32) is connected with the susceptor5. The aerosol generating system of one of the preceding claims, characterized in that the cavity (16) of the first (14) and / or a second positioning segment (32) is adapted to position at least one susceptor (10) at the center of the substrate segment (12) .

6. The aerosol generating system of one of the preceding claims, characterized in that the susceptor (10) is bent at least once about a longitudinal axis (X) thereof.

7. The aerosol generating system of one of the preceding claims, characterized in that the aerosol generating substrate is a sheet of material and wound at least once around the susceptor (10) .

8. The aerosol generating system of one of the preceding claims, characterized in that the first and / or a second positioning segment (s) (14, 32) comprise (s) a filter material such as acetate.

9. The aerosol generating system of one of the preceding claims, characterized in that the cavity (16) of the first and / or a second positioning segment (s) (14, 32) is premanufactured before assembling the system.

10. The aerosol generating system of one of claims 1 to 8, characterized in that the cavity (16) of the first and / or a second positioning segment (s) (14, 32) is formed by pressure during inserting the susceptor (10) into the substrate segment (12) and partly into the first and / or second positioning segment(s) (14,32) .

11. The aerosol generating system of one of the preceding claims , characterized in the susceptor (10) is longer than the substrate segment (12) .

12. The aerosol generating system of one of the preceding claims, forming an aerosol generating article (5) .

13. The aerosol generating system of one of claims 1 to 11, comprising an aerosol generating article (5) and an aerosol generating device (6) configured to operate with the aerosol generating article (5) ; the aerosol generating device (6) integrating the first positioning segment (14) .

14. A method for producing an aerosol generating system comprising the steps of: providing a first positioning segment (14) ; providing a substrate segment (12) adjacent to the first positioning segment (14) or designed to be adjacent to the first positioning segment (14) in use, the substrate segment (12) comprising an aerosol generating substrate and at least one susceptor (10) incorporated in the aerosol generating substrate and adapted to cooperate with at least one induction coil (26) surrounding the article (20) in use; forming a cavity (16) in the first positioning segment (14) adapted to adjust the position of at least one susceptor (10) inside the aerosol generating substrate; accommodating a portion of at least one susceptor (10) in the cavity (16) formed in the first positioning segment (14) so as to position the susceptor (10) .

15. The method of claim 14, characterized by additionally providing a second positioning segment (32) , the substrate segment (12) being arranged or designed to be arranged between the first (14) and the second positioning segments (32) ; the second positioning segment (32) comprising a cavity (16) adapted to adjust the position of at least one susceptor (10) inside the aerosol generating substrate.

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