Aerosol-generating article with improved heating profile

Abstract

The present disclosure relates to an aerosol-generating article for use in an aerosol-generating device (100), the article (1) comprising: a body (2) comprising an aerosol-forming substance configured to be heated by the aerosol-generating device (100); an insert (10) disposed at least partially within the substance (5); wherein the insert (10) is configured to reduce a difference between a highest (T_high) and a lowest (T_low) temperature of a temperature profile along a cross-section (CS) of the substance (5) when the aerosol-forming substance is heated by the aerosol-generating device (100).

Description

[0001] AEROSOL-GENERATING ARTICLE WITH IMPROVED HEATING PROFILE

[0002] Technical field

[0003] The present invention relates to heated tobacco products (HTPs) and non-tobacco products used in smoking devices. More specifically, it addresses the issue of uneven heat distribution within the tobacco rod, which adversely affects the smoking experience, taste, and device performance.

[0004] The present invention also relates to a respective aerosol-generating device and an aerosol-generating system.

[0005] Technical background

[0006] Heated tobacco products are gaining popularity as an alternative to traditional combustible cigarettes. These products typically employ external heating elements to generate heat, which is then transferred to the tobacco rod to produce an inhalable aerosol. However, the heat transfer in these products is often non-uniform, leading to excessive heating on the outer part of the rod and insufficient heating in the inner core. This uneven heating results in several issues, including hot puffs, inadequate vapor volume, and inferior taste. This diminishes the overall smoking satisfaction.

[0007] Existing solutions in the market, such as those employing induction heating elements inside the tobacco rod, attempt to address this problem but come with their own set of limitations. For instance, the inclusion of metal strips for induction heating can complicate the manufacturing process and increase production costs. In addition, the inclusion of metal strips can entail potential interactions with the aerosol-forming substance that may affect the quality of the aerosol. Furthermore, the materials used for these inserts must be carefully selected to avoid adverse health effects when heated.

[0008] Another approach is to design the heating element in such a way that it provides more uniform heat distribution, but this often requires sophisticated and costly engineering solutions.

[0009] Despite the substantial advances in the field of aerosol-generating devices, there remains a need for improved methods and systems that can provide more consistent and efficient aerosol generation. Against this background, an object of the present invention is to provide an article with which the above-mentioned disadvantages can be addressed.

[0010] Summary of the invention

[0011] The above-mentioned objects are at least partially achieved by the subject-matter of the independent claims. Preferred embodiments are subject of the dependent claims, and other suitable aspects of the present invention are described through the overall disclosure of the present application.

[0012] General aspects

[0013] A 1stembodiment of the invention is directed to an aerosol-generating article for use in an aerosolgenerating device, the article comprising: a body comprising an aerosol-forming substance configured to be heated by the aerosol-generating device; an insert disposed at least partially within the substance; wherein the insert is configured to reduce a difference between a highest and a lowest temperature of a temperature profile along a cross-section of the substance when the aerosol-forming substance is heated by the aerosol-generating device.

[0014] In this manner, the aerosol-generating article for use in an aerosol-generating device of the present disclosure paves the way for improved temperature distribution within the aerosol-forming substance. In particular, the insert can be easily integrated into existing manufacturing processes without significantly increasing costs or complexity.

[0015] The insert is strategically configured to reduce the temperature differential across a cross-section of the substance when the aerosol-forming substance is heated. This arrangement may address the challenge of uneven heating, which can lead to inconsistent aerosol production and potentially degrade the user experience.

[0016] The body, which encompasses the aerosol-forming substance, may be designed to interface efficiently with the aerosol-generating device, ensuring optimal heat transfer.

[0017] The insert, placed within the substance, may act as a thermal regulator, distributing heat more evenly across the substance. This may help in extending the lifespan of the aerosol-forming substance by preventing localized overheating, which can cause premature degradation. Furthermore, the insert's positioning within the substance may be important; without wishing to be bound by theory, it may be designed to intercept and redistribute heat, thereby smoothing out temperature gradients that typically occur during the heating process. By doing so, the insert may provide a more consistent temperature profile, which may be essential for maintaining the quality and consistency of the aerosol generated.

[0018] The proposed aerosol-generating article for use in an aerosol-generating device may also address the challenge of achieving a uniform aerosol output, which may be crucial for user satisfaction and product reliability. The technical configuration of the insert and its interaction with the aerosol-forming substance may result in a more efficient and reliable aerosol-generating article, ultimately enhancing the performance of the aerosol-generating device.

[0019] A body comprising an aerosol-forming substance configured to be heated by the aerosol-generating device. The communication mechanism between the body and the aerosol-generating device may involve thermal conduction, where the device applies heat to the body, thereby initiating the aerosol-forming process. The connection may be established through the physical interface between the body and the heating element of the device, ensuring efficient transfer of heat to the aerosol-forming substance.

[0020] An insert disposed at least partially within the substance. The communication mechanism here may be the physical embedding of the insert within the aerosol-forming substance, allowing it to interact directly with the substance. The connection may be maintained through the structural integration of the insert into the body, ensuring that it remains in place during the heating process and can effectively influence the thermal properties of the substance.

[0021] The insert is configured to reduce a difference between a highest and a lowest temperature of a temperature profile along a cross-section of the substance when the aerosol-forming substance is heated by the aerosol-generating device. The communication mechanism may involve thermal regulation, where the insert modulates the distribution of heat within the substance. The connection may be achieved through the insert's material properties and design, which enable it to conduct heat more evenly, thereby minimizing temperature gradients and ensuring a more uniform aerosol generation. The modulation of the distribution of heat within the substance may therefore occur passively. Thereby, the present disclosure provides advances over commonly known aerosol-generating articles. For instance, prior art aerosol-generating articles do not focus on heating profiles or an even temperature distribution within the substance. Further, their way of manufacturing may often leave room for improvement. In the prior art, it cannot be ruled out that localized burning of the substance may occur, which is disadvantageous for the consumer as this can lead to bad taste or the like.

[0022] Heating of the aerosol-forming substance for forming aerosols may occur by way of at least the following methods. A heating element may be provided as an internal heating element, for instance a heating element in proximity to the aerosol-forming substance and / or a heating element that is integrally formed with the aerosol-forming substance. The heating element may alternatively be an external heating element. The heating element may be part of an aerosol-generating device.

[0023] The heating element could be heated by resistive and / or by inductive heating methods. Inductive heating methods provide the advantage that no wires are required. Therefore, the heating element may be arbitrarily arranged without the need of providing extensive electrical connections in its vicinity.

[0024] Temperatures

[0025] According to a 2ndembodiment, the difference between the highest and the lowest temperature when the aerosol-forming substance is heated by the aerosol-generating device is at most 50% of the highest temperature, preferably at most 40%, preferably at most 30%, preferably at most 25%, preferably at most 20% of the highest temperature.

[0026] This embodiment has the advantage that the insert may act as a thermal regulator, ensuring a more uniform temperature distribution across the cross-section of the substance. This uniformity may be helpful for consistent aerosol generation and improved user experience.

[0027] The new features introduced in this embodiment specify the extent to which the temperature difference is minimized.

[0028] For instance, the difference between the highest and the lowest temperature when the aerosol-forming substance is heated by the aerosol-generating device is at most 50% of the highest temperature. This feature may ensure that the temperature variation is significantly reduced, leading to more efficient heating and consistent aerosol production.

[0029] Preferably, this difference is further reduced to at most 40% of the highest temperature, enhancing the uniformity of the heating process. This reduction in temperature variation is beneficial as it prevents overheating of certain sections while ensuring adequate heating of others, thereby optimizing the overall performance of the aerosol-generating article.

[0030] Further refinement is achieved when the temperature difference is at most 30% of the highest temperature, which provides an even more balanced thermal profile. This level of precision in temperature control is advantageous for maintaining the integrity of the aerosol-forming substance and ensuring a consistent release of aerosol.

[0031] Additionally, a temperature difference of at most 25% of the highest temperature offers even greater uniformity, which is particularly beneficial for high-precision applications where exact temperature control may be important.

[0032] Finally, the most stringent feature specifies that the temperature difference is at most 20% of the highest temperature. This feature represents the pinnacle of thermal regulation within the aerosol-generating article, ensuring that the temperature profile is nearly uniform across the cross-section of the substance. This high level of control minimizes the risk of localized overheating or underheating, thereby maximizing the efficiency and consistency of aerosol generation.

[0033] Each of these features contributes to the overall goal of achieving a highly uniform temperature distribution, which is essential for the optimal performance of the aerosol-generating article.

[0034] According to a 3rdembodiment, the highest temperature of the temperature profile along the crosssection of the substance is least 150°C, preferably at least 160°C, preferably at least 170°C, preferably at least 180°C, preferably at least 190°C, preferably at least 200°C, preferably at least 210°C preferably at least 220°C;

[0035] and / or the highest temperature of the temperature profile along the cross-section of the substance is most 450°C, preferably at most 400°C, preferably at most 390°C, preferably at most 380°C, preferably at most 370°C, preferably at most 360°C, preferably at most 350°C. The feature wherein the highest temperature of the temperature profile along the cross-section of the substance is at least 150°C, preferably at least 160°C, preferably at least 170°C, preferably at least 180°C, preferably at least 190°C, preferably at least 200°C, preferably at least 210°C, preferably at least 220°C, may ensure the aerosol-forming substance reaches a sufficient temperature to generate an aerosol effectively. This temperature range may be critical for the volatilization of the aerosol-forming substance, ensuring that the substance may be adequately heated to produce a consistent and high-quality aerosol. The arrangement between the body comprising the aerosol-forming substance and the insert, may be such that the insert aids in maintaining this minimum temperature threshold across the cross-section of the substance, thereby ensuring uniform heating and efficient aerosol generation. This brings the advantage of enhancing the user experience by providing a reliable and consistent aerosol output, which may be helpful for the satisfaction and convenience of the end-user.

[0036] Furthermore, the feature wherein the highest temperature of the temperature profile along the crosssection of the substance is at most 450°C, preferably at most 400°C, preferably at most 390°C, preferably at most 380°C, preferably at most 370°C, preferably at most 360°C, preferably at most 350°C, may prevent overheating of the aerosol-forming substance. Overheating can lead to the degradation of the substance, potentially producing undesirable by-products and negatively affecting the taste and safety of the aerosol. The insert’s configuration to reduce the temperature difference across the cross-section may ensure that the highest temperature does not exceed these specified limits, thereby maintaining the integrity and quality of the aerosol-forming substance. This feature brings the advantage of protecting the substance from thermal degradation, ensuring that the aerosol produced is safe, pleasant, and consistent in quality.

[0037] The specific temperature limits also help in prolonging the life of the aerosol-generating device by preventing excessive thermal stress on its components. In summary, these features collectively ensure that the aerosol-generating article operates within an optimal temperature range, thereby enhancing the overall performance, safety, and user satisfaction of the aerosol-generating device.

[0038] According to a 4thembodiment, the insert is disposed fully within the substance.

[0039] This configuration may ensure that the insert is completely surrounded by the aerosol-forming substance, thereby facilitating a more uniform heat distribution throughout the substance when heated by the aerosol-generating device. The specific mechanism of communication between the components involves the direct thermal interaction between the insert and the surrounding aerosol-forming substance. By being fully embedded within the substance, the insert can more effectively influence heat transfer in the entire cross-section of the substance. Thereby, it is believed that temperature gradients can be minimized.

[0040] This arrangement enhances the overall efficiency of the heating process, it may be possible that the insert can absorb and redistribute heat more evenly.

[0041] The new feature of having the insert fully within the substance brings several advantages.

[0042] Firstly, it may optimize the thermal conductivity within the aerosol-forming substance, ensuring that the highest and lowest temperatures within the cross-section are closer together. This uniform temperature distribution may be helpful for consistent aerosol generation, as it prevents localized overheating or underheating, which could degrade the quality of the aerosol or the substance itself.

[0043] Secondly, this configuration can potentially improve the longevity and performance of the aerosolgenerating device. By maintaining a more stable temperature profile, the device may be less likely to experience thermal stress or damage, thereby extending its operational life. Additionally, the uniform heating facilitated by the fully embedded insert can enhance the user experience by providing a more consistent and reliable aerosol output. This consistency may be particularly important for users who rely on the device for therapeutic or recreational purposes, as it may ensure that each use delivers a predictable and satisfactory result. But also other users and use cases may particularly benefit from this.

[0044] Furthermore, the fully embedded insert can also contribute to the safety of the device. By reducing the likelihood of hot spots within the aerosol-forming substance, the risk of combustion may be minimized. This may be particularly important in regulatory environments.

[0045] Overall, the feature of having the insert fully within the substance represents an improvement in the design and functionality of the aerosol-generating article, enhancing its performance, reliability, and safety.

[0046] According to a 5thembodiment, the body is elongated and defines a longitudinal axis, and the insert is elongated and defines a longitudinal axis, wherein the longitudinal axis of the body is substantially parallel to the longitudinal axis of the insert. The body of the article is elongated and defines a longitudinal axis, which implies that the body has a length greater, e.g., significantly greater than its width or diameter, facilitating a streamlined shape conducive to efficient handling and insertion into the aerosol-generating device. This elongated form factor may ensure that the aerosol-forming substance within the body is distributed along a defined axis, promoting uniform heating and consistent aerosol generation.

[0047] Additionally, the insert within the body is also elongated and defines its own longitudinal axis, mirroring the structural characteristics of the body.

[0048] This parallelism in design between the body and the insert may ensure that the insert can be optimally positioned within the body, thereby maximizing its effectiveness in reducing temperature differentials. The longitudinal axis of the body being substantially parallel to the longitudinal axis of the insert means that both components are aligned in such a manner that their respective axes run in the same direction, which may be helpful for maintaining structural integrity and ensuring that the insert remains in its intended position during the heating process. This parallel alignment facilitates a more uniform distribution of heat along the cross-section of the substance, as the insert can more effectively moderate temperature variations across the elongated body.

[0049] The specific mechanism of communication between the components involves the spatial alignment and geometric congruence of the body and the insert, which together create a synergistic effect that enhances the overall thermal management within the aerosol-generating article.

[0050] By ensuring that the longitudinal axes of both the body and the insert are substantially parallel, the design minimizes potential hotspots and cold spots within the aerosol-forming substance, thereby improving the consistency and quality of the aerosol produced. This structural configuration not only optimizes the heating efficiency but also contributes to the longevity and reliability of the aerosol-generating article, making it a more effective and user-friendly component for use in aerosol-generating devices.

[0051] According to a 6thembodiment, the longitudinal axis of the body is substantially coaxial to the longitudinal axis of the insert.

[0052] This embodiment establishes a specific spatial relationship between the body and the insert, ensuring that the insert is essentially centrally aligned within the body. The coaxial alignment facilitates uniform heating and efficient thermal conduction from the aerosolgenerating device to the aerosol-forming substance. By positioning the insert along the same longitudinal axis as the body, the heat distribution within the aerosol-forming substance is optimized, thereby enhancing the performance of the aerosol-generating article.

[0053] The insert’s central placement within the body may ensure that the heat is evenly distributed across the cross-section of the substance, which may be important for reducing the temperature gradient. This reduction in temperature variation across the substance’s cross-section may ensure a more consistent aerosol generation, improving the overall user experience by providing a uniform aerosol output.

[0054] Additionally, the coaxial alignment minimizes the risk of localized overheating or underheating, which could otherwise degrade the aerosol-forming substance or produce undesirable by-products.

[0055] The specific mechanism of communication between the components involves the thermal interaction facilitated by the coaxial arrangement, where the insert acts as a thermal regulator, distributing heat more evenly throughout the aerosol-forming substance.

[0056] This embodiment brings the new feature of enhanced thermal management within the aerosol-generating article, ensuring that the temperature profile is more uniform, which is essential for maintaining the integrity and quality of the aerosol produced.

[0057] The coaxial alignment also simplifies the manufacturing process, as it provides a clear and straightforward assembly guideline, ensuring that the insert is correctly positioned within the body. This precise alignment contributes to the reliability and consistency of the aerosol-generating article, making it more effective and user-friendly.

[0058] Overall, the coaxial arrangement of the longitudinal axes of the body and the insert is a critical feature that significantly improves the thermal performance and operational efficiency of the aerosol-generating article, ensuring a high-quality aerosol output and a better user experience. Dimensions and shapes

[0059] According to a 7thembodiment, a dimension of the insert perpendicular to its longitudinal axis is at most 90%, preferably at most 80%, preferably at most 70%, preferably at most 60%, preferably at most 50%, preferably at most 40%, preferably at most 30%, preferably at most 20%, of a dimension of the body perpendicular to the longitudinal axis of the body.

[0060] A dimension perpendicular to its longitudinal axis that is at most 90% of a dimension of the body perpendicular to the longitudinal axis of the body may ensure that the insert occupies a substantial portion of the cross-sectional area within the body, thereby enhancing the thermal management capabilities of the insert with regard to the rod.

[0061] As the dimension of the insert perpendicular to its longitudinal axis is reduced to at most 80%, 70%, 60%, 50%, 40%, 30%, and 20% of the dimension of the body perpendicular to the longitudinal axis of the body, the insert becomes progressively smaller in relation to the body. This progressive reduction in the size of the insert relative to the body allows for a more precise control over the temperature distribution within the aerosol-forming substance. Specifically, it is believed that the smaller insert sizes can enable a more targeted and efficient heat transfer within the rod, however, it should not be too small, as this may weaken its functionality in reducing the temperature gradient across the cross-section of the substance when heated by the aerosol-generating device.

[0062] The communication between the components, namely the body and the insert, is facilitated through the spatial configuration where the insert is disposed at least partially within the aerosol-forming substance. This spatial configuration allows the insert to influence the thermal properties of the aerosol-forming substance directly. By reducing the size of the insert relative to the body, the thermal conductivity and heat distribution can be finely tuned to achieve a more uniform temperature profile.

[0063] This uniformity in temperature may be important for optimizing the aerosol generation process, ensuring consistent aerosol production, and enhancing the overall user experience.

[0064] The new features brought by these specific dimensions of the insert include improved thermal management, enhanced efficiency in heat distribution, and a more consistent aerosol output. These improvements are significant in maintaining the quality and consistency of the aerosol produced, which is essential for user satisfaction and the effectiveness of the aerosol-generating article. Additionally, the ability to fine-tune the insert size provides flexibility in the design and manufacturing of the aerosolgenerating article, allowing for customization based on specific performance requirements and user preferences.

[0065] Overall, these features contribute to a more efficient and effective aerosol-generating article, with enhanced thermal properties and improved user experience.

[0066] According to an 8thembodiment, a dimension of the insert perpendicular to its longitudinal axis is at least 5%, preferably at least 10%, preferably at least 15%, preferably at least 20% of a dimension of the body perpendicular to the longitudinal axis of the body.

[0067] The insert, which is disposed at least partially within the aerosol-forming substance and is configured to reduce temperature variation across the substance when heated, has a dimension perpendicular to its longitudinal axis that is at least 5% of the corresponding dimension of the body. This dimensional specification may ensure that the insert is sufficiently large to influence the thermal profile effectively, thereby enhancing the uniformity of heat distribution across the aerosol-forming substance.

[0068] Preferably, the dimension of the insert perpendicular to its longitudinal axis is at least 10% of the corresponding dimension of the body, which further optimizes the insert's ability to mitigate temperature disparities within the substance. This increased dimension enhances the thermal conductivity and heat distribution properties of the insert, contributing to a more consistent aerosol generation process.

[0069] More preferably, the dimension of the insert perpendicular to its longitudinal axis is at least 15% of the corresponding dimension of the body. This further enlargement of the insert's dimension provides an even greater surface area for heat transfer, thereby improving the overall efficiency of the aerosol-generating article.

[0070] The most preferred embodiment specifies that the dimension of the insert perpendicular to its longitudinal axis is at least 20% of the corresponding dimension of the body. This maximized dimension may ensure that the insert plays a significant role in equalizing the temperature profile, thereby reducing the difference between the highest and lowest temperatures along the cross-section of the substance. The specific mechanisms of communication between the components involve the thermal interaction between the insert and the aerosol-forming substance. The insert's material properties and its dimensional characteristics facilitate efficient heat absorption and distribution, which in turn minimizes temperature gradients within the substance.

[0071] By specifying these dimensional relationships, the new features bring enhanced thermal management capabilities to the aerosol-generating article, ensuring a more uniform and efficient aerosol production process. This results in improved performance of the aerosol-generating device, providing a more consistent and satisfying user experience.

[0072] According to a 9thembodiment, the insert has a length along its longitudinal axis of at least 50%, preferably at least 60%, preferably at least 70%, preferably at least 80%, preferably at least 85% of a length of the substance along the longitudinal direction of the body, and / or the insert has a length along its longitudinal axis of at most 200 %, preferably at most 150%, preferably at most 100%, preferably at most 95%, preferably at most 90%, preferably at most 85% of a length of the substance along the longitudinal direction of the body.

[0073] The insert has a length along its longitudinal axis of at least 50%, preferably at least 60%, preferably at least 70%, preferably at least 80%, preferably at least 85% of the length of the substance along the longitudinal direction of the body. This feature may ensure that the insert extends substantially within the aerosol-forming substance, thereby maximizing its influence on the temperature profile across the crosssection of the substance. The substantial length of the insert relative to the aerosol-forming substance allows for more uniform heat distribution, which may be important in reducing the temperature differential between the highest and lowest temperatures within the substance. This uniformity in temperature may provide for a consistent aerosol generation, improving the efficiency and quality of the aerosol produced.

[0074] Additionally, the insert's length along its longitudinal axis may be specified to be at most 200%, preferably at most 150%, preferably at most 100%, preferably at most 95%, preferably at most 90%, preferably at most 85% of the length of the substance along the longitudinal direction of the body. This upper limit may ensure that the insert does not excessively extend beyond the substance, which could potentially disrupt the structural integrity of the aerosol-generating article or interfere with the proper functioning of the aerosol-generating device. By confining the insert's length within these specified limits, the design maintains a balance between effective temperature regulation and structural coherence. The specific mechanisms of communication between the components involve the insert's interaction with the aerosol-forming substance, where the insert's material properties and dimensions facilitate a more even heat distribution when the substance is heated by the device. This interaction is pivotal in achieving the desired temperature profile, thereby enhancing the overall performance of the aerosol-generating article.

[0075] The new features introduced by these dimensional constraints on the insert bring about a more controlled and efficient aerosol generation process, ensuring that the aerosol-forming substance is heated uniformly, which in turn leads to a consistent and high-quality aerosol output. These enhancements are helpful for meeting user expectations and maintaining the reliability of the aerosol-generating device.

[0076] According to a 10thembodiment, the insert has the shape of a cylinder.

[0077] The cylindrical insert, when disposed at least partially within the aerosol-forming substance, facilitates a more uniform distribution of heat across the cross-section of the substance. This uniform distribution is achieved through the cylindrical geometry, which inherently provides a symmetrical structure that can evenly interact with the surrounding aerosol-forming substance. The cylindrical shape aids in reducing thermal gradients by allowing heat to be conducted more uniformly from the aerosol-generating device through the insert and into the aerosol-forming substance.

[0078] This mechanism is particularly effective in minimizing hot spots and cold spots within the substance, thereby achieving the intended purpose of reducing the difference between the highest and lowest temperatures in the temperature profile along the cross-section of the substance.

[0079] The introduction of a cylindrical insert also brings the advantage of structural integrity and ease of manufacturing. Cylindrical shapes are inherently strong and can withstand the mechanical stresses during the assembly and operation of the aerosol-generating article. Additionally, the cylindrical insert can be easily fabricated using standard manufacturing processes, which can be beneficial for large-scale production. The cylindrical geometry also allows for a consistent and predictable interaction with the aerosol-forming substance, ensuring that the performance of the aerosol-generating article remains reliable and reproducible. Furthermore, the cylindrical insert can be designed to have specific dimensions and material properties that enhance its thermal conductivity, thereby further optimizing the heat distribution within the aerosol-forming substance. This embodiment, therefore, not only addresses the thermal management within the aerosol-generating article but also contributes to the overall efficiency and effectiveness of the aerosol-generating device. By ensuring a more uniform temperature profile, the cylindrical insert helps in achieving a consistent aerosol generation, which can improve the user experience by providing a stable and predictable aerosol output. This feature is important in maintaining the quality and consistency of the aerosol produced, which is a key aspect of the functionality and desirability of the aerosol-generating article.

[0080] According to an 11thembodiment, the insert comprises paper, preferably the insert consists of paper, most preferably the insert is a paper tube.

[0081] The paper insert interacts with the aerosol-forming substance and the heating element of the device to facilitate a more uniform heat distribution across the substance. This is achieved through the thermal properties of paper, which can act as an insulator or a conductor depending on its composition and structure, thereby aiding in the reduction of temperature differentials within the aerosol-forming substance.

[0082] The use of paper as the material for the insert brings the new feature of enhanced thermal management, which may be important for maintaining the quality and consistency of the aerosol generated.

[0083] In a more specific embodiment, the insert preferably consists of paper, which implies that the insert is exclusively made of paper without any additional materials. This further refines the thermal regulation mechanism by ensuring that the thermal properties of the insert are solely attributable to paper. The exclusive use of paper can enhance the predictability and reliability of the temperature profile across the substance, leading to more consistent aerosol production.

[0084] The absence of other materials eliminates potential variables that could affect the thermal dynamics within the aerosol-generating article.

[0085] In the most specific embodiment, the insert is a paper tube, which introduces a structural feature that can further optimize the thermal management. A paper tube insert provides a cylindrical geometry that can facilitate even heat distribution around its circumference and along its length. This structural configuration can enhance the efficiency of heat transfer from a heating element to the aerosol-forming substance, thereby minimizing temperature gradients. The paper tube's hollow structure may also allow for better airflow, which can contribute to a more consistent aerosol output. The introduction of a paper tube as the insert not only leverages the thermal properties of paper but also utilizes its structural advantages to achieve a more uniform temperature profile, thereby improving the overall performance of the aerosol-generating article.

[0086] According to a 12thembodiment, the insert has two ends, preferably seen along a longitudinal axis of the insert, wherein at least one end has a pointed shape.

[0087] In this further embodiment, the insert is characterized by having two ends, preferably aligned along its longitudinal axis. This structural detail facilitates a more uniform distribution of heat along the length of the insert, thereby contributing to the overall goal of reducing temperature disparities within the aerosolforming substance. The presence of two ends may ensure that the insert can effectively interact with the surrounding substance, promoting a more consistent thermal profile.

[0088] Additionally, at least one end of the insert is designed with a pointed shape. This pointed end may serve multiple functions: it can aid in the insertion process, ensuring that the insert is positioned accurately within the aerosol-forming substance, and it can also enhance the thermal conductivity at the point of contact, allowing for more efficient heat transfer. The pointed shape may also help in reducing any potential resistance when the insert is being embedded into the substance, ensuring a snug and secure fit.

[0089] These enhancements brought by the specific design of the insert, including its two ends and at least one pointed end, contribute to the performance of the aerosol-generating article. They ensure that the heat is distributed more evenly across the aerosol-forming substance, which may be helpful for the consistent generation of aerosol. This uniform heating not only improves the efficiency of the device but also enhances the user experience by providing a more reliable and consistent aerosol output. The detailed design considerations of the insert, therefore, play a critical role in optimizing the functionality of the aerosol-generating article, making it more effective and user-friendly.

[0090] According to a 13thembodiment, the insert is disposed at least partially within the substance by inserting the insert at least partially into the substance.

[0091] The insert's placement within the substance is achieved by physically inserting it at least partially into the substance, ensuring a more intimate and direct interaction between the insert and the aerosol-forming substance. This method of insertion enhances the thermal conductivity and heat distribution properties of the insert, thereby optimizing the temperature profile across the substance. By being at least partially embedded within the substance, the insert can more effectively mediate heat transfer, reducing hotspots and cold spots, which results in a more uniform aerosol generation process. This uniformity may be helpful for maintaining consistent aerosol quality and improving the overall user experience.

[0092] The new feature of inserting the insert at least partially into the substance brings about a more efficient thermal management system within the aerosol-generating article. It may ensure that the heat generated by the device is evenly distributed throughout the aerosol-forming substance, thereby enhancing the performance and reliability of the article. This configuration not only improves the consistency of the aerosol produced but also potentially extends the lifespan of the aerosol-forming substance by preventing localized overheating.

[0093] Furthermore, this embodiment may contribute to the structural integrity of the article, as the insert can provide additional support to the substance, preventing deformation or degradation under high temperatures.

[0094] Absence of heating means

[0095] According to a 14thembodiment, the article does not comprise internal heating means, and / or the body does not comprise susceptor material, and / or the insert does not comprise susceptor material.

[0096] The aerosol-generating article of this embodiment is characterized by the absence of internal heating means, which may imply that the heating of the aerosol-forming substance is dependent on external sources, such as the aerosol-generating device itself.

[0097] This may ensure that the article is simpler in design and potentially more cost-effective to manufacture, as it eliminates the need for integrated heating components within the article. The absence of internal heating means also reduces the complexity of the thermal management within the article, relying solely on the external device to provide the necessary heat. Additionally, the body of the article does not comprise susceptor material, which is typically used to enhance heating efficiency by converting electromagnetic energy into heat. By excluding susceptor material from the body, the article avoids potential issues related to uneven heating or hotspots that could arise from the presence of such materials. This feature also simplifies the material composition of the body, potentially reducing manufacturing costs and improving the consistency of the aerosol-forming substance's heating profile.

[0098] Furthermore, the insert within the article may also not comprise susceptor material. The insert's primary function may be to reduce the temperature gradient across the cross-section of the substance when heated by the aerosol-generating device. By not incorporating susceptor material, the insert avoids the risk of creating localized heating zones that could disrupt the uniformity of the temperature profile. This may ensure that the aerosol-forming substance is heated more evenly, enhancing the overall performance and user experience of the aerosol-generating article.

[0099] The exclusion of susceptor material from both the body and the insert contributes to a more uniform and controlled heating process, which may be helpful for maintaining the quality and consistency of the aerosol produced. These features collectively enhance the reliability and efficiency of the aerosolgenerating article while simplifying its design and potentially reducing production costs.

[0100] Aerosol-generating device and system

[0101] A 15thembodiment of the present disclosure is directed to an aerosol-generating device configured for receiving an aerosol-generating article, the aerosol-generating device comprising: a heating means for heating the aerosol-generating article, said article being according to any one of the embodiments described in here; and a power supply configured to power the heating means; optionally, wherein, when the aerosol-generating article is received in the aerosol-generating device, the heating means is arranged in proximity to the insert.

[0102] It is noted that the aerosol-generating device as described herein may be specifically defines to be configured to receive the aerosol-generating article and to heat said article, which is described elsewhere herein. Hence, the device must be structurally and functionally aligned with the article. Hence, all advantages described with reference to the aerosol-generating article may equally be applicable to the aerosol-generating device. The power supply may be any suitable power supply, for example a DC voltage source, such as a battery, e.g., a lithium iron phosphate battery. Alternatively, the power supply may be a Nickel cadmium battery, a Nickel-metal hydride battery, or a Lithium based battery, for example a Lithium-Cobalt, a Lithium-Iron-Phosphate, Lithium Titanate, or a Lithium-Poly mer battery. The power supply may be located within a body of the aerosol-generating device, or it may be another form of charge storage device such as a capacitor. The power supply may allow for recharging and may have a capacity that allows for storing enough energy for one or more ordinary use cycles. A use cycle may be understood as consuming substantially all of the aerosol-forming substance of the aerosol-generating article. If liquid consumables are used, which are also encompassed by the present disclosure, a use cycle may be understood as consuming substantially all of the liquid.

[0103] It is appreciated that the power supply requires less capacity than prior art power supplies, as the heating process is more efficient due to the coating material as described elsewhere herein.

[0104] A 16thembodiment of the present disclosure is directed to an aerosol-generating system comprising: an aerosol-generating article according to any one of the embodiments described in here; and an aerosolgenerating device according to the 15thembodiment.

[0105] It is noted that the aerosol-generating system as described herein may include all aspects and / or embodiments described herein, even if not expressly described as belonging to the aerosol-generating system but rather with reference to the aerosol-generating article or the aerosol-generating device. It is also to be understood that the features and advantages described with reference to the aerosol-generating system may equally be applicable to the aerosol-generating article and the aerosol-generating device.

[0106] Method

[0107] A 17thembodiment of the present disclosure is directed to a method for manufacturing an article according to any one of the embodiments described in here, the method comprising: providing the body comprising an aerosol-forming substance; providing the insert; inserting the insert at least partially into the aerosol-forming substance of the body. It is noted that the method as described herein may include all aspects and / or embodiments described herein, even if not expressly described as belonging to the method but rather with reference to the aerosol-generating article or the aerosol-generating device. It is also to be understood that the features and advantages described with reference to the method may equally be applicable to the aerosol-generating article and the aerosol-generating device.

[0108] According to an 18thembodiment, the insert is in direct contact with the aerosol-forming substance, preferably with the entire outer surface of the insert.

[0109] This makes manufacturing easier, since no additional space and / or material needs to be provided between the aerosol-forming substance and the insert.

[0110] According to a 19thembodiment, the insert comprises an essentially even cylindrical surface.

[0111] This may have the advantage that the outer surface of the insert does not comprise any bumps, protmsions, indentations, recesses or the like. Thereby, the outer surface of the insert may be essentially smooth.

[0112] According to a 20thembodiment, the insert is not configured to receive a heating element.

[0113] This makes manufacturing easier, since the insert does not need to be provided with additional features that make it more robust, e.g., to withstand external impacts or the like, which may be necessary when the insert is configured to receive a heating element.

[0114] According to a 21stembodiment, the insert is a singular, pre-formed insert.

[0115] Thereby, the insert could be placed as a single part, reducing manufacturing steps of the article. Thus, manufacturing could be simplified, for instance in comparison to a plurality of individual inserts.

[0116] Brief description of the figures

[0117] In the following, preferred embodiments are described, by way of example only. Reference is made to the following accompanying figures: Figure 1 shows an exemplary embodiment of an aerosol-generating article with a body and an aerosol-forming substance and an insert according to the present disclosure, disposed within the substance along a longitudinal axis.

[0118] Figure 2 shows an exemplary embodiment of an aerosol-generating article with an insert disposed within an aerosol-forming substance according to the present disclosure, illustrating the temperature profile along a crosssection of the substance.

[0119] Detailed description of preferred embodiments

[0120] Definitions

[0121] The term “aerosol-generating article” as used herein may also be referred to as a consumable or consumable article. Such an aerosol-generating article may comprise an aerosol-forming substance, which can be heated to generate an aerosol and / or an inhalable vapor for the user.

[0122] The term “susceptor” generally refers to a material that absorbs electromagnetic radiation (such as microwaves) and converts it into heat.

[0123] The term “aerosol-forming substance” used in the present disclosure may include materials that can volatilize upon heating. Thereby, a volatilized component in the form of an aerosol may be provided. Said aerosol-forming substance may include any tobacco-containing material. However, in some examples, no tobacco-containing material is provided. Additionally, or alternatively, the aerosol-forming substance may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Further, the aerosol-forming substance may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. The aerosol-forming substance may be provided in any desired form including but not limited to the form of a solid, a liquid, a gel or a wax or any other suitable form. Said aerosol-forming substance may also be a combination or a blend of materials. Said aerosol-forming substance may particularly comprise components such as nicotine, propylene glycol, PG, and / or vegetable glycerin, VG. Embodiments shown in the figures

[0124] In the following, the invention is described with reference to the accompanying figures in more detail. However, the present invention can also be used in other embodiments not explicitly disclosed hereafter. As detailed below, the embodiments are compatible with each other, and individual features of one embodiment may also be applied to another embodiment.

[0125] Throughout the figures and description, the same reference numerals refer to the same elements, unless stated otherwise. The figures may not be drawn to scale, and the relative size, proportions, and depiction of elements in the figures may be exaggerated for the purpose of clarity, illustration, and convenience. The figures do not limit the scope of the claims but merely support the understanding of the invention.

[0126] Fig. 1 illustrates an embodiment of an aerosol-generating article 1 designed for use in an aerosolgenerating device 100 (indicated in Fig. 2). The article 1 comprises a body 2 that includes an aerosolforming substance 5. The body 2 is elongated and defines a longitudinal axis LA. Within the body 2, an insert 10 is disposed at least partially within the aerosol-forming substance 5. The insert 10 is also elongated and defines a longitudinal axis LA, which is substantially parallel to the longitudinal axis LA of the body 2.

[0127] The insert 10 is configured to reduce the difference between the highest and lowest temperatures of a temperature profile along a cross-section CS of the aerosol-forming substance 5 when heated by the aerosol-generating device. This temperature regulation ensures uniform heating of the aerosol-forming substance 5, enhancing the efficiency and consistency of aerosol generation.

[0128] The insert 10 is fully embedded within the aerosol-forming substance 5, as depicted in the figure. The insert 10 has a cylindrical shape, with its longitudinal axis LA aligned coaxially with the longitudinal axis LA of the body 2. The figure shows that the insert 10 has two ends, 11 and 12, with at least one end 11 having a pointed shape. This pointed end 11 facilitates the insertion of the insert 10 into the aerosolforming substance 5.

[0129] The dimensions of the insert 10 perpendicular to its longitudinal axis LA are shown to be smaller than the corresponding dimensions of the body 2. Specifically, the dimension of the insert 10 perpendicular (i.e., in the horizontal direction of Fig. 1) to its longitudinal axis LA is at most 90% of the dimension of the body 2 perpendicular to the longitudinal axis LA of the body 2. This ensures that the insert 10 fits well within the body 2 without occupying excessive space, allowing for adequate aerosol-forming substance 5 to be present around the insert 10.

[0130] Furthermore, the length (i.e., in the vertical direction of Fig. 1) of the insert 10 along its longitudinal axis LA is at least 50% of the length of the aerosol-forming substance 5 along the longitudinal direction of the body 2. This proportion ensures that the insert 10 extends through a significant portion of the aerosolforming substance 5, contributing effectively to the temperature regulation across the substance.

[0131] The insert 10 is composed of paper, preferably consisting entirely of paper, and most preferably is a paper tube. This material choice is advantageous for its thermal properties and compatibility with the aerosolforming substance 5. The paper insert 10 does not comprise any susceptor material, which is consistent with the design of the article 1 that does not include internal heating means or susceptor material within the body 2.

[0132] The figure also indicates that the insert 10 is disposed within the aerosol-forming substance 5 by inserting it at least partially into the substance 5. This method of insertion is straightforward and ensures that the insert 10 is properly positioned to perform its function of temperature regulation.

[0133] Overall, Figure 1 provides a detailed depiction of the aerosol-generating article 1, highlighting the structural relationship between the body 2, the aerosol-forming substance 5, and the insert 10. The configuration and dimensions of these components are designed to optimize the performance of the aerosol-generating article 1 when used in conjunction with an aerosol-generating device.

[0134] Fig. 2 illustrates an embodiment of an aerosol-generating article 1 configured for use in an aerosolgenerating device 100. The article 1 comprises a body 2 that includes an aerosol-forming substance 5. The body 2 is elongated and defines a longitudinal axis LA. The aerosol-forming substance 5 is configured to be heated by the aerosol-generating device 100.

[0135] Within the body 2, an insert 10 is disposed at least partially within the aerosol-forming substance 5. The insert 10 is also elongated and defines a longitudinal axis LA, which is substantially parallel to the longitudinal axis LA of the body 2. The insert 10 is configured to reduce the difference between the highest temperature T high and the lowest temperature T low of a temperature profile along a crosssection CS of the aerosol-forming substance 5 when it is heated by the aerosol-generating device 100. The insert 10 is fully enclosed within the aerosol-forming substance 5. The insert 10 has a cylindrical shape and comprises paper, preferably consisting of a paper tube. The insert 10 has two ends, 11 and 12, with at least one end 11 having a pointed shape, as seen along the longitudinal axis LA of the insert 10.

[0136] The aerosol-generating device 100 (only a part of it, namely the coil 101, is depicted) includes heating means, such as a coil 101, for heating the aerosol-generating article 1. The heating means 101 is arranged in proximity to the insert 10 when the aerosol-generating article 1 is received in the aerosol-generating device 100. The body 2 does not comprise internal heating means or susceptor material, and the insert 10 also does not comprise susceptor material.

[0137] The embodiment shows the insert 10 having a dimension perpendicular to its longitudinal axis LA that is at most 90% of a dimension of the body 2 perpendicular to the longitudinal axis LA of the body 2. Additionally, the insert 10 has a length along its longitudinal axis LA of at least 50% of the length of the aerosol-forming substance 5 along the longitudinal direction of the body 2.

[0138] The aerosol-generating article 1 is designed to ensure a more uniform temperature distribution across the aerosol-forming substance 5, thereby improving the efficiency and consistency of aerosol generation. The insert 10, being made of paper, provides a cost-effective and environmentally friendly solution for achieving the desired temperature profile within the aerosol-forming substance 5.

[0139] The figure further shows a tube, such as a paper tube 3, of the article 1, which encloses the aerosolforming substance 5 and the insert 10. The paper tube 3 can be designed to interface with the aerosolgenerating device 100, ensuring proper alignment and heating of the aerosol-forming substance 5. The article 1 also includes a filter 6, which is arranged in proximity to the paper tube 3. The article 1 also includes a tipping paper 20, which is wrapped around the other parts.

[0140] In operation, the aerosol-generating device 100 heats the aerosol-forming substance 5 through the heating means 101, which is in proximity to the insert 10. The insert 10 helps to distribute the heat more evenly across the cross-section CS of the aerosol-forming substance 5, reducing the temperature gradient and ensuring a consistent aerosol output.

[0141] Overall, the embodiment depicted in Figure 2 provides a detailed view of the components and their arrangement within the aerosol-generating article 1, highlighting the technical features that contribute to its functionality and performance in conjunction with the aerosol-generating device 100. The present embodiments specifically provide for an improved article by proposing the insertion of a closed paper tube through the center of the substance. It is believed that this approach may decrease the effective depth of the substance, thereby promoting more uniform heating. Additionally, to maintain the same volume and weight of tobacco, the length of the substance may be extended. This solution is applicable not only to substances comprising tobacco but also to, e.g., botanical and paper-based substances, e.g., in the form of rods, making it versatile across various product types.

[0142] The proposed article leverages existing technologies in rod-making, such as those used for cigarette filters with capsules, and can be implemented using current manufacturing processes. This may ensure that the solution is both practical and cost-effective, providing a significant improvement over existing products in the market.

[0143] It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teaching. The disclosed examples and embodiments are presented for purposes of illustration only. Other embodiments may include some or all of the features disclosed herein. Therefore, it is the intent to cover all such modifications and alternate embodiments as may come within the true scope of this invention.

[0144] List of reference signs

[0145] 1 aerosol-generating article

[0146] 2 body

[0147] 3 tube

[0148] 5 aerosol-forming substance

[0149] 6 filter

[0150] 10 insert

[0151] 11 first end

[0152] 12 second end

[0153] 20 tipping paper

[0154] 100 aerosol-generating device

[0155] 101 coil CS cross-section of the substance

[0156] LA longitudinal axis

[0157] T high highest temperature of the cross-section T low lowest temperature of the cross-section

Claims

Claims1. An aerosol-generating article for use in an aerosol-generating device (100), the article (1) comprising:a body (2) comprising an aerosol-forming substance configured to be heated by the aerosol-generating device (100);an insert (10) disposed at least partially within the substance (5);wherein the insert (10) is configured to reduce a difference between a highest (T high) and a lowest (T low) temperature of a temperature profile along a cross-section (CS) of the substance (5) when the aerosol-forming substance is heated by the aerosol-generating device (100).

2. The article (1) according to the preceding claim, wherein the difference between the highest and the lowest temperature when the aerosol-forming substance (5) is heated by the aerosolgenerating device (100) is at most 50% of the highest temperature, preferably at most 40%, preferably at most 30%, preferably at most 25%, preferably at most 20% of the highest temperature.

3. The article (1) according to the preceding claim, wherein the highest temperature of the temperature profile along the cross-section (CS) of the substance (5) is least 150°C, preferably at least 160°C, preferably at least 170°C, preferably at least 180°C, preferably at least 190°C, preferably at least 200°C, preferably at least 210°C preferably at least 220°C;and / or wherein the highest temperature of the temperature profile along the crosssection (CS) of the substance (5) is most 450°C, preferably at most 400°C, preferably at most 390°C, preferably at most 380°C, preferably at most 370°C, preferably at most 360°C, preferably at most 350°C.

4. The article (1) according to any one of the preceding claims, wherein the insert (10) is disposed fully within the substance (5).

5. The article (1) according to any one of the preceding claims, wherein the body (2) is elongated and defines a longitudinal axis (LA), and the insert (10) is elongated and defines a longitudinal axis (LA),wherein the longitudinal axis (LA) of the body (2) is substantially parallel to the longitudinal axis (LA) of the insert (10).

6. The article (1) according to the preceding claim, wherein the longitudinal axis (LA) of the body (2) is substantially coaxial to the longitudinal axis (LA) of the insert (10).

7. The article (1) according to claim 5 or 6, wherein a dimension of the insert (10) perpendicular to its longitudinal axis (LA) is at most 90%, preferably at most 80%, preferably at most 70%, preferably at most 60%, preferably at most 50%, preferably at most 40%, preferably at most 30%, preferably at most 20%, of a dimension of the body (2) perpendicular to the longitudinal axis (LA) of the body (2).

8. The article (1) according to any one of claims 5 to 7, wherein a dimension of the insert (10) perpendicular to its longitudinal axis (LA) is at least 5%, preferably at least 10%, preferably at least 15%, preferably at least 20% of a dimension of the body (2) perpendicular to the longitudinal axis (LA) of the body (2).

9. The article (1) according to any one of claims 5 to 8, wherein the insert (10) has a length along its longitudinal axis (LA) of at least 50%, preferably at least 60%, preferably at least 70%, preferably at least 80%, preferably at least 85% of a length of the substance (5) along the longitudinal direction of the body (2), and / orwherein the insert (10) has a length along its longitudinal axis (LA) of at most 200%, preferably at most 150%, preferably at most 100%, preferably at most 95%, preferably at most 90%, preferably at most 85% of a length of the substance (5) along the longitudinal direction of the body (2).

10. The article according to any one of the preceding claims, wherein the insert has the shape of a cylinder.

11. The article (1) according to any one of the preceding claims, wherein the insert (10) comprises paper, preferably consists of paper, most preferably is a paper tube.

12. The article (1) according to any one of the preceding claims, wherein the insert (10) has two ends (11, 12), preferably seen along a longitudinal axis (LA) of the insert (10), wherein at least one end (11) has a pointed shape.

13. The article according to any one of the preceding claims, wherein the insert is disposed at least partially within the substance by inserting the insert at least partially into the substance.

14. The article (1) according to any one of the preceding claims, wherein the article (1) does not comprise internal heating means, and / orwherein the body (2) does not comprise susceptor material, and / orwherein the insert (10) does not comprise susceptor material.

15. The article according to any one of the preceding claims, wherein the insert is a singular, preformed insert.

16. The article (1) according to any one of the preceding claims, wherein the insert is in direct contact with the aerosol-forming substance, preferably with the entire outer surface of the insert.

17. The article (1) according to any one of the preceding claims, wherein the insert is in direct contact with the aerosol-forming substance, preferably with the entire outer surface of the insert.

18. The article (1) according to any one of the preceding claims, wherein the insert is not configured to receive a heating element.

19. An aerosol-generating device (100) configured for receiving an aerosol-generating article, the aerosol-generating device (100) comprising:a heating means for heating the aerosol-generating article, said article (1) being according to any one of claims 1 to 12; anda power supply (101) configured to power the heating means;optionally, wherein, when the aerosol-generating article is received in the aerosolgenerating device (100), the heating means is arranged in proximity to the insert (10).

20. An aerosol-generating system comprising:an aerosol-generating article according to any one of claims 1 to 18; andan aerosol-generating device (100) according to claim 19.

21. A method for manufacturing an article (1) according to any one of claims 1 to 18, the method comprising:providing the body (2) comprising an aerosol-forming substance (5); providing the insert (10);inserting the insert (10) at least partially into the aerosol-forming substance (5) of the body (2).

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