Aerosol-generating system

Abstract

The aerosol-generating system (8) comprises a capsule (1) comprising a shell (10) comprising a base (101) and at least one side wall (100) extending from the base. The capsule further comprises a lid (11) sealed on the at least one side wall (100) for forming a sealed capsule (1). The shell (100) contains an aerosol-forming substrate (2) and comprises susceptor material for heating the aerosol-forming substrate (2) within the shell (1). The system further comprises a power source (700) connected to a load network comprising an inductor (702) for being inductively coupled to the susceptor material of the shell (1).

Claims

1. A hand-held aerosol-generating system, comprising: a capsule comprising a shell comprising a base and at least one side wall extending from the base, the capsule further comprising a lid sealed on the at least one side wall and configured to form a sealed capsule, the shell containing an aerosol-forming substrate, and the base and the at least one side wall of the shell being made of susceptor material configured to heat the aerosol-forming substrate within the shell; a power source connected to a load network, the load network comprising an inductor configured to be inductively coupled to the susceptor material of the shell; a thermal insulation layer at least partially surrounding the susceptor material of the shell, wherein the thermal insulation layer is a material layer; and an aerosol-generating device comprising the inductor and a device housing comprising a cavity configured to receive the capsule, wherein the device housing further comprises the thermal insulation layer, and wherein the aerosol-generating device further comprises a mouthpiece.

2. The system of claim 1, wherein at least portions of an inner side of the shell are coated or lined with susceptor material.

3. The system of claim 1, wherein the thermal insulation layer is arranged between the capsule and the inductor.

4. The system of claim 1, wherein the lid of the capsule is frangible.

5. The system of claim 1, wherein the aerosol-generating device further comprises a piercing member configured to pierce the lid of the capsule.

6. The system of claim 5, wherein the mouthpiece comprises at least one air inlet and at least one air outlet, and the piercing member comprises at least one first conduit extending between the at least one air inlet and a distal end of the piercing element, the mouthpiece further comprising at least one second conduit extending between the distal end of the piercing element and the at least one air outlet, such that in use, when a user draws on the mouthpiece, air flows along an airflow pathway extending from the at least one air inlet, through the at least one first conduit, through a portion of the capsule, through the at least one second conduit and exits the at least one outlet.

7. The system of claim 1, wherein the aerosol-forming substrate comprises nicotine and an aerosol-former.

8. The system of claim 1, wherein the aerosol-forming substrate is in the form of particle, strip, crimped or folded sheet, pellet, viscous material.

9. The system of claim 1, wherein the capsule further comprises a sachet arranged in the shell, the sachet comprising a porous container containing the aerosol-forming substrate.

10. The system of claim 1, wherein the shell is made of only the susceptor material.

11. The system of claim 1, wherein the inductor is an inductor coil positioned within the housing.

12. The system of claim 3, wherein the inductor is an inductor coil positioned within the housing.

13. The system of claim 1, wherein the mouthpiece includes a piercing portion at a first end that is configured to pierce the lid of the capsule.

14. The system of claim 13, wherein the mouthpiece includes an air opening at a second end, the second end is opposite to the first end, and the mouthpiece includes a second conduit extending from the first end to the second end.

15. The system of claim 6, wherein the at least one first conduit at least partially extends along a first direction, and the at least one second conduit at least partially extends along a second direction, the second direction being perpendicular to the first direction.

16. The system of claim 1, wherein the mouthpiece comprises at least one air outlet arranged at a mouthpiece proximal end, and at least one air inlet arranged between the mouthpiece proximal end and an opposite arranged mouthpiece distal end.

17. The system of claim 16, wherein the mouthpiece is configured to be attachable to the device housing, and wherein the mouthpiece is further configured such that by attaching the mouthpiece to the housing a piercing portion pierces the lid of the capsule and forms an airflow pathway from the at least one air inlet of the mouthpiece, through the capsule to the at least one air outlet of the mouthpiece.

18. The system of claim 1, wherein the lid is formed of a material comprising no ferromagnetic material or no paramagnetic material.

19. The system of claim 1, wherein the thermal insulation layer has a thermal conductivity of less than 1 Watt per (meter×Kelvin).

20. The system of claim 19, wherein the thermal conductivity is less than 0.1 Watt per (meter×Kelvin).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is further described with regard to embodiments, which are illustrated by means of the following drawings, wherein:

(2) FIG. 1 schematically shows a cross-section of an inductively heatable aerosol-generating system;

(3) FIG. 2 shows an example of a capsule for use in the system of FIG. 1.

(4) FIG. 3 shows another example of a capsule for use in the system of FIG. 1.

(5) FIG. 4 shows another example of a capsule for use in the system of FIG. 1.

DETAILED DESCRIPTION

(6) FIG. 1 shows a cross-sectional view of an inductively heatable aerosol-generating system 8 comprising an aerosol-generating device 7 and a capsule 1 as described below. The aerosol-generating device 7 comprises an outer housing 70 adapted to house a power supply 700 such as a rechargeable battery, control electronics 701, and an inductor 702, for example a inductor coil. The housing 70 further comprises a cavity 703 wherein a capsule 1 is received. The inductor 702 is embedded in the proximal portion of the housing 70 surrounding the cavity 703 and the capsule 1 arranged in the cavity 703. A thermal insulation layer 20 is arranged at least partly between at least one side wall of a shell of the capsule 1 and the inductor 702.

(7) FIG. 1 shows a cross-sectional view of an inductively heatable aerosol-generating system 8 comprising an aerosol-generating device 7 and a capsule 1 as described below. The aerosol-generating device 7 comprises an outer housing 70 adapted to house a power supply 700 such as a rechargeable battery, control electronics 701, and an inductor 702, for example a inductor coil. The housing 70 further comprises a cavity 703 wherein a capsule 1 is received. The inductor 702 is embedded in the proximal portion of the housing 70 surrounding the cavity 703 and the capsule 1 arranged in the cavity 703.

(8) The aerosol-generating device 7 further comprises a mouthpiece 71 attachable to a proximal end of the device housing 70. The mouthpiece 71 comprises a piercing portion 710 directing versus the cavity 703. The mouthpiece 71 further comprises two airflow conduits arranged in the mouthpiece 71, an inlet conduit 711 and an outlet conduit 712.

(9) When the capsule 1 is positioned in the cavity 703 of the housing 70, the susceptor material of the active substrate 2 comprised in the capsule 1 is inductively heatable by the inductor coil 702.

(10) In use, the user inserts the capsule 1 into the cavity 703 of the aerosol-generating device 7, and then attaches the mouthpiece 71 to the housing 70. By attaching the mouthpiece, the piercing portion 710 pierces the lid of the capsule 1, and forms an airflow pathway from the air inlet, through the capsule 1 to the air outlet. The portion of the airflow pathway 714 entering the capsule 1 and the portion of the airflow pathway 715 exiting the capsule 1 are indicated by arrows. The user then activates the device 7, for example by pressing a button (not shown). In activating the device, the inductor 702 is supplied with power by the control electronics 701 from the power supply 700. When the temperature of the content of the capsule 1 reaches an operating temperature of for example between about 220 degree Celsius and about 240 degree Celsius, the user may be informed by means of an indicator (not shown) that the device is ready for use and that the user may draw on the mouthpiece 71. When the user draws on the mouthpiece, air enters the air inlet, proceeds through the conduit 711 within the mouthpiece 71 and into the capsule 1, entrains vaporised aerosol-forming substrate, and then exits the capsule 1 via the outlet conduit 712 in the mouthpiece 71.

(11) FIG. 2 shows a capsule 1 containing aerosol-forming substrate 2. The capsule 1 contains a shell 10 that is sealed with a lid 11. The shell 10 comprises a flange 12 for adhering the lid 11 to the shell 10. The shell 10 comprises a base 101 and a side wall 100. The shell 10 of the capsule 1 or the entire capsule 1 may be made from a susceptor material capable of being inductively heated such as to heat and vaporize the aerosol-forming substrate 2 in the capsule 1. Preferably, the shell 10 is made of stainless steel. The shell may also be made or comprise different materials, however, the shell preferably comprises more than 5%, preferably more than 20%, preferably more than 50% or 90% of ferromagnetic or paramagnetic materials. In the embodiment shown in FIG. 3, at least portions of an inner side of the shell 10 may be coated or lined with susceptor material 30.

(12) FIG. 4 shows an embodiment in which the aerosol-forming substrate 2 is prefilled into a sachet 40, which sachet 40 is then inserted into the shell 10. Thus, a capsule 1 may comprise a sachet 40 arranged in the shell 10. The sachet 40 comprises a porous container containing the aerosol-forming substrate 2.

(13) Preferably, the lid 11 is formed of a material comprising no, or a limited amount of ferromagnetic material or paramagnetic material.

(14) The shell 10 of the capsule 1 typically comprises a food-safe material, as in most cases, the capsule 1 is to be used with a device for inhalation of an aerosol generated be vaporizing the aerosol-forming substrate. Next to stainless steel, further examples of some food-safe materials include polyethylene terephthalate (PET), amorphous polyethylene terephthalate (APET), high density polyethylene (HDPE), polyvinyl chloride (PVC), low density polyethylene (LDPE), polypropylene, polystyrene and polycarbonate. In some cases, especially when the material of the shell comprises no susceptor material, the shell 10 can be lined with a susceptor material or a food-safe susceptor material to allow inductive heating of the shell 10, to prevent drying of the aerosol-forming substrate 2 and to protect the aerosol-forming substrate 2.

(15) A shell 10 of a capsule 1 can be lidded with, for example a heat-sealable lidding film, to make a fully enclosed and airtight capsule 1. A sealed capsule may have the advantage of preserving freshness of the contents, and preventing spill of the active material within the capsule 1 during transport or handling by a user.

(16) Preferably, a capsule 1 is formed and shaped for easy insertion into a cavity of an inductive heating device and to preferably snugly fit into the cavity of the device, for example a device according to the invention and as described herein.

(17) The lid 11 of a capsule 1 may also be made by a variety of materials. Typically, the lid comprises a food-safe material. The lid 11 can be sealed onto the capsule 1 after the active substrate 2 has been filled into the capsule 1. Many methods of sealing the lid 11 upon the shell 10 of a capsule 1 are known to those skilled in the art. One example of a method of sealing the lid on a shell of a capsule comprising a flange 12 is heat sealing. Preferably, the lid 11 of the capsule 1 is considered food-safe to at least about 350 degree Celsius. The lid 11 can be a commercially-available film for use with foods cooked in a conventional oven, and are often referred to as dual-ovenable (for microwave and conventional oven use). The dual-ovenable films typically comprise a PET (polyethylene terephthalate) base layer and an APET (amorphous polyethylene terephthalate) heat-sealing layer. The APET heat-sealing layer then comes in contact with the flange 12 of the shell 10 of the capsule 1. Such lidding films can readily be metallized, or foilized in advance to improve the barrier performance of the film regarding moisture, oxygen and other gases.

(18) The material of a capsule 1, in particular the shell 10, can serve to preserve the freshness of the fill material, and increase shelf life of the capsule. A capsule or lid or shell may also improve the visual appeal and perceived value of a capsule 1. The material of the capsule can also allow for improved printing and visibility of product information such as brand and indication of flavour.

(19) A capsule 1 may have apertures or vents (not shown) in the capsule. These apertures may allow for the content within the capsule 1 to have access to the environment. The capsule 1 may also be composed of a material, or preferably comprise a lid that can be punctured or opened when put into a device capable of vaporizing the contents of the capsule 1. For example, if a capsule 1 is heated to a certain temperature, the contents vaporize, and the aperture or apertures created by the device allow the vapour content from the heated capsule 1 to escape. The capsule 1 may also comprise a lid 11 or a seal that can be opened, for example peeled of, immediately prior to the capsule 1 being inserted within a device.

(20) Preferably, the capsule 1 is intended for a single use and may be replaced by a new one after use. The type of product contained within the capsule 1 may be marked on the capsule, may be indicated by the colour, size, or shape of the capsule 1.

(21) Any material that is capable of being aerosolized and inhaled by a user may be used in a device or capsule 1 according to the invention. Such materials may include, but are not limited to those containing tobacco, natural or artificial flavourants, coffee grounds or coffee beans, mint, chamomile, lemon, honey, tea leaves, cocoa, and other non-tobacco alternatives based on other botanicals. Compounds may be used, which can be vaporized (or volatized) at a relatively low temperature and preferably without harmful degradation products. Examples of compounds include, but are not limited to, menthol, caffeine, taurine, and nicotine.

(22) Preferably, tobacco or tobacco material is filled into the capsule 1. Here, tobacco or tobacco material is defined as any combination of natural and synthetic material comprising tobacco. A capsule can be prepared using cured tobacco, an aerosol-former such as glycerine or propylene glycol and flavourings. For example, tobacco may be chopped into fine pieces (for example, less than 2 mm diameter, preferably less than 1 mm), adding the other ingredients, and mixing until even consistency is achieved. The aerosol-forming substrate 2 may also be processed into a paste-like consistency, for example, with tobacco particle sizes less than 1 mm. Such a paste-like substrate or slurry may facilitate the processing of filling the capsule 1.

(23) A tobacco containing slurry may also be spread and dried to form a sheet, so called cast leaf. The dried leaf may be inserted into the capsule in a crimped and folded form.

(24) A tobacco sheet, for example a cast leaf, may have a preferred thickness in a range between about 0.5 millimeter and about 2 millimeter, for example 1 millimeter. Deviations in thickness of up to about 30 percent may occur due to manufacturing tolerances.

(25) The cast leaf may also be processed, for example, by chopping the sheet into small pieces or strips, for example of 1-2 mm in width.

(26) Volumes of active substrate comprise, for example, about 0.25 cubic centimetre active substrate per capsule 1.