Aerosol-generating system and capsule for use in an aerosol-generating system

Abstract

A capsule for use in an aerosol-generating system includes a shell including a base and at least one side wall extending from the base. The capsule further includes a lid sealed on the at least one side wall for forming a sealed capsule. The shell contains an aerosol-forming substrate and susceptor material for heating the aerosol-forming substrate in the shell.

Claims

1. An inductively heatable capsule for use in an aerosol-generating system, the capsule comprising: a shell comprising a base and at least one side wall extending from the base; and a frangible lid sealed on the at least one side wall for forming a sealed capsule, the shell containing an aerosol-forming substrate and susceptor material for heating the aerosol-forming substrate in the shell, wherein the shell comprises thermally insulating material, wherein the aerosol-forming substrate and the susceptor material are loosely arranged in the capsule, and wherein a ratio of an amount of susceptor material to an amount of aerosol-forming substrate is 1:1 to 1:4.

2. The capsule of claim 1, wherein the susceptor material is in the form of strip, rod, filament, particle, crimped or folded sheet or mesh.

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

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

5. The capsule of claim 1, wherein the susceptor material is coated with the aerosol-forming substrate.

6. The capsule of claim 1, comprising a sachet arranged in the shell, the sachet comprising a porous container, wherein the aerosol-forming substrate and the susceptor material are contained in the porous container.

7. An inductively heatable 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 frangible lid sealed on the at least one side wall for forming a sealed capsule, the shell containing an aerosol-forming substrate and susceptor material for heating the aerosol-forming substrate in the shell; a thermal insulation layer at least partially surrounding the aerosol-forming substrate and the susceptor material comprised in the capsule; a power source connected to a load network, the load network comprising an inductor for being inductively coupled to the susceptor material in the shell, and an aerosol-generating device comprising a mouthpiece and a piercing member for piercing the frangible lid of the capsule.

8. The system of claim 7, comprising an inductive heating and aerosol-generating device comprising the inductor and a device housing comprising a cavity for receiving the capsule.

9. The system of claim 8, wherein the device housing comprises the thermal insulation layer.

10. The system of claim 7, wherein the thermal insulation layer is arranged between the capsule and the inductor.

11. The system of claim 7, 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 member, the mouthpiece further comprising at least one second conduit extending between the distal end of the piercing member 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.

12. The system of claim 7, wherein a thermal conductivity of the thermal insulation layer is less than 1 Watt per (meterKelvin).

13. The system of claim 7, wherein the shell comprises thermally insulating material, and wherein the aerosol-forming substrate and the susceptor material are loosely arranged in the capsule, and wherein a ratio of an amount of susceptor material to an amount of aerosol-forming substrate is 1:1 to 1:4.

14. The capsule of claim 1, wherein the susceptor material is coated with two aerosol-forming substrate coatings, which two aerosol-forming substrate coatings differ in one or in a combination of composition, density, porosity, coating thickness.

15. The capsule of claim 1, wherein the capsule is an air-tight capsule.

16. The capsule of claim 1, wherein the porosity of the aerosol-forming substrate and susceptor material is between 0.2 and 0.35.

17. The capsule of claim 1, wherein the capsule is filled with an amount of aerosol-forming substrate between 150 mg and 400 mg.

18. The capsule of claim 1, wherein the shell comprises a flange for adhering the frangible lid to the shell.

19. The capsule of claim 18, wherein the flange is an outwardly directing flange.

20. The capsule of claim 1, wherein the shell comprises no paramagnetic or ferromagnetic material.

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 shows an example of a capsule;

(3) FIGS. 2 to 4 illustrate different inductively heatable capsule fillings;

(4) FIG. 5 shows cross sections of an inductively heatable bead with one of two coatings;

(5) FIG. 6 shows cross sections of an inductively heatable flake with one of two coatings;

(6) FIG. 7 schematically shows a cross-section of an inductively heatable aerosol-generating system.

DETAILED DESCRIPTION

(7) FIG. 1 shows a capsule 1 containing an active substrate 2 comprising an aerosol-forming substrate and susceptor material for use with a device capable of inductively heat the susceptor material of the active substrate 2 and capable of vaporizing the aerosol-forming substrate. 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 variety of materials including, but not limited to, metals, rigid plastics, flexible plastics, paper, paperboard, cardboard, and wax paper. Preferably, the shell and also the lid 11 is formed of a material comprising no, or a limited amount of ferromagnetic material or paramagnetic material. In particular, the shell and lid may comprise less than 20 percent, in particular less than 10 percent or less than 5 percent or less than 2 percent of ferromagnetic or paramagnetic material.

(8) 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. 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, polycarbonate, and many varieties of paper products. In some cases, especially when the material is paper, the shell 10 can be lined with a material or a food-safe material to prevent both drying of the aerosol-forming substrate and to protect the active substrate 2.

(9) 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.

(10) 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.

(11) 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.

(12) The material of a capsule 1, in particular the shell 10, can serve to preserve the freshness of the content, 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.

(13) 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.

(14) 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.

(15) 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.

(16) 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, flavourings and susceptor material. For example, tobacco may be chopped into fine pieces (for example, less than 2 millimeter diameter, preferably less than 1 millimeter), adding the other ingredients, and mixing until even consistency is achieved. The active substrate may also be processed into a paste-like consistency, for example, with tobacco particle sizes less than 1 millimeter and susceptor material in the form of particles. Such a paste-like substrate or slurry may facilitate the processing of filling the capsule 1.

(17) 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, while the susceptor material may be combined with the cast leaf either before or after insertion of the cast leaf into the capsule.

(18) A tobacco sheet, for example a cast leaf, may have a preferred thickness in a range between about 0.5 millimeter and about 1.5 millimeter, for example 1 millimeter.

(19) The cast leaf may also be processed, for example, by chopping the sheet into small pieces or strips, for example of 0.5 millimeter to 1.5 millimeter in width.

(20) A tobacco slurry may also be directly spread onto a sheet of susceptor material such that after drying of the aerosol-forming substrate, the active substrate is formed by a susceptor sheet coated with aerosol-forming substrate. Such a sheet of active substrate may then be cut, gathered or folded and inserted into a capsule.

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

(22) In FIG. 2 to FIG. 4 schematically drawn capsules 1 in tubular form are filed with different examples of active substrate.

(23) In FIG. 2 several strips of aerosol-forming substrate 20 and a strip of susceptor material 30, for example, a strip of a stainless steel foil, are filled into the capsule 1. Depending on a desired ratio of aerosol-forming substrate and susceptor material, more than one strip of susceptor material may be provided. Depending on a desired consuming experience, amount of aerosol formed or puffs that shall be available with one capsule 2, the number of aerosol-forming substrate strips 20 may be enhanced or reduced. A strip of aerosol-forming substrate 20 may have a width, for example, of about 0.8 millimeter and 1 millimeter, while a strip length may, for example, be between 4 millimeter and 10 millimeter. Strip sizes for the susceptor material 30 may be about 2 to 4 millimeter in width with a same length as the strip of aerosol-forming substrate 20.

(24) In FIG. 3 the capsule 1 is filled with a plurality of strips of aerosol-forming substrate 20. The susceptor material is provided in the form of a plurality of beads, for example ferromagnetic beads. The susceptor beads may have preferred diameters in a range between 0.3 millimeter and 2.5 millimeter.

(25) In FIG. 4 the active substrate is provided in the form of strips 21 containing the susceptor material 32. The susceptor material is provided in the form of particles, which particles are embedded in the aerosol-forming substrate. The susceptor particles may have preferred sizes in a range between 20 micrometer and 50 micrometer.

(26) Preferably, the susceptor particles are incorporated into the aerosol-forming substrate upon manufacturing of the active substrate. Such substrates may provide a very homogeneous and regular susceptor material distribution in the aerosol-forming substrate.

(27) Active substrate 2 may also be provided in the form of a plurality of particles having a susceptor core and an aerosol-forming substrate coating.

(28) In FIG. 5 and FIG. 6 four examples of active substrate 2 particles in the form of beads (FIG. 5) and in the form of flakes (FIG. 6) are shown.

(29) FIG. 5 shows a cross section of a susceptor core particle 33 in the form of a granule, which is coated with one or two aerosol-forming substrate coatings 22,23. Therein, a second coating 23 coats a first coating 22. The aerosol-forming substrate of the first coating 22 and of the second coating 23 may be the same or may be different, for example different in any one or a combination of composition, density, porosity, coating thickness.

(30) The beads shown in FIG. 5 are inductively heatable and ready for being filled into a capsule 1 in a desired amount, for example, about a few tenths of beads up to a maximum of about 200 beads per capsule.

(31) Preferably, the susceptor granule 33 is a metallic granule made of a metal or metal alloy, for example an austenitic or martensitic stainless steel. Preferably, the first and second aerosol-forming substrate coatings 22,23 are tobacco containing substrate coatings. In the embodiments shown in FIG. 5, the second coating 23 has about half the thickness of the first coating 22.

(32) Sizes of particles, as well as of coatings may be determined by average circular diameter sizes. Susceptor granules, as well as the final beads 2 often do not have an exact round shape such that an average diameter 55,56 or an average coating thickness 51,52 is determined for the susceptor granules 33 and the final beads.

(33) An average diameter for a susceptor granule 33 may be in a range between 0.1 millimeter and 4 millimeter, preferably between 0.3 millimeter and 2.5 millimeter.

(34) An average thickness 51 for a first aerosol-forming substrate coating 22 may be in a range between 0.05 millimeter and 4.8 millimeter, preferably between 0.1 millimeter and 2.5 millimeter.

(35) Thus, an average diameter 55 of a granule comprising one coating 22 of aerosol-forming substrate may be between 0.2 millimeter and a maximum of 6 millimeter, preferably between 0.5 millimeter and 4 millimeter.

(36) An average thickness 52 for a second aerosol-forming substrate coating 23 may be in a range between 0.05 millimeter and 4 millimeter, preferably between 0.1 millimeter and 1.3 millimeter.

(37) Thus, an average diameter 56 of a granule comprising two coatings 20,21 of aerosol-forming substrate may be between 0.3 millimeter and a maximum of 6 millimeter, preferably between 0.7 millimeter and 4 millimeter.

(38) While a maximum particle size is 6 millimeter, preferably 4 millimeter, even more preferably 2 millimeter, an average diameter 55 of a particle having one substrate coating is typically smaller than an average diameter 56 of the particle having two substrate coatings.

(39) When using a tobacco and aerosol-former containing slurry as aerosol-forming substrate coating, preferably a fluid bed granulation method is used for high volume production of particles. If low moisture slurry is used, preferably, powder granulation methods may be used for particle production. Preferably rotative coating granulators are used for the manufacture of beads.

(40) FIG. 6 shows cross sections of a susceptor core particle in the form of a flake 34, which is coated with one or two aerosol-forming substrate coatings 24,25. The second coating 25 of aerosol-forming substrate coats the first coating 24. A plurality of the inductively heatable coated flakes as shown in FIG. 6 may be used in a capsule according to the invention.

(41) A diameter of a susceptor flake 34 may be between 0.2 millimeter and 4.5 millimeter, preferably between 0.5 millimeter and 2 millimeter. A thickness of the susceptor flake 34 may be between 0.02 millimeter and 1.8 millimeter, preferably between 0.05 millimeter and 0.3 millimeter.

(42) A thickness 61,62 for a first and a second aerosol-forming substrate coating 24,25 may be in the same ranges and in the same preferred ranges as the thicknesses for the above described coatings for beads.

(43) Thus, a diameter of a flake coated with one aerosol-forming coating may be in a range between 0.3 millimeter and a maximum of 6 millimeter, preferably between 0.7 millimeter and 4 millimeter. A thickness of a flake coated with one aerosol-forming coating may be in a range between 0.12 millimeter and a maximum of 6 millimeter, preferably between 0.25 millimeter and 4 millimeter.

(44) A diameter of a flake coated with two aerosol-forming coatings may be in a range between 0.4 millimeter and a maximum of 6 millimeter, preferably between 0.9 millimeter and 4 millimeter. A thickness of a flake 1 coated with two aerosol-forming coatings may be in a range between 0.22 millimeter and a maximum of 6 millimeter, preferably between 0.45 millimeter and 4 millimeter.

(45) FIG. 7 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 above. 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 the capsule 1 is received. The inductor 702 is embedded in the proximal portion of the housing 70 surrounding the cavity 703 as well as the capsule 1 arranged in the cavity 703.

(46) 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.

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

(48) 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 180 degree Celsius and about 220 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.