ARTICLE FOR FORMING AN AEROSOL

Abstract

An article (1) for forming an aerosol. The article (1) comprise an aerosol-forming substrate (2) and a first major surface (1a) which is substantially flat. The aerosol-forming substrate (2) comprises a first region (20) having a first density and second region (21) having a second density. The first density is different to the second density. The article (1) is insertable into the heating chamber of a device for generating an aerosol.

Claims

1. An article for forming an aerosol, the article comprising an aerosol-forming substrate and a first major surface which is substantially flat, the aerosol-forming substrate formed from an aerosol-forming material comprising a first region having a first density and a second region having a second density, where the first density is different to the second density, the article being insertable into the heating chamber of a device for generating an aerosol.

2. Article according to claim 1, wherein the article comprises a second major surface which is substantially flat.

3. Article according to claim 2, wherein the first and second major surfaces are substantially parallel to one another.

4. Article according to claim 3, wherein the first and second major surfaces are spaced from one another by less than 5 mm.

5. Article according to claim 1, wherein the article has a generally parallelepiped shape.

6. Article according to claim 1, wherein the first region is at least partially surrounded by the second region.

7. Article according to claim 1, wherein the first region is at or adjacent one or more peripheral zones of the article.

8. Article according to claim 1, wherein the first region is sandwiched by the second region.

9. Article according to claim 1, wherein at least part of the article is formed of foam.

10. Article according to claim 9, wherein the foam is an open-celled foam.

11. Article according to claim 9, wherein the foam is a reticulated open-celled foam.

12. Article according to claim 9, wherein the aerosol-forming substrate comprises the foam.

13. Article according to claim 1, wherein the aerosol-forming substrate comprises tobacco.

14. Article according to claim 1, wherein the article comprises one or more metal elements.

15. Method of using an article for forming an aerosol, the method comprising: a) providing an article for forming an aerosol comprising an aerosol-forming substrate and having a first major surface which is substantially flat, the aerosol-forming substrate comprising a first region having a first density and a second region having a second density, the first density being different to the second density; b) inserting the article into a heating chamber of a device for generating an aerosol; c) irradiating the article in the heating chamber with electromagnetic radiation to generate aerosol from the aerosol-forming substrate; and d) flowing air through the aerosol-forming substrate.

Description

[0066] The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which:

[0067] FIG. 1 is a schematic perspective view of an article for forming an aerosol according to an embodiment of the invention;

[0068] FIG. 2 is a schematic cross-sectional view along line A-A of the article for forming an aerosol shown in FIG. 1;

[0069] FIG. 3 is a schematic perspective view of an article for forming an aerosol according to a further embodiment of the invention;

[0070] FIG. 4 is a schematic perspective view of an article for forming an aerosol according to a further embodiment of the invention; and

[0071] FIG. 5 is a schematic cross-sectional view along line B-B of the article for forming an aerosol shown in FIG. 4;

[0072] FIG. 6 is a schematic perspective view of an article for forming an aerosol according to a further embodiment of the invention; and

[0073] FIG. 7 is a schematic cross-sectional view along line C-C of the article for forming an aerosol shown in FIG. 6.

[0074] Referring now to FIGS. 1 and 2, there is shown an article 1 for forming an aerosol according to an embodiment of the invention. The article 1 comprises an aerosol-forming substrate 2 having first and second regions 20, 21. The first region 20 is sandwiched by the second region 21 in this embodiment.

[0075] The article 1 has first and second major surfaces 1a, 1b which are substantially flat, in this embodiment. In embodiments, however, the article 1 may have only a first major surface 1a which is substantially flat. The first and second major surfaces 1a, 1b extend in parallel relations to one another, in this embodiment. The second region 21 is directly adjacent each of the first and second major surfaces 1a, 1b, with the first region 20 spaced therefrom.

[0076] The article 1 has a generally parallelepiped shape, in this embodiment. The article 1 has a width w, a length I and a thickness t. The first and second regions 20, 21 of the aerosol-forming substrate 2 each extend across both the width w and length I of the article 1. Neither of the first and second regions 20, 21, however, extend across the thickness t of the article 1. The article has a first, upstream end US and a second, downstream end DS, opposed to the upstream end US.

[0077] The first region 20 of the aerosol-forming substrate 2 has a relatively lower density than does the second region 21 of the aerosol-forming substrate 2, in this embodiment. Both first and second regions 20, 21 of the aerosol-forming substrate 2 are formed from reticulated open-celled foam, in this embodiment. However, in embodiments, the aerosol-forming substrate 2 may comprise a different structure. For example, the aerosol-forming substrate 2 may comprise a fluid, a solid or a fluid and a solid mixture. Where the aerosol-forming substrate 2 is a fluid it may be held or retained within a matrix, for example a carrier material. The carrier material may comprise a foam, such as a reticulated open-celled foam. Where the aerosol-forming substrate 2 is a solid it may comprise one or more of: powder, granules, pellets, shreds, strands, strips or sheets of aerosol-forming substrate 2. Solid aerosol-forming substrate 2 may be retained within a carrier material which may have a matrix structure (e.g. comprise a foam, such as a reticulated open-celled foam).

[0078] The aerosol-forming substrate comprises reconstituted tobacco, in this embodiment.

[0079] The article 1 optionally comprises a wrapper or cover layer (not shown) which circumscribes its outer surfaces. The optional wrapper or cover layer may be removed before use of the article 1 in a device for generating an aerosol (not shown). Alternatively, the optional wrapper or cover layer may be left covering the outer surfaces of the article 1 when it is inserted into a heating chamber of the device for generating an aerosol.

[0080] Aerosol-forming substrate 2 for forming the first region 20 may be formed separately from aerosol-forming substrate 2 for forming the second region 21. A casting process may be utilized. For example, aerosol-forming substrate for forming the first region 20 may be cast on a first moving belt (for example a first part of the moving belt) while aerosol-forming substrate for forming the second region 20 may be cast on a second moving belt (or on a second part of the first moving belt). The aerosol-forming substrate of the first region and second regions may be combined into the relations shown in FIGS. 1 and 2 using an extrusion process. Alternatively, the aerosol-forming substrate of the first and second regions may be combined into the relations shown in FIGS. 1 and 2 using a lamination technique. Where an extrusion process is used, an elongate strip of combined aerosol-forming substrate comprising regions corresponding to the first and second regions may be formed. This elongate strip may then be sequentially cut or otherwise severed at desired locations along its length in order to form the required length of individual articles 1 for forming an aerosol.

[0081] Where an optional wrapper or cover layer is provided this may be wrapped about the first and second regions 20, 21 of aerosol-forming substrate 2 prior to or subsequent to cutting into the required length of an article 1 for forming an aerosol.

[0082] Alternatively, the first and/or second region 20, 21 of aerosol-forming substrate 2 may be moulded into its desired size and/or shape. For example, the second region 21 may be formed first (for example via moulding) with the first region 20 then moulded thereonto. In embodiments, where a wrapper or cover layer is provided the first and/or second region 20, 21 may be moulded in the wrapper or cover layer. In embodiments, the first and second regions 20, 21 may be manufactured using different techniques (for example one region 20, 21 may be formed by extrusion whilst the other region 20, 21 may be formed by moulding).

[0083] In use, a user inserts an article 1 for forming an aerosol into a heating chamber of a device for generating an aerosol. The article 1 is heated in the heating chamber such that volatile compounds are released in a vapour form from the aerosol-forming substrate 2. Air is drawn (for example by the user drawing on a mouthpiece of the device or, optionally, a filter or mouthpiece end of the article 1) through and/or past the article 1. The vapour of volatile compounds are entrained in the air flow and are caused or allowed to cool, whereupon the vapour condenses to form an aerosol. The aerosol may then be inhaled by the user of the device for generating an aerosol.

[0084] Advantageously, the non-round cross-sectional shape of the article 1 provides relatively enhanced efficiency of aerosol-formation than is achieved with prior art articles for forming an aerosol (which typically have a round cross-section, as explained above). A parallelepiped shaped article 1 is particularly advantageous in this respect. For a given volume a parallelepiped shape has a greater surface area to volume ratio than does a cylinder or a sphere. Accordingly, thermal energy may be transferred more readily into all parts of the parallelepiped shaped article 1 than is achievable using a prior art article for forming an aerosol having a cylindrical shape. Furthermore, due to the relatively increased surface area to volume ratio of the parallelepiped shaped article 1 versus prior art articles for forming a substrate having a cylindrical shape, volatile compounds may be extracted from the article with relatively greater ease.

[0085] Furthermore, due to the relatively lower density of the first region 20 with respect to the density of the second region 21, the porosity of the first region 20 may be relatively greater than is the porosity of the second region 21. Accordingly, the flow of air through the article 1 (where air flows therethrough, in use), from the upstream end US to the downstream end US of the article 1, may encounter relatively reduced resistance in the first region 20 than in the second region 21, and therefore may be relatively faster in the first region 20 than in the second region 21. The pressure in the first region 20 may therefore be lower than the pressure in the second region 21, thereby acting to draw volatilized compounds from the second region 21 into the air flow through the first region 20 (and hence enhancing egress of such volatilized compounds from the article 1).

[0086] Additionally, provision of regions 20, 21 of aerosol-forming substrate 2 having different densities allows the provision of relatively greater density in a second region 21, which may be configured to be adjacent a heating element of a device for generating an aerosol, in use, whist maintaining a desired average resistance to draw of the article 1, as a whole (through provision of a lower density first region 20).

[0087] In some embodiments, the first and/or second region 20, 21 may be at least partially resilient (for example may comprise a resilient material). Provision of a relatively less dense first region 20 may provide the first region 20 with relatively greater resiliency than that of the relatively denser second region 21. The article 1 may be shaped and/or sized to at least slightly exceed the size and/or shape of a heating chamber of a device for generating an aerosol into which it is intended to be inserted, in use. Accordingly, insertion of the article 1 into the heating chamber of the device may at least partially compress the article 1. Advantageously, resiliency of the first and/or second region 20, 21 may enhance the intimacy of contact of the first and/or second major surface 1a, 1b of the article 1 with heating surfaces of the heating chamber of the device for generating an aerosol. Transfer of thermal energy into the article 1 may, thereby, be relatively enhanced. Provision of a relatively denser second region 21 may provide a desired mass of aerosol-forming substrate (for example adjacent heating surfaces of the heating chamber into which the article is inserted), whilst provision of the relatively less dense first region 20 may more effectively resiliently bias the article into intimate contact with the heating surfaces of a heating chamber, within which it is inserted, to thereby allow more efficient heating of the mass of aerosol-forming substrate in the article 1.

[0088] Referring now to FIG. 3, there is shown an article 11 for forming an aerosol according to a further embodiment of the invention, wherein like features to those described in respect of the article 1 shown in FIGS. 1 and 2 are designated by like references preceded by a 1 and will not be described further herein. In this embodiment, the first and second regions 120, 121 of the aerosol-forming substrate 12 each extend across both the thickness t and the length I of the article. However, neither the first nor the second regions 120, 121 extend across the width w of the article 1.

[0089] Referring now to FIGS. 4 and 5, there is shown an article 101 for forming an aerosol according to a further embodiment of the invention, wherein like features to those described in respect of the article 1 shown in FIGS. 1 and 2 are designated by like references preceded by a 10 and will not be described further herein. In this embodiment, the first and second regions 1020, 1021 of the aerosol-forming substrate 102 each extend across the length I of the article 101. The first region 1020 does not extend across the width w or the thickness t of the article 101. The second region 1021 extends across the width w and the thickness t of the article 101, in regions of the article 101 absent the first region 1020.

[0090] Referring now to FIGS. 6 and 7, there is shown an article 201 for forming an aerosol according to a further embodiment of the invention, wherein like features to those described in respect of the article 1 shown in FIGS. 1 and 2 are designated by like references preceded by a 20 and will not be described further herein. The article 201 comprises an optional metallic element 3 located in the first region 2020 of the aerosol-forming substrate 202. The optional metallic element 3 extends along the length I of the article 201 but not across the thickness t or the width w of the article 201, in this embodiment. In use, the optional metallic element 3 may be inductively heated by an inductive coil of a device for generating an aerosol. The metallic element 3 may be formed from any suitable metal which generates heat when subjected to a magnetic field.

[0091] While the article 1, 11, 101, 201 is shown as generally parallelepiped in shape this need not be the case and, instead, the article 1, 11, 101, 201 may have any suitable shape comprising a first major surface which is substantially flat. Additionally or alternatively, the relative densities of the regions 20, 21, 120, 121, 1020, 1021, 2020, 2021 of any of the articles 1, 11, 101, 201 may be reversed, in embodiments. Additionally or alternatively, the article 1, 11, 101, 201 may comprise more than two regions 20, 21, 120, 121, 1020, 1021, 2020, 2021, for example three, four or more regions of aerosol-forming substrate 2, 12, 102, 202. Where more than two regions 20, 21, 120, 121, 1020, 1021, 2020, 2021 are provided the further regions may have a similar density or a different density to that of the first or second region 20, 21, 120, 121, 1020, 1021, 2020, 2021 of aerosol-forming substrate 2, 12, 102, 202.

[0092] While the article 1, 11, 101, 201 is described as comprising aerosol-forming substrate 2, 12, 102, 202 comprising reconstituted tobacco this need not be the case and, instead, the aerosol-forming substrate 2, 12, 102, 202 may comprise any suitable material or mix of materials. For example, the aerosol-forming substrate 2, 12, 102, 202 may comprise tobacco which is not reconstituted. Additionally or alternatively, although the first and second regions 20, 21, 120, 121, 1020, 1021, 2020, 2021 of the aerosol-forming substrate 2, 12, 102, 202 are described as comprising the same material and the same structure in the articles 1, 11, 101, 201 this need not be the case and, instead, the first and second regions 20, 21, 120, 121, 1020, 1021, 2020, 2021 of aerosol-forming substrate 2, 12, 102, 202 may comprise different materials and/or may have a different structure (e.g. only one may be formed from a foam or a reticulated open-celled foam). Additionally or alternatively, the aerosol-forming substrate 2, 12, 102, 202 and/or the article 1, 11, 101, 201 may comprise one or more additives, for example a volatile flavour-generating component, an aerosol former, a flavourant, nicotine or the like.

[0093] Additionally or alternatively, although the metallic element 3 is described as being located in the first region 2020 of the aerosol-forming substrate 202 this need not be the case and, instead, the metallic element 3 may be located in the second region 2021 alone or in both the first and second regions 2020, 2021. Additionally or alternatively, although the metallic element 3 is described as extending along the length I of the article 201 this need not be the case and, instead, the metallic element 3 may have any suitable size and shape (for example relative to the article 201). Additionally or alternatively, although the metallic element 3 is shown as having the form of a strip this need not be the case and, instead, the metallic element 3 may comprise any suitable shape, for example a loop or coil. Additionally or alternatively, the metallic element 3 may comprise plural metallic elements 3. Where plural metallic elements 3 are provided they may have similar sizes and/or shapes or may have different sizes and/or shapes. Where plural metallic elements 3 are provided they may be uniformly or randomly distributed in the article 201, for example in one or more region 2020, 2021 of the aerosol forming substrate 202. Additionally or alternatively, while a metallic element 3 has been described only in respect of the article 201 shown in FIGS. 6 and 7, it will be appreciated that any embodiment of the invention may comprise a metallic element 3 (which may have any of the above-described features or characteristics).

[0094] The schematic drawings are not necessarily to scale and are presented for purposes of illustration and not limitation. The drawings depict one or more aspects described in this disclosure. However, it will be understood that other aspects not depicted in the drawings fall within the scope of this disclosure.