Particle and aerosol-forming system comprising such particles

Abstract

A particle includes a core of susceptor material and a first coating including a first aerosol-forming substrate. The core of susceptor material is coated with the first coating including the first aerosol-forming substrate. Additionally, an aerosol-generating system includes a plurality of such particles. The system further includes an inductor for being inductively coupled to the core of susceptor material of at least some particles of the plurality of particles.

Claims

1. An individual particle comprising: a core of susceptor material; and a first coating comprising a first aerosol-forming substrate, wherein the core of susceptor material is individually coated with the first coating comprising the first aerosol-forming substrate.

2. The particle of claim 1, being a granule or flake.

3. The particle of claim 1, wherein a maximum size of the particle is 6 mm.

4. The particle of claim 1, wherein the core of susceptor material is a susceptor granule or susceptor flake.

5. The particle of claim 4, wherein a size of a susceptor granule is between 0.2 mm and 2.4 mm and wherein a maximal length of a susceptor flake is between 0.2 mm and 4.5 mm.

6. The particle of claim 1, wherein a first thickness of the first coating is between 0.05 mm and 4.8 mm.

7. The particle of claim 1, further comprising a second coating comprising a second aerosol-forming substrate.

8. The particle of claim 7, wherein a second thickness of the second coating is between 0.05 mm and 4 mm.

9. The particle of claim 7, wherein the first coating comprising the first aerosol-forming substrate and the second coating comprising the second aerosol-forming substrate differ in at least one of composition, porosity, coating thickness or shape of coating surface.

10. The particle of claim 1, further comprising at least one protection layer.

11. The particle of claim 10, wherein the protection layer is an outer most material of the particle.

12. The particle of claim 1, wherein the core of susceptor material is a metallic susceptor particle.

13. An aerosol-generating system comprising: a plurality of individual particles, each particle comprising a core of susceptor material and at least one individual coating comprising an aerosol-forming substrate; and a power source connected to a load network, the load network comprising an inductor for being inductively coupled to the core of susceptor material of at least some particles of the plurality of particles.

14. The system of claim 13, further comprising: an aerosol-generating device comprising: a device housing comprising a cavity arranged in the device housing, the cavity containing the plurality of particles, and a closure closing a proximal end of the cavity, wherein the closure comprises at least one opening for aerosol generated in the cavity to pass through the closure, the at least one opening having a size smaller than a size of a smallest particle of the plurality of particles, thereby retaining the plurality of particles in the cavity.

15. The system of claim 14, wherein the closure is porous or is in the form of a grid, web or mesh.

16. The system of claim 13, wherein the plurality of particles comprises different types of particles, wherein different types of particles differ in at least one of number of coatings, size, shape, shape or composition of susceptor material, thickness, porosity or composition of aerosol-forming substrate coating, aerosol delivery profile.

17. An aerosol-generating device for use in the system according to claim 13, the device comprising: a device housing comprising a cavity arranged in the device housing, the cavity having an internal surface adapted to accommodate a plurality of individual particles comprising a core of susceptor material and at least an individual coating comprising aerosol-forming substrate; an inductor of a load network, which inductor is inductively coupled to the core of susceptor material of the plurality of particles during operation; and a mouthpiece having a distal end closing the cavity, the distal end comprising a porous material, a grid, mesh or web.

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. 1a-c show cross sections of a susceptor granule before and after two coating steps with aerosol-forming substrate;

(3) FIG. 2a-c show cross sections of a susceptor flake before and after two coating steps with aerosol-forming substrate;

(4) FIG. 3 illustrates aerosol-forming substrate coatings with smooth surfaces;

(5) FIGS. 4 to 7 show susceptor particles in the form of regular round particles (FIG. 4); irregular round particles (FIG. 5); grit (angular form; FIG. 6); flakes (FIG. 7);

(6) FIG. 8 schematically illustrates an inductively heatable aerosol-generating device during preparation for use;

(7) FIG. 9 illustrates the device of FIG. 8 in operation.

DETAILED DESCRIPTION

(8) FIG. 1a shows a cross section of a susceptor core particle in the form of a granule 10 with rough surface 100. In FIG. 1b the susceptor core particle 10 is coated with a first coating of aerosol-forming substrate 20. This first coating 20 also has a rough surface 200. In FIG. 1c a second coating 21 of aerosol-forming substrate coats the first coating 20. Also this second coating 21 is provided with a rough surface 210. The aerosol-forming substrate of the first coating and of the second coating may be the same or different, for example different in any one or a combination of composition, density, porosity, coating thickness.

(9) The particles 1 shown in FIGS. 1b and 1c in the form of granules formed by the susceptor core 10 coated with one or two aerosol-forming substrate coatings 20,21 form particles 1 according to the invention, which particles 1 are inductively heatable and ready for use in an inductive heating device.

(10) Preferably, the susceptor granule 10 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 20,21 are tobacco containing substrate coatings. In the embodiment shown in FIGS. 1b and 1c, the second coating 21 has about half of the thickness of the first coating 20.

(11) Sizes of particles, as well as of coatings may be determined by average circumferences 500,550,560 as shown in the lower part of FIGS. 1a-c. Susceptor granules, as well as the final granules 1 often do not have an exact round shape such that an average diameter 50,55,56 or an average coating thickness 51,52 is determined for the susceptor granules 10 and the final granules 1.

(12) An average diameter 50 for a susceptor granule 10 may be in a range between 0.1 millimeter and 4 millimeter, preferably between 0.3 millimeter and 2.5 millimeter.

(13) An average thickness 51 for a first aerosol-forming substrate coating 20 may be in a range between 0.05 millimeter and 4.8 millimeter, preferably between 0.1 millimeter and 2.5 millimeter.

(14) Thus, an average diameter 55 of a granule comprising one coating 20 of aerosol-forming substrate may be between 0.2 millimeter and a maximum of 6 millimeter, preferably between 0.5 millimeter and 4 millimeter.

(15) An average thickness 52 for a second aerosol-forming substrate coating 21 may be in a range between 0.05 millimeter and 4 millimeter, preferably between 0.1 millimeter and 1.3 millimeter.

(16) 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.

(17) While a maximum particle size is 6 millimeter, preferably 4 millimeter, even more preferably 2 millimeter, an average diameter 55 of the particle shown in FIG. 1b having one coating is typically smaller than an average diameter 56 of the particle shown in FIG. 1c having two coatings.

(18) 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 1. 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 granules.

(19) FIG. 2a shows a cross section of a susceptor core particle in the form of a flake 11. In FIG. 2b the susceptor flake 11 is coated with a first coating of aerosol-forming substrate 22. In FIG. 2c a second coating 23 of aerosol-forming substrate coats the first coating 22. A plurality of the inductively heatable flake 1 as shown in FIG. 2b or FIG. 2c may be used in an inductively heatable device for aerosol generation.

(20) A diameter 60 of a susceptor flake may be between 0.2 millimeter and 4.5 millimeter, preferably between 0.5 millimeter and 2 millimeter. A thickness 600 of the susceptor flake may be between 0.02 millimeter and 1.8 millimeter, preferably between 0.05 millimeter and 0.3 millimeter.

(21) A thickness 61,62 for a first and a second aerosol-forming substrate coating 22,23 may be in the same ranges and in the same preferred ranges as the thicknesses for the above described coatings for granules.

(22) Thus, a diameter 65 of a flake 1 coated with one aerosol-forming coating as shown in FIG. 2b 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 1 coated with one aerosol-forming coating 22 may be in a range between 0.12 millimeter and a maximum of 6 millimeter, preferably between 0.25 millimeter and 4 millimeter.

(23) A diameter 66 of a flake 1 coated with two aerosol-forming coatings 22,23 as shown in FIG. 2c 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.

(24) FIG. 3 shows cross sections of a susceptor granule 10 with rough surface 100 that is coated with a first aerosol-forming substrate coating 20 and a second aerosol-forming substrate coating 21. The granule 1 formed after the first coating 20 has a smooth surface 200. Also after application of the second coating 21, the surface 210 of the second coating is smooth providing a granule 1 having a smooth surface.

(25) It becomes clear from the examples shown in FIGS. 1, 2 and 3 that surfaces of core particles and of different coatings may be rough or smooth, independent of each other and may be the result of a desired manufacturing process or may be chosen according to a desired result. A surface characteristic may be chosen independently of a composition, compaction or density of a coating. It also becomes clear that also further aerosol-former substrate coatings may be applied, for example a third or fourth coating, however, within a granulometry range defined herein, that is, keeping a maximum particle size in the size range defined herein.

(26) In addition, a protection layer may be provided in between individual coatings or, preferably, as most outer layer of the particle 1. Preferably, an outer protection layer is provided as moisture protection but may in combination or alternatively be used as marking layer. For example, a specific colour may be indicative of a specific flavour or aerozolization profile when used in a specific heating device.

(27) FIGS. 4 to 7 show examples of susceptor particles of different forms that are suitable as susceptor core in the manufacture of particles according to the invention. In FIG. 4 a plurality of susceptor particles in the form of regularly sized spheres or beads is shown. FIG. 5 shows a plurality of susceptor particles, wherein the particles are irregularly sized spheres or beads. FIG. 6 shows susceptor core particles in the form of grit. The susceptor particles basically have the form of granules not having any predominant dimension, however, the shapes of the granules are angular and irregular (various flat surface sections for example combined with rounded surface sections). In FIG. 7 susceptor flakes are shown. The flakes are flat, mostly having two parallel flat sides but of irregular circumferential shape.

(28) The inductively heatable aerosol-generating device shown in FIG. 8 and FIG. 9 comprises a main housing 70 and a mouthpiece 71. The main housing 70, preferably in tubular form, comprises a cavity 701 for receiving a plurality of inductively heatable particles 1, preferably particles as described herein. The main housing 70 also comprises an inductor, here in the form of an induction coil 703, for inductively heating the susceptor core of the particles 1 arranged in the cavity 701. The induction coil 703 is arranged to surround the cavity in longitudinal direction and to be able to heat inductive material arranged in the cavity 701.

(29) The main housing 70 also comprises a battery and a power management system (not shown).

(30) The mouthpiece 71 forms the proximal or most downstream element of the device.

(31) The bottom of the cavity 701 as well as the bottom or distal end of the mouthpiece 71 is closed by a porous element 700,710 for example a porous material or a grid or mesh. The porous elements 700,710 (in the mounted state of the mouthpiece as shown in FIG. 9) are adapted to hold the particles 1 in the cavity 701 and to allow an airflow to pass through the porous elements, through the cavity 701 and into and through the mouthpiece 71.

(32) The main housing 70 is provided with air-inlet channels 702 to allow air 90 from the environment to enter the housing 70 and pass into the cavity 701. Therein, the air 90 picks up aerosol formed in the cavity by heating the particles 1. The aerosol containing air 91 continuous further downstream leaving the device through an outlet opening 711 of the mouthpiece 71 at the proximal end of the mouthpiece, which airflow 90, 91 is illustrated in FIG. 9.

(33) As shown in FIG. 8 a reservoir 8 may be provided for particles 1. The reservoir 8 may comprise an amount of particles corresponding to one refill of the cavity 701. Preferably, the reservoir 8 comprises an amount of particles sufficient for a plurality of refills of the cavity 701. The reservoir 8 may contain a predefined mixture of particles 1 or may contain identical particles. By the availability of a plurality of particles in a reservoir 8, a user may dose or mix particles according to his or her needs.

(34) Upon preparing a device for use, the mouthpiece 71 may be removed from the main housing 70 such as to provide open access to the cavity 701. Removal may be a complete detachment of the mouthpiece 71 from the housing 70 as shown in the example of FIG. 8. Removal may also be an incomplete removal, for example a hinging away of the mouthpiece, where the mouthpiece 71 remains connected to the housing 70 via a hinge.

(35) The cavity 701 may then be filled with a desired amount of particles 1. After repositioning of the mouthpiece 71 on the housing 70 the device is ready for being used.