AN AEROSOL-GENERATING ARTICLE COMPRISING A BARRIER

Abstract

An aerosol-generating article for an aerosol-generating system is provided, the article including: a storage portion having an outlet; an aerosol-forming substrate contained within the storage portion; and a vaporisable barrier to seal the outlet, in which the barrier includes one or more polymers, has a polymer content of greater than or equal to 1 percent by weight, is configured to be vaporised during a first heating cycle of the article during first use of the article in the system, further includes one or more metal salts, and the salts are selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propanoates, metal stearates, and metal undecanoates. An aerosol-generating system, and a method of manufacturing an aerosol-generating article, are also provided.

Claims

1.-13. (canceled)

14. An aerosol-generating article for an aerosol-generating system, the aerosol-generating article comprising: a storage portion having an outlet; an aerosol-forming substrate, the aerosol-forming substrate being contained within the storage portion; and a vaporisable barrier configured to seal the outlet, wherein the vaporisable barrier comprises one or more polymers, wherein the vaporisable barrier has a polymer content of greater than or equal to 1 percent by weight, wherein the vaporisable barrier is configured to be vaporised during a first heating cycle of the aerosol-generating article during first use of the aerosol-generating article in the aerosol-generating system, wherein the vaporisable barrier further comprises one or more metal salts, and wherein the one or more metal salts are selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propanoates, metal stearates, and metal undecanoates.

15. The aerosol-generating article according to claim 14, wherein the vaporisable barrier further comprises one or more metal stearates.

16. An aerosol-generating article for an aerosol-generating system, the aerosol-generating article comprising: a storage portion; an aerosol-forming substrate, the aerosol-forming substrate being contained within the storage portion; a heater configured to heat the aerosol-forming substrate; and a vaporisable barrier disposed between the storage portion and the heater, wherein the vaporisable barrier comprises one or more polymers, and wherein the vaporisable barrier has a polymer content of greater than or equal to 1 percent by weight, wherein the vaporisable barrier is configured to be vaporised during a first heating cycle of the aerosol-generating article during first use of the aerosol-generating article in the aerosol-generating system, wherein the vaporisable barrier further comprises one or more metal salts, and wherein the one or more metal salts are selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propanoates, metal stearates, and metal undecanoates.

17. The aerosol-generating article according to claim 16, wherein the vaporisable barrier further comprises one or more metal stearates.

18. The aerosol-generating article according to claim 14, wherein the vaporisable barrier is thermally degradable when heated to a temperature of between 60 degrees Celsius and 300 degrees Celsius.

19. The aerosol-generating article according to claim 18, wherein the vaporisable barrier further comprises a material that is vaporisable when heated to a temperature of between 180 degrees Celsius and 300 degrees Celsius.

20. The aerosol-generating article according to claim 16, wherein the vaporisable barrier is thermally degradable when heated to a temperature of between 60 degrees Celsius and 300 degrees Celsius.

21. The aerosol-generating article according to claim 20, wherein the vaporisable barrier further comprises a material that is vaporisable when heated to a temperature of between 180 degrees Celsius and 300 degrees Celsius.

22. The aerosol-generating article according to claim 14, wherein the vaporisable barrier has a polymer content of between about 5 percent by weight and about 40 percent by weight.

23. The aerosol-generating article according to claim 16, wherein the vaporisable barrier has a polymer content of between about 5 percent by weight and about 40 percent by weight.

24. The aerosol-generating article according to claim 14, wherein the one or more polymers are selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, low density polyethylene, and starch.

25. The aerosol-generating article according to claim 16, wherein the one or more polymers are selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, low density polyethylene, and starch.

26. The aerosol-generating article according to claim 14, wherein the vaporisable barrier further comprises starch.

27. The aerosol-generating article according to claim 14, wherein the vaporisable barrier is mechanically fixed to a liquid-side of a component of the aerosol-generating article.

28. The aerosol-generating article according to claim 16, wherein the vaporisable barrier is mechanically fixed to a liquid-side of a component of the aerosol-generating article.

29. The aerosol-generating article according to claim 14, wherein the vaporisable barrier is formed on a component of the aerosol-generating article.

30. The aerosol-generating article according to claim 27, wherein the component of the aerosol-generating article is a heater or a wicking material.

31. An aerosol-generating system, comprising: an aerosol-generating article according to claim 14; and an aerosol-generating device.

32. A method of manufacturing an aerosol-generating article, the method comprising: providing an aerosol generating article comprising: a storage portion, an aerosol-forming substrate, the aerosol-forming substrate being contained within the storage portion, and a heater configured to heat the aerosol-forming substrate; and providing a vaporisable barrier between the storage portion and the heater, wherein the vaporisable barrier comprises one or more polymers, wherein the vaporisable barrier has a polymer content of greater than or equal to 1 percent by weight, wherein the vaporisable barrier is configured to be vaporised during a first heating cycle of the aerosol-generating article during first use of the aerosol-generating article in the aerosol-generating system, wherein the vaporisable barrier further comprises one or more metal salts, wherein the one or more metal salts are selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propanoates, metal stearates, and metal undecanoates.

33. The method according to claim 32, wherein the vaporisable barrier further comprises one or more metal stearates.

Description

[0162] Specific embodiments will now be described, by way of example only, with reference to the following examples and the accompanying drawings, in which:

[0163] FIG. 1 shows schematically a sectional side view of an aerosol-generating system comprising an aerosol-generating device and an aerosol-generating article according to the invention;

[0164] FIG. 2 shows schematically a sectional view of the aerosol-generating system of FIG. 1, with the aerosol-generating article inserted into the aerosol-generating device;

[0165] FIG. 3 shows schematically a sectional view of an alternative aerosol-generating system comprising an aerosol-generating device and an aerosol-generating article according to the invention;

[0166] FIG. 4 shows schematically a sectional view of an aerosol-generating article according to the invention before it has been used; and

[0167] FIG. 5 shows schematically a sectional view of an aerosol-generating article according to the invention after it has been used.

[0168] Aerosol-generating systems for delivering to a user typically comprise an atomiser configured to generate an inhalable aerosol from an aerosol-forming substrate. Some known aerosol-generating systems comprise a thermal atomiser such as an electric heater that is configured to heat and vaporise the aerosol-forming substrate to generate an aerosol. Other known aerosol-generating systems comprise a non-thermal atomiser that is configured to generate an aerosol from the aerosol-forming substrate using, for example, impinging jet, ultrasonic or vibrating mesh technologies. Typical aerosol-forming substrates for use in aerosol-generating systems are nicotine formulations, which may be liquid nicotine formulations comprising an aerosol former such as glycerine and/or propylene glycol.

[0169] An aerosol generating system can comprise an aerosol-generating device and an aerosol-generating article containing an aerosol-forming substrate. Typical aerosol-generating systems may suffer from a problem of unwanted leakage of the aerosol-forming substrate out of the aerosol-generating article. Leakage of an aerosol-forming substrate may occur in a number of different situations, such as: when there is too much of the aerosol-forming substrate in a reservoir of the aerosol-generating article; when the material forming one or more parts of the aerosol-generating article or system fails to retain the aerosol-forming substrate as designed; due to a change in pressure, for example when at a high altitude during transport by an aeroplane; or at a high temperature, for example due to hot weather.

[0170] It would be desirable to provide an aerosol-generating article that provides a reduced risk of leakage of the aerosol-forming substrate from the aerosol-generating article or system compared to typical aerosol-generating articles.

[0171] FIGS. 1 and 2 show an aerosol-generating system including an aerosol-generating device 10 and an aerosol-generating article 20. In this example, the aerosol-generating article 20 is cartridge.

[0172] The aerosol-generating device 10 is configured to receive the aerosol-generating article 20 in a cavity 18. The aerosol-generating article 20 includes a housing 24. The housing 24 defines a storage portion 22. The storage portion 22 has a storage portion opening that can be covered by a removable cover 26. An aerosol-forming substrate is disposed in the storage portion 22.

[0173] In the example shown in FIGS. 1 and 2, the aerosol-generating article 20 includes an atomiser configured to generate an aerosol from the aerosol-forming substrate in the storage portion 22. The atomiser may be a thermal atomiser. In the example shown in FIGS. 1 and 2 the atomiser is an electric heater 30. In other examples, the atomiser may be another type of atomiser, such as a non-thermal atomiser.

[0174] In the example of FIGS. 1 and 2, the aerosol-generating article 20 contains an aerosol-forming substrate and an atomiser and may therefore be referred to as a “cartomiser”.

[0175] The aerosol-generating article 20 is replaceable by a user when the aerosol-forming substrate provided in the storage portion 22 is depleted.

[0176] FIG. 1 shows the aerosol-generating article 20 just prior to insertion into the aerosol-generating device 10. The arrow 1 in FIG. 1 indicates the direction of insertion of the aerosol-generating article 20 in to the aerosol-generating device 10.

[0177] The aerosol-generating device 10 is portable and has a size comparable to a conventional cigar or cigarette. The aerosol-generating device 10 comprises a main body 11 and a mouthpiece portion 12. The main body 11 contains a battery 14, such as a lithium iron phosphate battery, control electronics 16 and a cavity 18.

[0178] The mouthpiece portion 12 is connected to the main body 11 by a hinged connection 21 and can move between an open position as shown in FIG. 1 and a closed position as shown in FIG. 2. The mouthpiece portion 12 is placed in the open position to allow for insertion and removal of an aerosol-generating article 20 and is placed in the closed position when the aerosol-generating system is to be used to generate aerosol.

[0179] The mouthpiece portion 12 comprises a plurality of air inlets 13 and an outlet 15. In use, a user sucks or puffs on the outlet 15 to draw air from the air inlets 13, through the mouthpiece portion to the outlet 15, and thereafter into the mouth or lungs of the user. Internal baffles 17 are provided to force the air flowing through the mouthpiece portion 12 past the aerosol-generating article 20.

[0180] The housing 24 includes a capillary material soaked in the aerosol-forming substrate. The capillary material in this example is positioned adjacent the electric heater 30.

[0181] The cavity 18 has a circular cross-section and is sized to receive a housing 24 of the aerosol-generating article 20. Electrical connectors 19 are provided at the sides of the cavity 18 to provide an electrical connection between the control electronics 16 and battery 14 and corresponding electrical contacts on the aerosol-generating article 20. This setup allows power to be supplied to the electric heater 30.

[0182] FIG. 2 shows the aerosol-generating article 20 inserted into the cavity 18 of the aerosol-generating device 10. In this position, the electrical connectors 19 rest against the corresponding electrical contacts on the aerosol-generating article 20. The cover 26 has been fully removed and the mouthpiece portion 12 has been moved to a closed position.

[0183] The mouthpiece portion 12 is retained in the closed position by a clasp mechanism (not illustrated). It will be apparent to a person of ordinary skill in the art that other suitable mechanisms for retaining the mouthpiece in a closed position may be used, such as a snap fitting or a magnetic closure.

[0184] The mouthpiece portion 12 in a closed position retains the aerosol-generating article 20 in electrical contact with the electrical connectors 19 so that a good electrical connection is maintained in use, whatever the orientation of the aerosol-generating system is.

[0185] In use, when the aerosol-generating device 10 is activated by a user, the electric heater 30 aerosolises at least a portion of the aerosol-forming substrate in the storage portion 22. As a user sucks or puffs on the outlet 15, air flows through the air inlets 13 and over the electric heater 30 and the capillary material. The air flowing over the electric heater 30 and the capillary material entrains the volatized aerosol components from the vaporised aerosol-forming substrate. The air with entrained aerosol-forming substrate then flows out through the outlet 15 and to the user. This air flow regime is shown in FIG. 2.

[0186] FIG. 3 shows an alternative aerosol-generating system. The embodiment shown in FIG. 3 works in much the same way as the embodiment shown in FIGS. 1 and 2. However, in the embodiment of FIG. 3, the aerosol-generating article 20 is not removable from the aerosol-generating device 10. Instead, after the storage portion 22 has been depleted of aerosol-generating substrate, the storage portion 22 can be refilled by a user through a storage portion opening 40.

[0187] In FIG. 3 the storage portion opening 40 is shown in an open position in which it can be refilled with aerosol-generating substrate. The storage portion opening 40 can however be sealed with a closure such as a cap (not shown).

[0188] The embodiment shown in FIG. 3 otherwise works in a similar way to the aerosol-generating system shown in FIGS. 1 and 2.

[0189] FIGS. 4 and 5 are schematic sectional views of an alternative aerosol-generating article 200. FIG. 4 shows the aerosol-generating article 200 before it has been used by the user. The aerosol-generating article 200 includes a body 212 defining a storage portion 210 having a storage portion opening 215. Aerosol-forming substrate 211 is disposed in the storage portion 210. The aerosol-generating article 200 includes a heater 222 located across the storage portion opening 215. In this example, the heater 222 has a heating element in the form of a mesh layer 223. The aerosol-generating article 200 also includes a transfer element 224. The transfer element 224 is preferably formed from a porous material. In the example of FIG. 4, the transfer element 224 is formed from a layer of glass fibers. The transfer element 224 provides control of the flow of the aerosol-forming substrate 211 from the storage portion 210 to the mesh layer 213 of the heater 222.

[0190] In use, the aerosol-forming substrate flows from the storage portion 210 and into the porous transfer element 224. The aerosol-forming substrate then flows to the mesh layer 223 of the heater 222, where it is thermally vaporised into an aerosol.

[0191] FIG. 4 shows that the aerosol-generating article also includes a vaporisable barrier 225. The vaporisable barrier 225 is provided during manufacture of the aerosol-generating article 200. The vaporisable barrier 225 seals the storage portion 210 by blocking the flow of the aerosol-forming substrate 211 from the storage portion 210 to the heater 222.

[0192] In the example of FIG. 4, the vaporisable barrier 225 is attached to the an internal surface of the storage portion 210. In this specific example, the vaporisable barrier 225 is attached to the heater 222, which forms a surface of the storage portion 210.

[0193] The vaporisable barrier 225 may be connected to the aerosol-generating article 200 through use of a number of different methods. In the example of FIG. 4, the vaporisable barrier 225 has been mechanically fixed to the heater 222 after the vaporisable barrier 225 has been formed. In another example, the vaporisable barrier 225 may be formed on the aerosol-generating article 200 by casting a drop of a barrier formulation on the aerosol-generating article 200.

[0194] The vaporisable barrier 225 is formed so that it vaporises after the first use of the aerosol-generating article 200. That is, all of the mass of the vaporisable barrier 225 enters the vapour phase in the first heating cycle of the aerosol-generating article 200.

[0195] FIG. 4 shows the aerosol-generating article 200 before first use and after it has been manufactured, with the vaporisable barrier 225 in place. FIG. 5 shows the aerosol-generating article 200 after first use, during which the vaporisable barrier 225 has been vaporised by the heater 222.

[0196] Advantageously, the vaporisable barrier 225 that is applied to the aerosol-generating article 200 during manufacture of the aerosol-generating article 200 physically blocks flow of the aerosol-forming substrate 211 out of the storage portion 210 before the aerosol-generating article 200 has been first used. The vaporisable barrier 225 thereby prevents leakage of the aerosol-forming substrate 211 out of the aerosol-generating article 200 before it is first used, which may improve shelf-life of the aerosol-generating article 200. The vaporisable barrier 225 can even reduce or prevent leakage under pressure such as during transportation on an aeroplane.

[0197] In addition, given that the vaporisable barrier 225 is put in place during the manufacturing process, there is no need for a large window for a sealing tab, which gives more freedom for designing an aerosol-generating article 200. Not having a sealing tab also simplifies the assembly process.

[0198] The vaporisable barrier 225 may be melted or vaporised by the heater 222 during first use of the aerosol-generating article 200 (that is, during the first heating cycle). This allows the aerosol-generating article 200 to be used as normal by a user.

EXAMPLES

[0199] Two mixtures for forming a vaporisable barrier according to the invention (Examples A and B) are prepared having the compositions shown in Table 1.

TABLE-US-00001 TABLE 1 Example A B Glycerine (% by weight) plasticizer 28 17 Propylene Glycol (% by weight) plasticizer 2.8 16 Sodium Stearate (% by weight) metal salt 1.8 0 Polyvinyl Alcohol (% by weight) polymer 7.2 7 Water (% by weight) 60.2 60

[0200] The examples A and B are prepared by:

[0201] Mixing the polyvinyl alcohol, glycerine and propylene glycol together at 90 degrees Celsius;

[0202] Adding the sodium stearate to the mixture;

[0203] Keeping the formulation at 90 degrees Celsius for 20 minutes whilst stirring;

[0204] Drying the formulation at 40 degrees Celsius for a period of time in order to form the example; and

[0205] Applying the example to the aerosol-generating article 200.

[0206] The step of applying the example to the aerosol-generating article 200 depends on the method in which the vaporisable barrier 225 is being attached to or formed on the aerosol-generating article 200.

[0207] In the example of FIGS. 4 and 5, the vaporisable barrier 225 is mechanically fixed between the storage portion 210 and the heater 222. In this example, examples A and B are dried in for example a ventilated oven. The resulting film is then mechanically fixed to the aerosol-generating article 200 to provide the vaporisable barrier 225.

[0208] In another example, a drop of the example mixture is cast on to a component of the aerosol-generating article 200. The mixture then solidifies into the vaporisable barrier 225.

[0209] After formation of the vaporisable barrier 225, the storage portion 210 of the aerosol-generating article 200 can be filled with aerosol-forming substrate 211.

[0210] The exemplary embodiments described above are not intended to limit the scope of the claims. Other embodiments consistent with the exemplary embodiments described above will be apparent to those skilled in the art. Features described in relation to one embodiment may also be applicable to other embodiments.