Abstract
A consumable for an aerosol generating device includes a heating layer of an aerosol substrate formed to be positioned in sandwich between two electrodes of the device. The heating layer of aerosol substrate includes flavorant material and an aerosol forming agent. The layer further includes electrically conductive material in particulate form embedded in the layer, wherein the electrically conductive material is arranged in the heating layer to conduct electrical current between the two electrodes and to heat the aerosol substrate to a temperature sufficient to aerosolize the aerosol forming agent. A method for manufacturing such a consumable, a device for delivering a tobacco aerosol including the consumable, and a method for production of tobacco aerosol with the device are also provided.
Claims
1. A consumable for an aerosol generating device comprising a heating layer of an aerosol substrate formed to be positioned in sandwich between two electrodes of the device, wherein the heating layer of the aerosol substrate comprises flavorant material and an aerosol forming agent, wherein the heating layer further comprises electrically conductive material in particulate form embedded in the heating layer, wherein the electrically conductive material is arranged in the heating layer to conduct electrical current between the two electrodes and to heat the aerosol substrate to a temperature sufficient to aerosolize the aerosol forming agent when the heating layer is positioned between the two electrodes of the device.
2. The consumable according to claim 1, wherein: the electrically conductive material has an electrical conductivity of at least 3*10.sup.2 S/m (at 20? C.).
3. The consumable according to claim 1, wherein: a thickness of the heating layer is between 0.5 and 3 mm.
4. The consumable according to claim 1, wherein: the electrically conductive material is distributed in and on the heating layer in an amount to allow electricity to flow from one electrode through a thickness of the heating layer to the other electrode when the heating layer is positioned between the two electrodes of the device.
5. The consumable according to claim 1, wherein: the electrically conductive material is randomly distributed inside the heating layer and on a surface area of the heating layer.
6. The consumable according to claim 1, wherein: the electrically conductive material comprises graphite and/or charcoal particles.
7. The consumable according to claim 1, wherein: the electrically conductive material comprises an amount of 2.5 to 50 wt. % regarding to the heating layer.
8. The consumable according to claim 1, wherein: the heating layer further comprises a binder in an amount between 0.5 and 2.5 wt. % regarding to the consumable.
9. The consumable according to claim 1, wherein: the aerosol forming agent comprises an amount of less than 25 wt. % regarding to the consumable.
10. The consumable according to claim 1, wherein: the heating layer further comprises water in an amount between 10 and 49.5 wt. % regarding to the consumable.
11. The consumable according to claim 1, wherein: the flavorant material comprises tobacco in an amount up to 47.5 wt. % regarding to the consumable.
12. The consumable according to claim 11, wherein: the tobacco comprises tobacco powder with a particle size lower than 1000 microns.
13. The consumable according to claim 11, wherein: the tobacco comprises flue cured tobacco in an amount between 1 and 47.5 wt. % regarding to the consumable.
14. A method for manufacturing a consumable for an aerosol generating device, comprising the steps of: mixing flavorant material with electrically conductive material in particulate form, an aerosol forming agent, and water to form a paste or dough, pressing the paste or dough into a heating layer, and solidifying the heating layer by curing and/or drying.
15. A device for delivering a tobacco aerosol comprising the consumable according to claim 1, comprising: a pair of electrodes and a source of electrical energy to supply the electrodes, wherein the electrodes comprising a contact surface are configured to press the heating layer of the consumable in sandwich along at least a portion of a surface area of the heating layer.
16. The consumable according to claim 1, wherein: a thickness of the heating layer is between 0.5 and 2 mm.
17. The consumable according to claim 1, wherein: the electrically conductive material comprises an amount between 2.5 and 25 wt. % regarding to the heating layer.
18. The consumable according to claim 8, wherein: the binder is CMC.
19. The consumable according to claim 9, wherein: the aerosol forming agent is glycerin and/or propylene glycol.
Description
[0053] The figures show:
[0054] FIG. 1a schematic cross-sectional view of a consumable comprising conductive material between two electrodes with one particle of the conductive material;
[0055] FIG. 1b schematic cross-sectional view of a consumable comprising conductive material between two electrodes with two touching particles of the conductive material;
[0056] FIG. 1c schematic top view of a consumable comprising conductive material between two electrodes;
[0057] FIG. 2 schematic view of a device for delivering aerosol with two electrodes and consumable arranged between the electrodes;
[0058] FIG. 3 flow chart of a method for manufacturing a consumable comprising a conductive material;
[0059] FIG. 4 flow chart of a method of aerosol production with a device comprising two electrodes and a consumable arranged between the electrodes;
[0060] FIG. 5a schematic view of a cartridge comprising consumable arranged as a spiral;
[0061] FIG. 5b schematic view of a cartridge comprising consumable arranged as a hyperbolic spiral.
[0062] In FIGS. 1a and 1b schematic cross-sectional views of a consumable 1 comprising conductive material 7 between two electrodes 4a, b are shown. In both figures, the shown consumable 1 comprises at least flavorant material 5, electrically conductive material 7 and optionally aerosol forming agent 6. It is conceivable that the consumable 1 further comprises ingredients which form an aerosol substrate (not shown). The flavorant material 5 may be a tobacco material for enhancing the aerosol substrate with an individual tobacco taste and/or may be another flavoring substance which is added additionally or alternatively to the tobacco material. The ingredients, especially the electrically conductive material 7 is provided in particulate form. In particular, the ingredient may be provided as a solid powder comprising particles of the conductive material. Such particulate ingredients are preferably embedded in the heating layer 3 or the consumable 1. However, preferably the consumable 1 is formed as a layer, in particular being or comprising a heating layer 3. Also preferably the layer 3 or the consumable 1 is arranged between two electrodes 4a, b in an aerosol generating device 2 (shown in FIG. 2).
[0063] The two electrodes 4a, b are spaced to each other being connected with the consumable 1 or the heating layer 3. Preferably a distance between the electrodes 4a, b is considered as a thickness 8 of the consumable 1. The thickness 8 of the consumable 1 or the heating layer 3 could preferably be in range of 0.5 mm and 5 mm, preferably in the range of 0.5 and 2 mm. In particular, the thickness 8 is dependent on the size of the aerosol generating device 2 (shown in FIG. 2) and a size of the electrodes 4a, b. Especially the handy devices 2 preferably comprise electrodes 4a, b with small average contact surfaces 11. In an example, the contact surfaces 11 comprise an area of 215 mm.sup.2. But it is also conceivable that the contact surfaces 11 comprise the area in range of 150 mm.sup.2 and 300 mm.sup.2. As shown in the FIG. 1a, the contact surfaces 11 of the electrodes 4a, b are in direct contact to the consumable 1 or the heating layer 3. In an example, 70% to 95% of the contact surfaces 11 touch the consumable 1 or the heating layer 3. Preferably the electrodes 4a, b apply pressure to the consumable 1 or the heating layer 3 to reduce the contact resistance between the electrodes and the conductive particles.
[0064] The first 4a and the second 4b electrode are supplied with a voltage source 19. In a state of use of the aerosol generating device 2, the electrical current flows from the one electrode 4b through the consumable 1 to the other electrode 4a. In an example, the voltage source 19 is supplied by a rechargeable battery, such as lithium-ion, with a voltage value of 3.7 V. But it is also conceivable to use other electrical energy sources 10 (shown in FIG. 2) for supplying the electrodes 4a, b with energy.
[0065] The consumable 1 as shown in FIG. 1a preferably comprises a thickness 8, after compression equal to or lower than the largest dimensions of conductive particles. The conductive material 7 is shown as a particle. It is conceivable that the consumable 1 comprises more than one particle of the conductive material 7. Preferably, the consumable comprises a plurality of particles randomly dispersed in the consumable. For example, the electrically conductive material 7 comprises particles of particle size of about 780 microns. In particular, the electrically conductive material 7 was activated carbon particles under reference Jacobi EcoSorb MB3-10H. It is conceivable that the resistance between the electrodes depends on the size of the particles of the conductive material 7. The electrically conductive material 7 preferably may comprise two contact points 7a with the electrodes 4a, b which are preferably arranged parallel to each other. Preferably the current flows from the one contact point 7a to the other thereby electrically connecting the electrodes 4a, b. In another embodiment (see FIG. 1b), the electrical conductive material 7 comprising at least two particles preferably comprises at least three contact points 7a. Preferably two contact points 7a touch the electrodes 4a, b and the third contact point 7a is a contact point between the particles of the conductive material 7. Of course, an electrically conductive material 7 with both arrangements of FIGS. 1a, 1b in the consumable is also possible. Preferably, the thickness 8 of the consumable is substantially equal to the particle size to ensure contacts points 7a with the electrodes for a plurality of particles. The thickness of the consumable may be 0 to 20% larger than the particle size to ensure contact points after compression of the consumable between the electrodes. For example, the particle size of the electrically conductive particles may be respectively about 250 microns, or 300 microns, or 350 microns, or 400 microns, or 450 microns, or 500 microns, or 550 microns, or 600 microns, or 650 microns, or 700 microns, or 750 microns, or 800 microns and the thickness of the consumable or distance 8 between the electrodes may be respectively between 200 and 250 microns, or between 300 and 360 microns, or between 350 and 420 microns, or between 400 and 480 microns, or between 450 and 540 microns, or between 500 and 600 microns, or between 55 and 660 microns, or between 600 and 720 microns, or between 650 and 780 microns, or between 700 and 840 microns, or between 750 and 900 microns, or between 800 and 960 microns.
[0066] The FIGS. 1a and b show in particular preferred embodiments, wherein the resistance at the thickness 8 of the consumable 1 decreases. The current flows better with a thickness 8 of the consumable which allows as few as possible contact points 7a to the electrodes 4a, b. Due to this, the transition resistance is preferably proportional to the thickness 8 and/or to a number of contact points 7a.
[0067] FIG. 1c shows a schematic top view of a consumable 1 comprising conductive material 7 between two electrodes 4a, b. As can be seen in the FIG. 1b, the consumable 1 is arranged between the electrodes 4a, b (4b not shown). Preferably the consumable 1 or the heating layer 3 comprises at least one surface area 3a which touches the contact surfaces 11 (not shown) of the electrodes 4a, b. Due to the fact that the consumable 1 is pressed between the electrodes 4a, b, it is conceivable that only a portion of the surface 3b of the consumable 1 is heatable.
[0068] FIG. 2 shows a schematic view of a device 2 for delivering aerosol with two electrodes 4a, b and consumable 1 arranged between the electrodes 4a, b. The device 2 further comprises an electrical energy supply 10, a mouthpiece 12, an aerosol channel 13 and a cartridge 14. It is conceivable that the device 2 comprises further mechanical, electrical and/or electric components. Preferably the electrodes 4a, b are supplied with energy comprised in the electrical energy 10 supply. Due to this, the electrodes 4a, b preferably does not need an external voltage source 19 (not shown). But it is also possible that another embodiment of the device 2 comprises a voltage source 19 which supplies only the electrodes with energy (not shown).
[0069] Preferably the cartridge 14 comprises the consumable 1. The cartridge 14 is used for storage of the consumable 1. Also preferably the stored consumable 1 in the cartridge 14 is advantageously placed in a space saving way. The cartridge 14 is preferably connected to the electrodes 4a, b for supplying the electrodes 4a, b with fresh, in particular not burned consumable 1. It is conceivable that the cartridge comprises means for pushing the stored consumable 1 forwards to the electrodes 4a, b (not shown). This means could be a manual or electrical propulsion.
[0070] The heated consumable 1 which is arranged between two electrodes 4a, b preferably segregates inhalable aerosol 9. Preferably the aerosol 9 is guided through the aerosol channel 13 to the mouthpiece 12 of the device 2. Due to this, it is conceivable that the aerosol channel 13 is connected to the electrodes 4a, b. It is also possible that the electrodes 4a, b are arranged in the aerosol channel 13. In such a case, the aerosol channel 14 might be connected to the cartridge 13.
[0071] FIG. 3 shows a flow chart of a method for manufacturing a consumable 1 comprising a conductive material 7. First step of the method for manufacturing the consumable 1 could preferably be mixing 100 the ingredients of an aerosol substrate to provide a smooth mixture. Preferably the ingredients comprise solid and liquid. Also preferably the flavorant material 5, such as a tobacco material or other flavorant substance, and the conductive material 7 are provided in particulate form, preferably as powder. It is advantageous to mix the solid materials before adding liquid ingredients to the solid ingredients. An aerosol forming agent 6 and water are preferably provided as liquid ingredients. It is also conceivable to use binder for a smoother aerosol substrate mixture. It is also conceivable to soak porous conductive particles such as charcoal in a liquid forming agent before mixing with the other ingredients. After mixing 100 the ingredients, an aerosol substrate is obtained in form of dough or paste. The next step of the method for manufacturing is preferably the pressing step 101. Preferably the pressing step 101 comprises mechanical compression of the aerosol substrate for forming a consumable 1 to a layer. It is conceivable that the pressed consumable 1 is arranged between two wrappings after pressing step 101. Such wrappings are preferably useful for rolling or layering the consumable 1. In some embodiments the consumable 1 can be rolled or layered without using the wrappings. The wrapping layers can be paper layers. However, it is advantageous to bring the consumable 1 in a rolled shape for further storage in a cartridge 14. As a last step of the method for manufacturing the consumable could be the solidifying step 102. Preferably the pressed and/or rolled consumable 1 is dried and/or cured during the step 102. It is conceivable to arrange the consumable 1 in the cartridge 14 for further use in the device 2. The consumable 1 should comprise a certain amount of moisture for being elastic enough for further use. Preferably the consumable 1 is gradually rolled out in the further use in the device 2.
[0072] FIG. 4 shows a flow chart of a method for aerosol production with a device 2 comprising two electrodes 4a, b and a consumable 1 arranged between the electrodes 4a, b. The first step of the method for aerosol production is preferably arranging 200 the consumable 1 or the heating layer 3 between the electrodes 4a, b of the device 2. It is also conceivable that the consumable 1 is rolled out and guided to the electrodes 4a, b out of the cartridge 14 of the device 2 before arranging 200. The method for aerosol production further comprises a pressing step 201, wherein the electrodes 4a, b are pressed with a pressure amount to the consumable 1. Preferably the electrodes 4a, b are arranged parallel to each other (shown in FIG. 1a) and surround the consumable 1 from two sides or directions. The method further comprises a supplying step 202. The supplying step 202 comprises supplying the electrodes 4a, b with electrical current. Preferably the heating layer 3 or the consumable 1 conducts the current between the two electrodes 4a, b. Due to this, the method comprises a heating step 203. A temperature of the electrodes 4a, b preferably increases thereby heating the consumable 1 or heating layer 3. The inhalable aerosol 9 is generated from the consumable 1 or the heating layer 3 during the heating step 203.
[0073] FIG. 5a shows a schematic view of a cartridge 14 comprising consumable 1 arranged as a spiral. Preferably the consumable 1 or the heating layer 3 runs around a curve which emanates from a point (not shown), moving farther away as the consumable 1 revolves around the point. The consumable 1 is preferably arranged or stored in the cartridge 14. It is conceivable that the cartridge 14 is a storage box or another container which keeps the consumable fresh. The cartridge further comprises a leading channel 17 which is connected to the electrodes 4a, b of the device 2. It is also conceivable that the leading channel 17 is connected to the aerosol channel 13 of the device 2, wherein the electrodes 4a, b are arranged at least in part inside the aerosol channel 13. However, the cartridge 14 is preferably detachably connected to the electrodes 4a, b via connecting means 18. This could be useful in case of refill of the cartridge 14 with fresh consumable 1. It is conceivable that the device 2 further comprises a container 15 for used consumable 16. In some embodiments the used consumable 16 is preferably heated at a temperature up to 350 C?, wherein the used consumable 16 comprises a very small or no amount of liquids. If the amount of liquid forming agent is too low, a higher temperature, e.g. 350? C. (close to the combustion of tobacco) may be required to generate aerosol. If a sufficient amount of forming agent is contained in the consumable, the temperature to vaporize enough aerosol can be lowered e.g. below 300? C. The used consumable 16 preferably falls into the container 15 after the fresh consumable 1 is forwarded from the cartridge 14 to the electrodes 4a, b. It is also conceivable to arrange other constructions for storage of used consumable 16 in the device 2.
[0074] FIG. 5b shows a schematic view of a cartridge 14 comprising consumable 1 arranged as a hyperbolic spiral. The consumable 1 is preferably arranged in the cartridge 14 as shown in FIG. 5a. Preferably the consumable 1 is wrapped on a wrapper or a fixture (not shown) for a better support of the consumable 1 inside the cartridge 14. However, there many possibilities to arrange the consumable 1 or the heating layer 3 inside the cartridge 14. It is important to arrange the consumable 1 very compact inside the cartridge 14 to provide a long uptime of the cartridge 14 inside the device 2.
[0075] The consumable can be stored in alternative forms to the ones of FIGS. 5a, 5b such as a stack of a continuous accordion consumable or separate layers arranged in stack.
[0076] The applicant reserves his right to claim all features disclosed in the application document as being an essential feature of the invention, as long as they are new, individually or in combination, in view of the prior art. Furthermore, it is noted that in the figures features are described, which can be advantageous individually. Someone skilled in the art will directly recognize that a specific feature being disclosed in a figure can be advantageous also without the adoption of further features from this figure. Furthermore, someone skilled in the art will recognize that advantages can evolve from a combination of diverse features being disclosed in one or various figures.
LIST OF REFERENCE SYMBOLS
[0077] 1 consumable [0078] 2 aerosol generating device [0079] 3 heating layer [0080] 3a surface area of the layer [0081] 3b a portion of the surface of the layer [0082] 4a first electrode [0083] 4b second electrode [0084] 5 flavorant material/tobacco material [0085] 6 aerosol forming agent [0086] 7 electrically conductive material [0087] 7a contact point of the conductive material with the electrode [0088] 8 thickness of the heating layer/consumable [0089] 9 aerosol [0090] 10 electrical energy [0091] 11 contact surfaces of the electrodes [0092] 12 mouthpiece [0093] 13 aerosol channel [0094] 14 cartridge [0095] 15 container for used consumable [0096] 16 used consumable [0097] 17 leading channel [0098] 18 connecting means [0099] 19 voltage source [0100] 100 mixing the ingredients of the consumable [0101] 101 pressing the dough or the paste to a layer [0102] 102 solidifying the heating layer [0103] 200 arranging the heating layer/consumable between electrodes [0104] 201 pressing the electrodes on the heating layer/consumable [0105] 202 supplying the electrodes with electrical current [0106] 203 heating the heating layer
