An Aerosol Generating Article and Method of Manufacturing the Same

Abstract

An aerosol generating article for use with an aerosol generating device includes a substantially planar aerosol generating substrate, at least one airflow channel extending along the substantially planar aerosol generating substrate, and an inductively heatable susceptor positioned in the aerosol generating substrate. The aerosol generating article can optionally include a wrapping member surrounding the substantially planar aerosol generating substrate and the at least one airflow channel. Methods of manufacturing the aerosol generating article are also described.

Claims

1. An aerosol generating article for use with an aerosol generating device, the aerosol generating article comprising: a substantially planar aerosol generating substrate; at least one airflow channel extending along the substantially planar aerosol generating substrate; and an inductively heatable susceptor positioned in the aerosol generating substrate.

2. The aerosol generating article according to claim 1, wherein the aerosol generating article comprises a distal end, a proximal end, a longitudinal axis extending between the proximal end and the distal end, and the at least one airflow channel extends in a first direction substantially parallel to the longitudinal axis.

3. The aerosol generating article according to claim 1, wherein the at least one airflow channel comprises at least one groove formed in a surface of the substantially planar aerosol generating substrate.

4. The aerosol generating article according to claim 3, wherein the at least one groove comprises a plurality of grooves arranged side by side to form a fluted surface.

5. The aerosol generating article according to claim 1, wherein the at least one airflow channel comprises at least one airflow passage formed internally within the aerosol generating substrate.

6. The aerosol generating article according to claim 1, wherein: the aerosol generating substrate comprises a plurality of aerosol generating strips extending in a first direction and arranged intermittently in a second direction perpendicular to the first direction; the at least one airflow channel comprises a plurality of airflow channels and one of said airflow channels is formed between each pair of intermittently arranged aerosol generating strips.

7. The aerosol generating article according to claim 1, wherein the substantially planar aerosol generating substrate has a flat rectangular shape having a pair of first and second main surfaces, and the inductively heatable susceptor is substantially planar and lies substantially parallel to the main surfaces.

8. The aerosol generating article according to claim 7, wherein the at least one airflow channel is formed in the first main surface and the substantially planar inductively heatable susceptor is positioned in the aerosol generating substrate closer to the second main surface than to the first main surface.

9. The aerosol generating article according to claim 1, wherein the inductively heatable susceptor comprises discontinuities or holes therein.

10. The aerosol generating article according to claim 1, further comprising a wrapping member surrounding the substantially planar aerosol generating substrate and the at least one airflow channel.

11. The aerosol generating article according to claim 10, wherein the substantially planar aerosol generating substrate has a flat rectangular shape having a pair of first and second main surfaces and the wrapping member comprises a pair of first and second rectangular sheets attached, respectively, to the pair of first and second main surfaces.

12. The aerosol generating article according to claim 10, wherein the wrapping member has a porous inner surface facing towards the aerosol generating substrate for absorbing condensation and an anti-stick outer surface facing away from the aerosol generating substrate.

13. The aerosol generating article according to claim 1, wherein the aerosol generating article comprises a support member forming a mouth-end portion of the article, and the support member has a tubular form to receive a downstream end of the aerosol generating substrate and the at least one airflow channel.

14. A method of manufacturing an aerosol generating article according to claim 1, the method comprising: providing a substantially planar aerosol generating substrate; positioning an inductively heatable susceptor in the substantially planar aerosol generating substrate; and forming at least one airflow channel in the substantially planar aerosol generating substrate.

15. The method of manufacturing an aerosol generating article according to claim 1, the method further comprising: providing an inductively heatable susceptor; forming a substantially planar aerosol generating substrate around the inductively heatable susceptor; and forming at least one airflow channel in the substantially planar aerosol generating substrate.

16. The aerosol generating article according to claim 12, wherein the wrapping member comprises an anti-stick coating on the outer surface.

17. The aerosol generating article according to claim 9, wherein the inductively heatable susceptor comprises a mesh.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] FIG. 1 is a diagrammatic longitudinal cross-sectional view of a first example of an aerosol generating article;

[0046] FIG. 2 is a diagrammatic cross-sectional view along the line A-A in FIG. 1;

[0047] FIG. 3 is a diagrammatic cross-sectional view similar to FIG. 2 of a second example of an aerosol generating article;

[0048] FIG. 4 is a diagrammatic cross-sectional view similar to FIG. 3 of a third example of an aerosol generating article;

[0049] FIG. 5a is a diagrammatic longitudinal cross-sectional view of a fourth example of an aerosol generating article;

[0050] FIG. 5b is a diagrammatic cross-sectional view along the line B-B in FIG. 5a;

[0051] FIG. 6 is a diagrammatic longitudinal cross-sectional view of a fifth example of an aerosol generating article;

[0052] FIG. 7 is a diagrammatic longitudinal cross-sectional view of a sixth example of an aerosol generating article;

[0053] FIG. 8 is a diagrammatic cross-sectional view along the line C-C in FIG. 7;

[0054] FIG. 9 is a diagrammatic cross-sectional view similar to FIG. 2 of a seventh example of an aerosol generating article;

[0055] FIG. 10 is a diagrammatic cross-sectional view similar to FIG. 2 of an eighth example of an aerosol generating article;

[0056] FIG. 11 is a diagrammatic cross-sectional view similar to FIG. 2 of a ninth example of an aerosol generating article;

[0057] FIG. 12 is a diagrammatic cross-sectional view similar to FIG. 2 of a tenth example of an aerosol generating article; and

[0058] FIG. 13 is a diagrammatic cross-sectional view of an aerosol generating system comprising an aerosol generating device and an aerosol generating article according to the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

[0059] Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.

[0060] Referring initially to FIGS. 1 and 2, there is shown a first example of an aerosol generating article 1 for use with an electrically-operated aerosol generating device 102, an example of which will be described later in this specification with reference to FIG. 13. The aerosol generating article 1 is substantially planar and has a distal end 10 and a proximal end 12 (or mouth end) at the opposite end of the aerosol generating article 1. The proximal end 12 is downstream of the distal end 10 with respect to an airflow direction through the aerosol generating article 1 as represented in FIG. 1 by the three arrows. A longitudinal axis extends between the distal end 10 and the proximal end 12 to define a longitudinal direction of the aerosol generating article 1.

[0061] The aerosol generating article 1 comprises a substantially planar aerosol generating substrate 14. The aerosol generating substrate 14 comprises a bulk or mass of aerosol generating material and has a flat rectangular shape with a pair of oppositely disposed first and second main surfaces 14a, 14b. The aerosol generating article 1 is a consumable, or disposable, article in which the aerosol generating substrate 14 may comprise tobacco or a tobacco material.

[0062] The aerosol generating article 1 comprises a plurality of airflow channels 16 which, in the illustrated example, comprise a plurality of grooves 18 formed in the first main surface 14a of the aerosol generating substrate 14. The grooves 18 are arranged side-by-side and parallel to each other, and the grooves 18 extend in the longitudinal direction between the distal end 10 and the proximal end 12, substantially parallel to the longitudinal axis. Together, the grooves 18 form a fluted surface 20. The grooves 18 may be formed in any suitable manner, for example by pressing the first main surface 14a of the aerosol generating substrate 14 with a suitably shaped pressing tool. Three grooves 18 are shown in the example of FIGS. 1 and 2, but it will be understood that any suitable number of grooves 18 can be provided, for example depending on the desired resistance-to-draw of the aerosol generating article 1. It should also be noted that the grooves 18 may have any suitable cross-sectional shape including, but not limited to, square as illustrated in FIG. 2, rectangular, trapezoidal, or semi-circular.

[0063] The aerosol generating article 1 comprises a substantially planar inductively heatable susceptor 40 positioned in the aerosol generating substrate 14 and arranged substantially parallel to the first and second main surfaces 14a, 14b. The inductively heatable susceptor 40 includes a plurality of holes or discontinuities 42 to allow air and/or vapour to pass through it. In some embodiments, the inductively heatable susceptor 40 can comprise a substantially planar mesh 43. The inductively heatable susceptor 40 is positioned in the aerosol generating substrate 14 closer to the second main surface 14b than to the first main surface 14a, although other positions are possible and entirely within the scope of the present disclosure.

[0064] Referring now to FIG. 3, there is shown a second example of an aerosol generating article 2. The aerosol generating article 2 is similar to the aerosol generating article 1 described above with reference to FIGS. 1 and 2 and corresponding features are identified using the same reference numerals.

[0065] The aerosol generating article 2 includes a plurality of airflow channels 16 in the form of airflow passages 30 formed internally within the aerosol generating substrate 14. Like the grooves 18, the airflow passages 30 extend in the longitudinal direction, between the distal end 10 and the proximal end 12, substantially parallel to the longitudinal axis. The airflow passages 30 are arranged side-by-side within the aerosol generating substrate 14 closer to the first main surface 14a than the second main surface 14b, although different positions could be adopted provided that each airflow passage 30 is fully surrounded by the aerosol generating material that forms the aerosol generating substrate 14. It should also be noted that the airflow passages 30 may have a variety of cross-sectional shapes including, but not limited to, square as illustrated in FIG. 3, rectangular, circular, oval, or triangular.

[0066] Referring now to FIG. 4, there is shown a third example of an aerosol generating article 3. The aerosol generating article 3 is similar to the aerosol generating article 2 described above with reference to FIG. 3 and corresponding features are identified using the same reference numerals.

[0067] The aerosol generating article 3 includes an airflow channel 16 in the form of a single airflow passage 30 formed internally within the aerosol generating substrate 14. The airflow passage 30 extends in the longitudinal direction, between the distal end 10 and the proximal end 12, substantially parallel to the longitudinal axis. The airflow passage 30 is positioned closer to the first main surface 14a than to the second main surface 14b of the aerosol generating substrate 14 and is surrounded on all sides by the aerosol generating substrate 14, ensuring that volatile components can be released from the aerosol generating substrate 14 and entrained in air flowing through the airflow passage 30 during use of the aerosol generating article 3 in an aerosol generating device 102. The aerosol generating articles 1, 2, 3 described above can be manufactured by (i) providing a substantially planar aerosol generating substrate 14; (ii) positioning an inductively heatable susceptor 40 in the substantially planar aerosol generating substrate 14; and (iii) forming at least one airflow channel 16 (e.g., a groove 18 or an airflow passage 30) in the substantially planar aerosol generating substrate 14. Purely by way of example, steps (i) and (ii) could be performed by providing first and second aerosol generating sheets with the inductively heatable susceptor 40 positioned between them and thereafter pressing the aerosol generating sheets together to form the substantially planar aerosol generating substrate 14. Steps (ii) and (iii) could be performed in any order, for example the at least one airflow channel 16 could be formed in the substantially planar aerosol generating substrate 14 before the inductively heatable susceptor 40 is positioned in the aerosol generating substrate 14. Steps (ii) and (iii) could be performed simultaneously in some embodiments.

[0068] Alternatively, the aerosol generating articles 1, 2, 3 described above could be manufactured by (i) providing an inductively heatable susceptor 40; and (ii) forming a substantially planar aerosol generating substrate 14 around the inductively heatable susceptor 40. For example, the aerosol generating substrate 14 could be applied as a paste to the inductively heatable susceptor 40 (e.g., susceptor mesh 43) before being cured to form the substantially planar aerosol generating substrate 14 with the inductively heatable susceptor 40 positioned therein. As a final step, the method may comprise (iii) forming at least one airflow channel 16 (e.g., a groove 18 or an airflow passage 30) in the substantially planar aerosol generating substrate 14.

[0069] Referring now to FIGS. 5a and 5b, there is shown a fourth example of an aerosol generating article 4. The aerosol generating article 4 is similar to the aerosol generating article 1 described above with reference to FIGS. 1 and 2 and corresponding features are identified using the same reference numerals.

[0070] The aerosol generating article 4 has the same construction as the aerosol generating article 1 and in addition comprises a wrapping member 22 which surrounds the aerosol generating substrate 14, the inductively heatable susceptor 40, and the grooves 18. The aerosol generating substrate 14, the inductively heatable susceptor 40, and the grooves 18 are, thus, fully enclosed by the wrapping member 22 which may, for example, comprise cigarette paper or a similar material. The wrapping member 22 comprises a pair of rectangular sheets 24, 26 which are attached, respectively, to the first and second main surfaces 14a, 14b of the aerosol generating substrate 14. The rectangular sheets 24, 26 are typically formed by a single sheet of material which is wrapped around the aerosol generating substrate 14 and which may have overlapping edges that are adhered to each other to secure the wrapping member 22 in position around the aerosol generating substrate 14 and the grooves 18.

[0071] In an exemplary and non-limiting example, the aerosol generating substrate 14 may have a length (in the longitudinal direction of the aerosol generating article 4) of approximately 18.0 mm, may have a width of approximately 11.8 mm, and may have a thickness (or depth) of approximately 1.2 mm. The aerosol generating substrate 14 may be spaced inwardly from the distal end 10 of the aerosol generating article 4 by a small distance, for example approximately 3.0 mm, as shown in FIG. 5a. The aerosol generating article 4 may have a width of approximately 12.0 mm and a thickness (or depth) of approximately 1.4 mm to accommodate the aerosol generating substrate 14 and the inductively heatable susceptor 40 inside the wrapping member 22. The aerosol generating article 4 may have any suitable length between the distal end 10 and the proximal end 12 by varying the length of the portion of the wrapping member 22 that extends between the downstream end of the aerosol generating substrate 14 and the proximal end 12. As vapour flows through this portion of the wrapping member 22 during use of the aerosol generating article 4 in an aerosol generating device 102, the vapour may cool and condense to form an aerosol for inhalation by a user. Thus, the length of the portion of the wrapping member 22 that extends between the downstream end of the aerosol generating substrate 14 and the proximal end 12 of the aerosol generating article 4 may be selected at the time of manufacture to provide an aerosol with desired characteristics.

[0072] In some embodiments, the wrapping member 22 comprises a porous inner surface 22a which faces towards the aerosol generating substrate 14 and which is capable of absorbing condensation that may be formed during the heating process. Alternatively or in addition, the wrapping member 22 can comprise an anti-stick outer surface 22b facing away from the aerosol generating substrate 14 to reduce the risk of the wrapping member 22 sticking to surfaces of the aerosol generating device 102 when it has been heated. The anti-stick outer surface 22b may comprise an anti-stick coating on the outer surface 22b of the wrapping member 22.

[0073] The aerosol generating article 4 may be manufactured by the methods described above and comprises a further step of wrapping the substantially planar aerosol generating substrate 14 with a wrapping member 22 to form the substantially planar aerosol generating article 4.

[0074] Referring now to FIG. 6, there is shown a fifth example of an aerosol generating article 5. The aerosol generating article 5 is similar to the aerosol generating article 4 described above with reference to FIGS. 5a and 5b and corresponding features are identified using the same reference numerals.

[0075] The aerosol generating article 5 includes a support member 28 positioned at the proximal end 12 of the aerosol generating article 5 to form a mouth-end portion 34 which can be engaged by a user's lips during use of the aerosol generating article 5 in an aerosol generating device 102. The support member 28 typically comprises a self-supporting material such as cardboard or a plastics material and has a rectangular tubular form when viewed in cross-section to receive a downstream end of the aerosol generating substrate 14 and the grooves 18 formed in the first main surface 14a. The wrapping member 22 also surrounds the support member 28.

[0076] Referring now to FIGS. 7 and 8, there is shown a sixth example of an aerosol generating article 6. The aerosol generating article 6 is similar to the aerosol generating article 4 described above with reference to FIGS. 5a and 5b and corresponding features are identified using the same reference numerals.

[0077] In the aerosol generating article 6, the aerosol generating substrate 14 comprises a plurality of aerosol generating strips 32 which extend in a first direction, substantially parallel to the longitudinal direction of the aerosol generating article 6, between the distal end 10 and the proximal end 12. The aerosol generating strips 32 are spaced apart laterally, in other words they are arranged intermittently and spaced apart in a second direction perpendicular to the first direction. This intermittent arrangement (or spacing) of the aerosol generating strips 32 forms airflow channels 16, with an airflow channel 16 being formed between each adjacent pair of aerosol generating strips 32.

[0078] The aerosol generating article 6 is shown without a support member 28 at the proximal end 12. A support member 28 can, however, be provided at the proximal end 12 of the aerosol generating article 6 as explained above in connection with the aerosol generating article 5 of FIG. 6.

[0079] Referring now to FIGS. 9 and 10, there are shown a seventh and eighth examples of an aerosol generating article 7, 8. The aerosol generating articles 7, 8 are similar to the aerosol generating article 1 described above with reference to FIGS. 1 and 2 and corresponding features are identified using the same reference numerals.

[0080] In the aerosol generating articles 7, 8, the inductively heatable susceptor 40 comprises an inhomogeneous susceptor mesh 43. The inhomogeneous susceptor mesh 43 comprises a plurality of first susceptor elements 44 having a first thickness and a plurality of second susceptor elements 46 having a second thickness which is greater than the first thickness of the first susceptor elements 44.

[0081] In the aerosol generating article 7, the inhomogeneous susceptor mesh 43 is positioned in the aerosol generating substrate 14 so that the thinner first susceptor elements 44 are located adjacent to (specifically below) the grooves 18 where there is a shorter path to the surface of the aerosol generating substrate 14 and a lower density (or bulk) of the aerosol generating substrate 14. With this configuration, the time to first puff may be reduced.

[0082] In the aerosol generating article 8, the inhomogeneous susceptor mesh 43 is positioned in the aerosol generating substrate 14 so that the thicker second susceptor elements 46 are located adjacent to (specifically below) the grooves 18 and the thinner first susceptor elements 44 are located between the grooves 18 where there is a longer path to the surface of the aerosol generating substrate 14 and a higher density (or bulk) of aerosol generating substrate 14. With this configuration, a more uniform heating of the aerosol generating substrate 14 may be achieved, providing an increased volume of vapour during a predetermined time period (e.g., a total session time).

[0083] Referring now to FIGS. 11 and 12, there are shown a ninth and tenth examples of an aerosol generating article 9, 10. The aerosol generating articles 9, 10 are similar to the aerosol generating article 1 described above with reference to FIGS. 1 and 2 and corresponding features are identified using the same reference numerals.

[0084] In the aerosol generating articles 9, 10, the inductively heatable susceptor 40 comprises an inhomogeneous susceptor mesh 43. The inhomogeneous susceptor mesh 43 comprises a plurality of first susceptor elements 44 having a first spacing (or pitch) and a plurality of second susceptor elements 46 having a second spacing (or pitch) which is greater than the first spacing (or pitch) of the first susceptor elements 44.

[0085] In the aerosol generating article 9, the inhomogeneous susceptor mesh 43 is positioned in the aerosol generating substrate 14 so that the first susceptor elements 44 (with the smaller spacing or pitch) are located adjacent to the grooves 18 where there is a shorter path to the surface of the aerosol generating substrate 14 and a lower density (or bulk) of the aerosol generating substrate 14. This configuration provides the same effect as that described with reference to FIG. 9.

[0086] In the aerosol generating article 10, the inhomogeneous susceptor mesh 43 is positioned in the aerosol generating substrate 14 so that the second susceptor elements 46 (with the larger spacing or pitch) are located adjacent to the grooves 18 and the first susceptor elements 44 (with the smaller spacing or pitch) are located between the grooves 18 where there is a longer path to the surface of the aerosol generating substrate 14 and a higher density (or bulk) of aerosol generating substrate 14. This configuration provides the same effect as that described with reference to FIG. 10.

[0087] Referring now to FIG. 13, there is shown an aerosol generating system 100 comprising an aerosol generating device 102 and a fourth example of an aerosol generating article 4 as described above with reference to FIGS. 5a and 5b. It will be appreciated that the aerosol generating device 102 could be used in combination with an alternative aerosol generating article according to the present disclosure, such as the examples of the aerosol generating articles 1, 2, 3, 5, 6, 7, 8, 9, 10 described above with reference to FIGS. 1 to 4 and 6 to 12.

[0088] The aerosol generating device 102 comprises a receiving chamber 106 and an electromagnetic field generator 104 positioned in the device body 108. The electromagnetic field generator 104 may include a first planar coil 122 and a second planar coil 124, although it may be sufficient that just a single planar coil 122, 124 is provided. In the example illustrated in FIG. 13, the first and second planar coils 122, 124 are flat spiral coils positioned on opposite sides of the receiving chamber 106.

[0089] In use, a user inserts the aerosol generating article 4 into the receiving chamber 106. The aerosol generating device 102 may include a cover 110 and a pivotal mounting 112 that allows the cover 110 to be moved between a closed position shown in FIG. 13 and an open position (not shown). As will be understood by one of ordinary skill in the art, a user must pivot the cover 110 to the open position to permit insertion of the aerosol generating article 4 into the receiving chamber 106 and then pivot the cover 110 back to the closed position shown in FIG. 13 to retain the aerosol generating article 4 in position in the receiving chamber 106.

[0090] The aerosol generating device 102 includes a power source 114, e.g., a rechargeable battery, and a controller 116. The first and second planar coils 122, 124 can be energised by the power source 114 and controller 116, for example manually, e.g., via a user interface such as a button on the aerosol generating device 102, or automatically in response to a user drawing on a mouthpiece 118 of the aerosol generating device 102. The controller 116 may include, amongst other electronic components, an inverter which is arranged to convert a direct current from the power source 114 into an alternating high-frequency current for the first and second planar coils 122, 124. When the first and second planar coils 122, 124 are energised by the alternating high-frequency current, alternating and time-varying electromagnetic fields are produced that penetrate the receiving chamber 106 and the aerosol generating article 4 positioned therein. The electromagnetic fields couple with the inductively heatable susceptor 40 and generate eddy currents and/or magnetic hysteresis losses in the inductively heatable susceptor 40 causing it to heat up. The heat is then transferred from the inductively heatable susceptor 40 to the aerosol generating substrate 14, for example by conduction, radiation and convection.

[0091] The heat transferred from the inductively heatable susceptor 40 to the aerosol generating substrate 14 causes it to heat up without being burned and to thereby release one or more volatile components. The aerosol generating device 102 includes one or more air inlets 120 to allow air to flow into the aerosol generating article 4 and through the grooves 18 formed in the first main surface 14a of the aerosol generating substrate 14. The airflow direction is illustrated by the arrow in FIG. 13. The volatile components are entrained in the air flowing through the grooves 18 thereby forming a vapour. The vapour cools and condenses as it flows through the grooves 18 to form an aerosol which is inhaled by a user through the mouthpiece 118 of the aerosol generating device 102.

[0092] When the aerosol generating substrate 14 becomes depleted and no longer releases sufficient volatile components to generate an aerosol with acceptable qualities, the aerosol generating article 4 can be removed from the receiving chamber 106 after pivoting the cover 110 to the open position, and a replacement aerosol generating article 4 can be inserted in its place.

[0093] In the event that the aerosol generating device 102 is used in combination with an aerosol generating article having a support member 28, for example the fifth example of the aerosol generating article 5 described above with reference to FIG. 6, the support member 28 may project from an open end 106a of the receiving chamber 106 thereby enabling a user's lips to engage the mouth-end portion 34 of the aerosol generating article 5 formed by the support member 28.

[0094] It should be appreciated by one of ordinary skill in the art that the aerosol generating device 102 described with reference to FIG. 13 is a conceptual design example used to illustrate the principles of aerosol generating articles according to the present disclosure. The aerosol generating articles according to the present disclosure may be used with any inductively heated aerosol generating device 102 of suitable design.

[0095] Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications may be made to those embodiments without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

[0096] Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

[0097] Unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising, and the like, are to be construed in an inclusive as opposed to an exclusive or exhaustive sense; that is to say, in the sense of including, but not limited to.