An Aerosol-Generating Article in Form of a Disposable Shaped Cartridge Comprising a Foamed Aerosol-Generating Material

Abstract

The present invention relates to an aerosol-generating article comprising a disposable shaped cartridge and a foamed aerosol-generating material provided in the cartridge, wherein the disposable shaped cartridge comprises a base, a top, an internal wall and an external wall, wherein the base and the top of the cartridge are connected to the internal wall and the external wall, wherein the internal wall is provided to form one or more longitudinal channels void of and extending through the foamed aerosol-generating material.

Claims

1. An aerosol-generating article in form of a shaped cartridge comprising a foamed aerosol-generating material, wherein the shaped cartridge is disposable and comprises a base, a top, an internal wall and an external wall, wherein the base and the top of the cartridge are connected to the internal wall and the external wall, wherein the internal wall delimits one or more longitudinal channels void of and extending through the foamed aerosol-generating material.

2. The aerosol-generating article according to claim 1, wherein the one or more longitudinal channels extend from the base of the cartridge to the top and/or to the external wall of the cartridge.

3. The aerosol-generating article according to claim 1, wherein the one or more longitudinal channels extend predominantly parallel to or about a longitudinal axis of the cartridge.

4. The aerosol-generating article according to claim 1, wherein the one or more longitudinal channels are configured to fit about a heat-generating element of a heating device.

5. The aerosol-generating article according to claim 1, wherein the one or more longitudinal channels are straight or spiral.

6. The aerosol-generating article according to claim 1, wherein the cross-section perpendicular to the longitudinal axis of the one or more longitudinal channels comprises a circular, edged, oval or irregular profile.

7. The aerosol-generating article according to claim 1, wherein the cross section perpendicular to the external wall of the cartridge has a circular, square, rectangular, triangular, ridge or spoke, polygon or an irregular shape.

8. The aerosol-generating article according to claim 1, wherein the base of the cartridge is substantially flat and/or edged such as to increase the contact points with a heat-generating element of a heating device.

9. The aerosol-generating article according to claim 1, wherein the base of the cartridge has a surface complimentary to a shape of a heat-generating element of a heating device such as to increase the contact points between the base and the heat-generating element for the transmission of heat to the cartridge.

10. The aerosol-generating article according to claim 1, wherein the cartridge is made of a material comprising temperature-resistant polymeric foam, porous ceramic or non-oriented fibres.

11. The aerosol-generating article according to claim 1, wherein one or more openings are provided to the cartridge for filling of materials such as the aerosol-generating tobacco-containing substrates and/or a carrier matrix.

12. The aerosol-generating article according to claim 1, wherein the shaped cartridge is air permeable and/or has a mesh structure.

13. The aerosol-generating article according to claim 1, wherein the cartridge has one or more individual compartments, wherein the compartments are filled with same or different materials, comprising aerosol-generating tobacco-containing substrate and/or a stiff carrier matrix.

14. The aerosol-generating article according to claim 1, wherein between 10% and 33-% of the total volume of the cartridge is comprised of the longitudinal channels which are void of the foamed aerosol-generating material.

15. A vaping system, comprising: an aerosol-generating article according to claim 1; and a vaping device comprising a heating-generating element fit within the one or more longitudinal channels within the cartridge.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0044] FIG. 1 is a schematic perspective view of the aerosol-generating article in form of a disposable shaped cartridge of a first embodiment of the present invention.

[0045] FIG. 2a is a schematic perspective view of the aerosol-generating article in form of a disposable shaped cartridge of a second embodiment of the present invention.

[0046] FIG. 2b is a schematic perspective see-through view of the aerosol-generating article in form of a disposable shaped cartridge according to the second embodiment of the present invention.

[0047] FIG. 3a is a schematic perspective see-through view of the aerosol-generating article in form of a disposable shaped cartridge according to a third embodiment of the present invention.

[0048] FIG. 3b is a schematic sagittal cross-sectional perspective view of the aerosol-generating article in form of a disposable shaped cartridge according to the third embodiment of the present invention.

[0049] FIG. 3c is a schematic sagittal cross-sectional view of the aerosol-generating article in form of a disposable shaped cartridge according to the third embodiment of the present invention.

[0050] FIG. 4a is a sagittal cross-sectional perspective view of the aerosol-generating article in form of a disposable shaped cartridge according to the fourth embodiment of the present invention.

[0051] FIG. 4b is a schematic sagittal cross-sectional view of the aerosol-generating article in form of a disposable shaped cartridge according to the fourth embodiment of the present invention.

[0052] FIG. 5a is a sagittal cross-sectional perspective view of the aerosol-generating article in form of a disposable shaped cartridge according to the fifth embodiment of the present invention.

[0053] FIG. 5b is schematic top view of the aerosol-generating article in form of a disposable shaped cartridge according to the fifth embodiment of the present invention.

[0054] FIG. 6a is a schematic perspective view of the aerosol-generating article in form of a disposable shaped cartridge according to the sixth embodiment of the present invention.

[0055] FIG. 6b is a schematic perspective see-through view of the aerosol-generating article in form of a disposable shaped cartridge according to the sixth embodiment of the present invention.

[0056] FIG. 6c is a schematic sagittal cross-sectional view of the aerosol-generating article in form of a disposable shaped cartridge according to the sixth embodiment of the present invention.

[0057] FIG. 7a is a schematic perspective view of the aerosol-generating article in form of a disposable shaped cartridge according to the seventh embodiment of the present invention.

[0058] FIG. 7b is a schematic frontal view of the aerosol-generating article in form of a disposable shaped cartridge according to the seventh embodiment of the present invention.

[0059] FIG. 8a is a schematic perspective view of the aerosol-generating article in form of a disposable shaped cartridge according to the eighth embodiment of the present invention.

[0060] FIG. 8b is a schematic frontal view of the aerosol-generating article in form of a disposable shaped cartridge according to the eighth embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0061] FIG. 1 shows an exemplary embodiment of an aerosol-generating article 100 in form of a disposable shaped cartridge according to the present invention. The disposable shaped cartridge is predominantly of cylindrical shape. For a simpler and clearer illustration, the top layer 25 (cf. FIGS. 3c, 4b and 8b) of the cartridge of all figures illustrated herein is removed such that the longitudinal channel(s) 50 of the disposable shaped cartridge can be seen.

[0062] As shown in the FIG. 1, the internal wall 20 is provided to form one longitudinal channel 50. The longitudinal channel 50 is parallel to the vertical axis (longitudinal axis Y) of the cartridge. The longitudinal channel 50 extends from the base 15 of the cartridge to the top 25 of the aerosol-generating article 100 in form of a cartridge.

[0063] The ratio of the diameters of the longitudinal channel to the cylindrical cartridge of all embodiments can be provided between 1:30 and 1:2, preferably between 1:20 and 1:3 or 1:10 and 1:4, most preferably 1:5. The height of the cartridge can be provided in between 10 mm and 100 mm, preferably between 15 mm and 50 mm, most preferably around 25 mm.

[0064] The disposable shaped cartridge according to the present invention can be made of heat-resistant polymeric material. These heat-resistant polymers are for instance polyimides and their copolymers, polyamides and related copolymers, polyesters, aromatic polyethers and their derivatives, benzimidazoles, and ladder polymers. It should be noted that there are lots of other heat resistant synthetically developed or commercially succeeded polymers (less important) that are not mentioned herein, all completely described in books and review papers published in this field, may also be used as the material for the disposable cartridge.

[0065] It is disclosed herein that according to some embodiments, the mousse could also be covered by a (thin) coating on the sides (partially or fully) to prevent fingers sticking to the cartridge when handling. This coating could be heat-resistant, but could also be volatile, and disappear when being heated. The coating (plastic or so layer) could be on the outer perimeter only. Alternatively, instead of a coating material, it can be a thin layer which can be removed before being used. For instance, such material could be a non-heat resistant paper and can be removed before heating.

[0066] In addition, the same material could be used in several densities. For example, the mousse could be relatively dense on the outside, while airier in the center. This will provide more stiffness for handling, while improving airflow through the rest

[0067] Apart from heat-resistant polymeric material, porous ceramics e.g. porous ceramic having pore diameter (d) more than 10 μm can be used as the material for the disposable cartridge. Generally, porous ceramics have good properties such as mechanical strength, abrasion resistance, chemical and thermal stability. These porous network ceramic structures also have relatively low density, low mass and low thermal conductivity. Disclosed herein is that the ceramic for example could be a cup shape (with hole in the bottom) to hold the mousse. Alternatively, the ceramic could also be very open pores such as to hold the aerosol and tobacco trapped inside the pores.

[0068] A further alternative material for the disposable cartridge can be loose, non-oriented fibres, where these fibres can be used to form not only the cartridge but also as a supporting structure for the content of the cartridge e.g. foam or mousse. Examples of the non-oriented fibres such as those describes in patent document EP 3039060 A1 are suitable to be used in the present invention. For example, the fibers could form a very open matrix that would be filled with mousse.

[0069] FIGS. 2a and 2b are a second embodiment of the present invention where the aerosol-generating article 100 in form of a cartridge is provided in form of a triangular shape, having an external wall 10 and an internal wall 20. A longitudinal channel 50 formed from the internal wall 20 which is parallel to the vertical axis Y of the cartridge is provided to the centre region of the cartridge, extending from the base 15 to the top 25 (not shown), as can be seen in the FIG. 2b.

[0070] FIGS. 3a, 3b and 3c show another variant of the aerosol-generating article 100 in form of other disposable shaped cartridge, where the longitudinal channel 50 has a funnel shape 15b at the bottom region 15 of the cartridge. This embodiment has the advantage that more heated air can flow in contact with the wall of the cartridge.

[0071] A further variant to the examples shown in FIGS. 3a-3c are illustrated in FIGS. 4a and 4b, where a ridge 15c is provided to the base 15 of the cartridge, encircling the rim of the funnel shape 15b which is provided to the bottom part 15 of the longitudinal channel 50.

[0072] Apart from the above-described benefits, these variants of the disposable shaped cartridge are particularly suitable to be used to complement with the surface area of the heat-generating element where bulges are present on the heat-generating element. In other words, these cartridges can be selected or designed accordingly to complement with the contour of the heat-generating element of the heating device such that an optimum surface contact there between can be achieved.

[0073] Moreover, it is disclosed herein that by providing the funnel shape 15b and the ridge 15c, the temperature of the heated air can be reduced such that lower temperature e.g. 250° C., which is optimal for tobacco foam or mousse can be achieved, thereby the aerosol-generating substrate contained within the cartridge can be optimally heated.

[0074] FIG. 5a shows that multiple longitudinal channels 50 can also be provided to the disposable shaped cartridge. In other words, multiple internal walls 20 can be provided to the cartridge, each forming a longitudinal channel 50. The multiple longitudinal channels serve to evacuate the vapour from the aerosol-generating article and device. This also allowed a more controlled vapour to flow through the cartridge. The openings of the channels are preferably from the base 15 to the top 25, however it is also possible to be provided at the wall 10.

[0075] Moreover, apart from a cylindrical, square, triangular or polygon shape cartridge, the outer wall 10 of the cartridge can also be provided in a flowery mosaic shape or irregular shape (c.f. FIG. 5b). The longitudinal channel 50 can be straight or spiral or entangled, as shown in the FIGS. 6a, 6b and 6c. In this embodiment, when the longitudinal channel 50 is spiral, heated air may reach more region of the cartridge such that a more homogenised and consistent aerosol can be produced, as the material within the cartridge can be heated more evenly.

[0076] It is reiterated herein that the base 15 as well as other sides of the cartridge may not only be flat, but also in other forms such as to match the surface profile of the heat-generating element 140 where they adjoin to each other. For example, the base, when viewed from a vertical section of the cartridge perpendicular to a horizontal axis of the cartridge, can have one or more of the following shapes: V, N, U, n, Λ and ω. FIGS. 7a and 7b show that for example the base of the cartridge may be provided with multiple “V”s and inverted “V”s which are matched to the surface profile of the heat-generating element 140, as shown the FIG. 7b. Similarly, the cartridge may be provided in multiple “U”s and inverted “U”s which are matched to the surface profile of the heat-generating element 140 of a heating device, as illustrated in the FIGS. 8a and 8b. By providing disposable shaped cartridges having surface profiles complementary to the surface profile of the heat-generating element 140, more contact surfaces are created, thereby allowing a denser, more consistent aerosol to be released.

[0077] To this end, it is noted that in some instances, the surface of the cartridge contacted with the heat-generating element 140 may be deformed during heating as a result of the used-up mousse e.g. part of the materials being vaporised. For this reason, a stiffer carrier matrix for use as the material of the cartridge explained above can be used to prevent the collapse of the cartridge.

[0078] Present invention aims to improve conveying of heat from a heater of a heating device to aerosol-generating tobacco-containing substrates e.g. tobacco mousse contained in a shaped cartridge. This objective is achieve through having for instance having higher contact surface at the bottom of the shaped cartridge or by providing one or more longitudinal channels within the shaped cartridge, wherein the longitudinal channels are shaped according to the shape of the heating element such that an optimum surface contact is achieved for an efficient heat transfer. Moreover, in some instances where the heating elements could not reach to the longitudinal channels of the shaped cartridge, heated air or aerosol generated from the heating element traveling through the longitudinal channels is capable of heating higher surface area of the aerosol-generating tobacco-containing substrate. These characteristics of the present invention allows a more homogenise heating of the aerosol-generating tobacco-containing substrates, thereby generating denser, more consistent aerosol from a single use and disposable consumable.