Aerosol-generating device, and a capsule for use in an aerosol-generating device

Abstract

A capsule for an aerosol-generating device is provided, including a shell including a base and at least one side wall extending from the base, the shell containing an aerosol-forming substrate; and a lid sealed on the at least one side wall for forming a sealed capsule, wherein the base includes a recess extending into said shell along the longitudinal axis for receiving a heater of an aerosol-generating device. An aerosol-generating device is also provided, including a power supply; at least one heater; a cavity for receiving the capsule containing the aerosol-forming substrate; and a mouthpiece including a piercing element for piercing the lid of the capsule, wherein the at least one heater is configured to be insertable into a recess of the capsule. An aerosol-generating system including the aerosol-generating device and the capsule is also provided.

Claims

1. An aerosol-generating system, comprising: a capsule comprising: a shell comprising a base and at least one side wall extending from the base, the shell containing an aerosol-forming substrate having a solid component and comprising at least one of a nicotine salt matrix and tobacco, and a lid sealed on the at least one side wall for forming a sealed capsule, wherein the base comprises a recess extending into said shell along a longitudinal axis of the capsule; and an aerosol-generating device comprising: a power supply, at least one heater, a cavity configured to receive the capsule, and a mouthpiece comprising a piercing element configured to pierce the lid of the capsule, wherein the at least one heater is configured to be insertable into the recess of the capsule, and wherein the mouthpiece comprises at least one air inlet and at least one air outlet, and the piercing element comprises at least one first conduit extending between the at least one air inlet and a distal end of the piercing element, and at least one second conduit extending between the distal end of the piercing element and the at least one air outlet, such that in use, when a user draws on the mouthpiece, air flows along an airflow pathway extending from the at least one air inlet, through the at least one first conduit, through a portion of the capsule, through the at least one second conduit, and exits the at least one outlet.

2. The aerosol-generating system according to claim 1, wherein a shape and dimensions of an external surface of the at least one heater are configured to substantially match a shape and dimensions of the recess of the capsule.

3. The aerosol-generating system according to claim 1, wherein the at least one heater is frusto-conical.

4. The aerosol-generating system according to claim 1, comprising at least two heaters consisting of at least one first heater configured to be insertable in the recess of the capsule and at least one second heater within the cavity.

5. The aerosol-generating system according to claim 1, wherein the at least one second heater conforms to a shape of side walls of the cavity.

6. The aerosol-generating system according to claim 1, wherein the at least one heater is an electrically powered heater comprising at least one electrically resistive track provided on a flexible substrate.

7. The aerosol-generating system according to claim 1, wherein a longitudinal length of the recess is at least about 50% of a longitudinal length of the at least one side wall.

8. The aerosol-generating system according to claim 1, wherein the base is substantially circular, and the recess has a substantially circular cross-section, a ratio of a radius of the base to a radius of the recess at the base being between about 1.5 and about 4.0.

9. The aerosol-generating system according to claim 1, wherein the recess has a frusto-conical shape, and a substantially circular cross-section.

10. The aerosol-generating system according to claim 1, wherein a longitudinal length of the at least one side wall is at least 2 times a radius of the base.

11. The aerosol-generating system according to claim 1, wherein the capsule is filled with the aerosol-forming substrate to reach a level between about 90% and about 110% of a longitudinal length of the recess.

12. The aerosol-generating system according to claim 1, wherein the aerosol-forming substrate comprises nicotine and at least one aerosol-former.

Description

(1) The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

(2) FIG. 1 shows a cut-away isometric view of a capsule according to the present invention;

(3) FIG. 2 shows a cross-sectional view of a capsule according to the present invention;

(4) FIG. 3 shows a cross-sectional view of an aerosol-generating device according to the present invention;

(5) FIG. 4 shows a cross-sectional view of an aerosol-generating system according to the present invention;

(6) FIG. 5 show schematic diagrams of an electrically resistive heater for an aerosol-generating device according to the present invention;

(7) FIG. 6 show a manufacturing process of a capsule according to the present invention; and

(8) FIG. 7 shows a cross-sectional view of an alternative aerosol-generating device according to the present invention.

(9) FIG. 1(a) shows a cut-away isometric view of a capsule 100 for use in an aerosol-generating device. The capsule comprises a shell 102 containing an aerosol-forming substrate (not shown), the shell is sealed by a lid (not shown) which is sealed to the lip portion 104.

(10) The shell 102 of the capsule 100 comprises a thin-walled external side wall 106 and a thin-walled base 108. The base 108 comprises a recess 110 positioned centrally therein. The recess is frusto-conical in shape and is configured to receive a heater when the capsule is inserted into an aerosol-generating device.

(11) The shell of the capsule is formed using deep drawing in at least two stages. Stage 1 comprises deep drawing the shell and recess using a suitable die and punch. It will be appreciated by one of ordinary skill in the art that the shell and recess may alternatively be formed in two stages. The lip of the shell is then formed in the stage 2 of the process. The manufacturing process is described below in further detail with reference to FIG. 6.

(12) FIG. 1(b) shows a cross-sectional view of the capsule 100. The capsule 100 has longitudinal length L.sub.c, and the base of the capsule has a radius R.sub.b. The external side wall 106 of the shell has a thickness T.sub.s The recess 110 in the base 108 of the shell has a longitudinal length L.sub.r, and the radius of the recess 110 at the base is R.sub.r.

(13) The base of the capsule is approximately 4.5 mm in radius (R.sub.b), and the longitudinal length of the capsule is approximately 10.2 mm (L.sub.c). The walls of the capsule are approximately 0.3 mm in thickness (T.sub.s).

(14) FIG. 2 shows a cross-sectional view of the capsule 100 for use in an aerosol-generating device. As can be seen, and as described above, the lid 200 is sealed to the lip portion 104. The lid may be sealed using any suitable method, including: adhesive, such as an epoxy adhesive, heat sealing, ultrasonic welding, or laser welding. Before the lid is sealed to the lip portion, the shell 102 of the capsule is filled with an aerosol-forming substrate 202. Approximately 250 mg of aerosol-forming substrate is provided within the shell. The aerosol-forming substrate comprises a nicotine containing material, such as tobacco, and an aerosol-former. The aerosol-former is glycerine that provides a good mouth feel for the user; it has also been found that glycerine produces a suitably small aerosol droplet diameter as compared to other aerosol-formers.

(15) FIG. 3 shows a cross-sectional view of an aerosol-generating device 300 for use with a capsule 100 as described above. The aerosol-generating device comprises an outer housing 302, adapted to house: a power supply 304 such as a rechargeable battery; control circuitry 306; and an electrical heater 308. The housing 302 further comprises a cavity 309 configured to receive a capsule 100. The electrical heater is housed within a heater housing 310 having a frusto-conical shape configured to match the frusto-conical shape of the recess of a capsule. The aerosol-generating device 300 further comprises a mouthpiece 312 attachable to a proximal end of the aerosol-generating device housing 302. The mouthpiece comprises a piercing portion 314, and two airflow conduits, a first or inlet conduit 316 and a second or outlet conduit 318.

(16) FIG. 4 shows a cross-sectional view of an aerosol-generating system 400 comprising an aerosol-generating device 300 and a capsule 100 as described above; like reference numerals refer to like components. The capsule is received in the cavity of the housing and the heater is inserted within the recess of the capsule.

(17) In use, the user inserts the capsule 100 into the cavity of the aerosol-generating device 300, and then attaches the mouthpiece 312 to the housing 302. By attaching the mouthpiece, the piercing portion 314 pierces the lid of the capsule, and forms an airflow pathway from the air inlet, through the capsule to the air outlet. FIG. 4 shows the portion of the airflow pathway entering the capsule 402, and the portion of the airflow pathway 404 exiting the capsule. The user then presses a button (not shown) to activate the device. In activating the device, the heater is supplied with power by the control electronics 306 from the power supply 304. When the temperature of the capsule reaches the operating temperature of between about 220 degrees C. and about 240 degrees, the user is informed by means of an indicator (not shown) that the user may then draw on the mouthpiece. When the user draws on the mouthpiece, air enters the air inlet, proceeds through the conduit 316 within the mouthpiece and into the capsule, entrains vapourised aerosol-forming substrate, and then exits the capsule via the outlet conduit 318 in the mouthpiece.

(18) FIG. 5(a) shows the electrical heater 308 for the aerosol-generating device as described above. The electrical heater comprises a flexible polymeric substrate having an electrically resistive material, such as platinum, gold or silver, printed thereon in tracks (not shown). The heater 308 is provided with a tab 500 comprising electrical contacts 502 and 504 for connection to the power supply 304 via the control circuitry 306.

(19) FIG. 5(b) shows the electrical heater 308 formed into the frusto-conical shape as used in the aerosol-generating device 300. The heater is formed into the frusto-conical shape by rolling the flexible substrate. As shown in FIG. 5(c), the formed heater is then inserted into the heater housing 310, and potted into the housing by filling the housing with an epoxy compound 506 to retain the heater in place.

(20) As described above, the shell 102 of the capsule may be manufactured in a two-stage process, the shell 102 is then filled with the aerosol-forming substrate 202, and then sealed with lid 200 to form the capsule. The process will now be described in detail with reference to FIG. 6.

(21) The first stage of the process to form the shell is shown in FIGS. 6(a). 6(b) and 6(c). A die 600, having the required form of the shell, and a corresponding punch 602 is provided. A blank 604 which is substantially circular in shape is slidably clamped to the die by the clamp 606. The clamp 606 enables the blank 604 to slide along the top surface of the die 600 as it is drawn into the die 600 by the punch 602. It will be appreciated by one of ordinary skill that this process may involve a number of intermediate stages having multiple dies and punches to slowly reduce the size of the formed blank to the final required size.

(22) Once the first stage is complete, the second stage of the manufacturing process forms the lip 104 of the shell to enable the lid to be sealed to the shell. FIGS. 6(d) and 6(e) show this second stage of the process. The two-part die 608 and 610 is advanced onto the partially formed blank 604 to partially form the neck of the lip 104. To aid the forming process, the two-part die, or alternatively the blank, may be rotated about the longitudinal axis as the two-part die is advanced onto the blank. In FIG. 6(e) it can be seen that a further die is used to finally form the lip 104. The die is advanced onto the partially formed blank to bend the blank material into the lip. Again, the die, or the partially formed blank, may be rotated about the longitudinal axis to aid in the forming process.

(23) FIG. 6(f) shows the now formed shell 102 being filled with aerosol-forming substrate 202 by the spray gun 614. FIG. 6(g) shows the filled shell.

(24) FIGS. 6(h) and 6(i) show the final process of sealing the lid 200 to the shell 102. The lid 200 is advanced towards the shell 102 by the lid holder 616. The lid holder may be a vacuum holder or any other suitable holder as will be appreciated by one of ordinary skill in the art. The lid may be provided with glue or any other suitable sealing means. Finally, the lid 200 is sealed to the shell 102. In this example, the lid is heat sealed to the shell by the heater 618 which melts the adhesive pre-applied to the lid.

(25) As will be appreciated to one of ordinary skill in the art, the aerosol-generating device shown in FIG. 3 is only one example of aerosol-generating devices according to the present invention. One other such example is shown in FIG. 7. The aerosol-generating device 700 shown in FIG. 7 is similar to that shown in FIG. 3, and like reference numerals refer to like features.

(26) The aerosol-generating device comprises an outer housing 302, adapted to house: a power supply 304 such as a rechargeable battery; control circuitry 306; an internal electrical heater 308; and an external electrical heater 702. The housing 302 further comprises a cavity 309 configured to receive a capsule 100. The internal electrical heater 308 is housed within a heater housing 310 having a frusto-conical shape configured to match the frusto-conical shape of the recess of a capsule. The external heater 702 is provided within the cavity 309. The aerosol-generating device 300 further comprises a mouthpiece 312 attachable to a proximal end of the aerosol-generating device housing 302. The mouthpiece comprises a piercing portion 314, and two airflow conduits, a first or inlet conduit 316 and a second or outlet conduit 318.

(27) In use, the aerosol-generating device 700 operates in the same way as that aerosol-generating device 300 as described above with reference to FIG. 4. However, the control circuitry 306 provides power to both the internal heater 308 and the external heater 702. The additional external heater 702 provides further heating to the capsule to, for example, further decrease the time to first puff and to improve the heat transfer to the aerosol-forming substrate by yet further reducing the maximum distance from a heater the aerosol-forming substrate.