HOLLOW AEROSOL-GENERATING ARTICLE WITH TUBULAR SUBSTRATE LAYERS

Abstract

An aerosol-generating article is provided, including: a first tubular aerosol-forming substrate layer defining a cylindrical hollow central core; and a second tubular aerosol-forming substrate layer arranged around the first tubular aerosol-forming substrate layer, the first tubular aerosol-forming substrate layer being a gel layer. A method of manufacturing an aerosol-generating article, a method of generating an aerosol, and an aerosol-generating system are also provided.

Claims

1.-28. (canceled)

29. An aerosol-generating article, comprising: a first tubular aerosol-forming substrate layer defining a cylindrical hollow central core; and a second tubular aerosol-forming substrate layer arranged around the first tubular aerosol-forming substrate layer, wherein the first tubular aerosol-forming substrate layer is a gel layer.

30. The aerosol-generating article according to claim 29, wherein the first tubular aerosol-forming substrate layer and the second tubular aerosol-forming substrate layer are aligned coaxially.

31. The aerosol-generating article according to claim 29, wherein the first tubular aerosol-forming substrate layer is a nicotine-containing layer.

32. The aerosol-generating article according to claim 29, wherein the second tubular aerosol-forming substrate layer is a tobacco-containing layer.

33. The aerosol-generating article according to claim 29, wherein a melting point of the first tubular aerosol-forming substrate layer is different from a melting point of the second tubular aerosol-forming substrate layer.

34. The aerosol-generating article according to claim 33, wherein the melting point of the first tubular aerosol-forming substrate layer is lower than the melting point of the second tubular aerosol-forming substrate layer.

35. The aerosol-generating article according to claim 29, wherein the aerosol-forming substrate of the first tubular aerosol-forming substrate layer is different from the aerosol-forming substrate of the second tubular aerosol-forming substrate layer.

36. The aerosol-generating article according to claim 29, wherein the first tubular aerosol-forming substrate comprises a flavorant, and wherein the flavorant is menthol.

37. The aerosol-generating article according to claim 29, wherein a membrane is arranged between the first tubular aerosol-forming substrate layer and the second tubular aerosol-forming substrate layer.

38. The aerosol-generating article according to claim 29, further comprising a homogenization portion downstream of the first and the second tubular aerosol-forming substrates, wherein the homogenization portion is a hollow tubular portion.

39. The aerosol-generating article according to claim 38, further comprising a mouthpiece filter downstream of the homogenization portion.

40. The aerosol-generating article according to claim 29, wherein the gel layer comprises one or more of agar, agarose, sodium alginate, and Gellan gum.

41. The aerosol-generating article according to claim 29, wherein one or more of a melting temperature of the gel layer is above 50 degrees Celsius, or 60 degrees Celsius, or 70 degrees Celsius and an aerosolization temperature of the gel layer is in a range of 120 degrees Celsius to 200 degrees Celsius.

42. A method of manufacturing an aerosol-generating article, the method comprising: providing a first sheet being a gel layer of a first aerosol-forming substrate; providing a second sheet of a second aerosol-forming substrate on the first sheet; and rolling the first and the second sheets thereby forming a hollow tubular aerosol-generating article, wherein the gel layer defines a cylindrical hollow central core.

43. The method according to claim 42, wherein the first and the second sheets are rolled such that opposite edges of the first and the second sheets are brought into contact.

44. The method according to claim 42, wherein, after providing the first sheet, a membrane is placed on the first sheet, and wherein the second sheet is provided on the membrane.

45. A method of generating an aerosol, the method comprising: providing an aerosol-generating article according to claim 29; heating the first tubular aerosol-forming substrate layer to a first temperature; and concurrently heating the second tubular aerosol-forming substrate layer to a second temperature, wherein the first temperature differs from the second temperature.

46. An aerosol-generating system, comprising: an aerosol-generating article according to claim 29; and an aerosol-generating device comprising a cavity configured to receive the aerosol-generating article.

47. The aerosol-generating system according to claim 46, wherein the aerosol-generating system is configured to heat the first tubular aerosol-forming substrate layer to a first temperature and the second tubular aerosol-forming substrate layer to a second temperature, and wherein the first temperature differs from the second temperature.

48. The aerosol-generating system according to claim 46, wherein the aerosol-generating device further comprises an induction heating arrangement, wherein the induction heating arrangement comprises an induction coil and a susceptor assembly, wherein the susceptor arrangement comprises a central susceptor arranged centrally within the cavity, and a peripheral susceptor arranged distanced from and around the central susceptor.

Description

[0139] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0140] FIG. 1 shows an embodiment of the aerosol-generating article;

[0141] FIG. 2 shows a cross-sectional view of an aerosol-generating device and an aerosol-generating article according to the present invention;

[0142] FIG. 3 shows the airflow through the aerosol-generating device;

[0143] FIG. 4 shows an embodiment of a susceptor assembly; and

[0144] FIG. 5 shows the susceptor assembly of FIG. 4 a with inserted aerosol-generating article.

[0145] FIG. 1 shows a substrate portion 16 of an aerosol-generating article 12 that can be inserted into a cavity 14 of an aerosol-generating device 10. The substrate portion 16 of the aerosol-generating article 12 shown in FIG. 1 preferably comprises a first tubular aerosol-forming substrate layer 38 and a second tubular aerosol-forming substrate layer 40. The first tubular aerosol-forming substrate layer 38 is arranged inside of the substrate portion 16 and surrounded by the second tubular aerosol-forming substrate layer 40. The first tubular aerosol-forming substrate layer 38 preferably comprises one or both of a nicotine and flavor substrate.

[0146] The second tubular aerosol-forming substrate layer 40 preferably comprises a tobacco aerosol-generating substrate. By providing two separate airflows, the first airflow may be adjusted to influence one or both of nicotine and flavor of the generated aerosol and the second airflow may be adjusted to generate the desired aerosol from the tobacco substrate. The first tubular aerosol-forming substrate layer 38 is arranged adjacent the hollow inner of the aerosol-generating article 12. Between the first tubular aerosol-forming substrate layer 38 and the second tubular aerosol-forming substrate layer 40, a membrane such as a film or foil may be provided. The membrane may be configured to prevent substrate from the first tubular aerosol-forming substrate layer 38 to enter the second tubular aerosol-forming substrate layer 40 or vice versa. The membrane may be configured to reduce heat from traveling between the tubular aerosol-forming substrate layers 38, 40. The membrane may be configured as a thermally insulating membrane. Circumscribing the second tubular aerosol-forming substrate layer 40, a wrapping paper may be arranged. The wrapping paper may be a conventional cigarette wrapper. The wrapping paper may be air impermeable. The wrapping paper may enable air to enter into the second tubular aerosol-forming substrate layer 40 from the periphery of the substrate portion 16.

[0147] FIG. 2 shows the aerosol-generating device 10 and the aerosol-generating article 12. In other words, FIG. 2 shows an aerosol-generating system comprising the aerosol-generating device 10 and the aerosol-generating article 12.

[0148] The aerosol-generating device 10 comprises the cavity 14 for insertion of the aerosol-generating article 12. When the aerosol-generating article 12 is inserted into the cavity 14, the substrate portion 16 of the aerosol-generating article 12 is inserted into the cavity 14. A filter portion 18 of the aerosol-generating article 12 sticks out of the cavity 14 and a user may directly draw on the filter portion 18 of the aerosol-generating article 12.

[0149] A resilient sealing element 20 is arranged at a downstream end 22 of the cavity 14. The resilient sealing element 20 is configured to aid insertion of the aerosol-generating article 12 into the cavity 14 and holding of the aerosol-generating article 12 after insertion of the aerosol-generating article 12 into the cavity 14. The resilient sealing element 20 has a funnel shape. The resilient sealing element 20 has a circular shape surrounding the downstream end 22 of the cavity 14.

[0150] The aerosol-generating device 10 comprises an induction assembly. The induction assembly comprises an induction coil 24. The induction assembly further comprises a susceptor assembly. The susceptor assembly comprises, preferably consists of, a central susceptor arrangement 26 and a peripheral susceptor arrangement 28. The central susceptor arrangement 26 is arranged within the peripheral susceptor arrangement 28. Between the central susceptor arrangement 26 and the peripheral susceptor arrangement 28, the cavity 14 for insertion of the aerosol-generating article 12 is provided. The cavity 14 has a hollow tubular cylinder-shaped volume.

[0151] The aerosol-generating article 12 is sandwiched between the central susceptor arrangement 26 and the peripheral susceptor arrangement 28. The central susceptor arrangement 26 and the peripheral susceptor arrangement 28 may be arranged distanced from each other so as to hold the aerosol-generating article 12 within the cavity 14. The distance between the central susceptor arrangement 26 and the peripheral susceptor arrangement 28 may be identical or slightly smaller than the distance between the outer diameter of the aerosol-generating article 12 and the inner diameter of the aerosol-generating article 12. The substrate portion 16 of the aerosol-generating article 12 is preferably a hollow tubular substrate portion 16. Consequently, the substrate portion 16 of the aerosol-generating article 12 can be pushed over the central susceptor arrangement 26. In this case, the central susceptor arrangement 26 penetrates into the hollow tubular volume of the substrate portion 16 of the aerosol-generating article 12. At the same time, the peripheral susceptor arrangement 28 abuts the periphery of the substrate portion 16 of the aerosol-generating article 12. When the substrate portion 16 of the aerosol-generating 12 is inserted into the cavity 14, the first tubular aerosol-forming substrate layer 38 may be heated by the heat of the central susceptor arrangement 26. The second tubular aerosol-forming substrate layer 40 may be heated by the heat of the peripheral susceptor arrangement 28.

[0152] FIG. 2 further shows a first air inlet 30 and a second air inlet 32. The first air inlet 30 is fluidly connected with the central susceptor arrangement 26. The central susceptor arrangement 26 is preferably hollow. Airflow may be enabled from the first air inlet 30 towards the hollow inner of the central susceptor arrangement 26 and downstream out of the cavity 14 of the aerosol-generating device 10. The second air inlet 32 is fluidly connected with the periphery of the peripheral susceptor arrangement 28. When the aerosol-generating article 12 is inserted into the cavity 14, two separate airflows are provided. The first airflow from the first air inlet 30 flows through the hollow inner volume of the aerosol-generating article 12. The second airflow from the second air inlet 32 flows from the periphery of the aerosol-generating article 12 into the aerosol-generating article 12 and further downstream out of the cavity 14 of the aerosol-generating device 10.

[0153] The first air inlet 30 and the second air inlet 32 may be configured adjustable. Particularly, the cross-sectional area of one or both of the first air inlet 30 and the second air inlet 32 may be configured adjustable. In this way, properties of the generated aerosol such as the nicotine content and the flavor may be adjusted by adjusting the airflow through one or both of the first air inlet 30 and the second air inlet 32.

[0154] For adjusting one or both of the first air inlet 30 and the second air inlet 32, the aerosol-generating device 10 may comprise a controller 42. The controller 42 may further be configured to control operation of the induction assembly. Particularly, the controller 42 may be configured to control the supply of electrical energy from a power source to the induction coil 24. The power supply 44 may be configured as a battery.

[0155] FIG. 3 shows the airflow through the aerosol-generating device 10 in more detail. The airflow is indicated by the arrows. Two separate airflow channels 46, 48 are provided. The first airflow channel 46 starts at the first air inlet 30 and fluidly connects the hollow inner of the central susceptor arrangement 26 with the first air inlet 30. The air from the first airflow channel 46 enters the central susceptor arrangement 26 at the base of the central susceptor arrangement 26. Inside of the central susceptor arrangement 26, an aerosol may be formed. The aerosol may be formed by heating of the first tubular aerosol-forming substrate layer 38 as well as of the air inside of the central susceptor arrangement 26 by the central susceptor arrangement 26. The substrate of the first tubular aerosol-forming substrate layer 38 is volatilized by the heat of the central susceptor arrangement 26. The contact area between the air and the first tubular aerosol-forming substrate layer 38 may be optimized by gaps between the individual central susceptors 34 and by providing the central susceptors 34 as porous susceptors. The volatilized substrate is entrained by the air flowing through the central susceptor arrangement 26. The generated aerosol flows through the central susceptor arrangement 26 downstream towards the filter portion 18 of the aerosol-generating article 12. The filter portion 18 may comprise a homogenization portion 50 such as a hollow acetate tube for cooling of the aerosol directly adjacent and downstream of the substrate portion 16. Downstream of the homogenization portion, an acetate tow filter 52 may be provided in the aerosol-generating article 12.

[0156] The second airflow channel 48 starts at the second air inlet 32. The second airflow channel 48 fluidly connects the second air inlet 32 with the periphery of the substrate portion 16 of the aerosol-generating article 12 after insertion of the aerosol-generating article 12 into the cavity 14. The periphery of the substrate portion 16 may be part of the cavity 14. The peripheral susceptor arrangement 28 is arranged in the periphery of the substrate portion 16 and preferably in contact with the substrate portion 16. The contact area between the air and the second tubular aerosol-forming substrate layer 40 may be optimized by gaps between the individual peripheral susceptors 36 and by providing the peripheral susceptors 36 as porous susceptors. The air from the second airflow channel 48 may entrain volatilized substrate of the second tubular aerosol-forming substrate layer 40 heated by the peripheral susceptor arrangement 28. The aerosol may be drawn downstream through the second tubular aerosol-forming substrate layer 40. Subsequently, the aerosol may be drawn into the filter portion 18 of the aerosol-generating article 12. In the filter portion 18 of the aerosol-generating article 12, the aerosol generated within the aerosol-generating article 12 by means of the heat of the central susceptor arrangement 26 may mix with the aerosol generated by the peripheral susceptor arrangement 28 by heating the second tubular aerosol-forming substrate layer 40.

[0157] FIG. 4 shows an embodiment of the susceptor assembly. The peripheral susceptor assembly 28 comprising the individual peripheral susceptors 36 is arranged surrounding the central susceptor arrangement 26 comprising the individual central susceptors 34. Between the peripheral susceptor assembly 28 and the central susceptor assembly 26, the cavity 14 for insertion of the substrate portion 16 of the aerosol-generating article 12 is provided. The cavity 14 has a cylindrical shape. The peripheral susceptor assembly 28 comprises four individual peripheral susceptors 36. The individual peripheral susceptors 36 have a curved shape so that the peripheral susceptor arrangement 28 has a ring-shaped cross-section. The central susceptor assembly 26 comprises four individual central susceptors 34. The individual central susceptors 34 have a curved shape so that the central susceptor arrangement 26 has a ring-shaped cross-section.

[0158] FIG. 5 shows the susceptor assembly of FIG. 4 with inserted substrate portion 16 of the aerosol-generating article 12. The substrate portion 16 comprising the first tubular aerosol-forming substrate layer 38 and the second tubular aerosol-forming substrate layer 40 is sandwiched between the central susceptor arrangement 26 and the peripheral susceptor arrangement 28. As can be seen in FIG. 5, the hollow inner of the central susceptor arrangement 26 is free so that air can flow through the hollow inner of the central susceptor arrangement 26. An aerosol may thus be formed within the central susceptor arrangement 26 by heating of the central susceptor arrangement 26. The heated central susceptor arrangement 26 heats the first tubular aerosol-forming layer 38 to generate aerosol. Additionally, the peripheral susceptor arrangement 28 heats the second tubular aerosol-forming substrate layer 40 to create an aerosol. Air may flow from the periphery of the aerosol-generating article 12 into the second tubular aerosol-forming substrate layer 40 and be subsequently drawn downstream. Downstream of the substrate portion 16 of the aerosol-generating article 12, the aerosol generated by heating of the first tubular aerosol-substrate forming layer 38 may mix with the aerosol generated by heating of the second tubular aerosol-forming substrate layer 40. Downstream of the substrate portion 16, the homogenization portion 50 may be provided. Depending on the heating temperature, the substrates of one or more of the first and second tubular aerosol-forming substrate layers 38, 14 may be volatilized in the area of the substrate portion 16 and the aerosol may subsequently form within the homogenization portion 50.