RU2820642C2 - Aerosol generating system and capsule for use in aerosol generating system - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: group of inventions relates to a hand-held aerosol-generating system with induction heating and a capsule used in said system. Hand-held aerosol-generating system with induction heating comprises a capsule containing a shell having a base and at least one side wall extending from the base. Capsule additionally comprises a fragile cover tightly fixed on said at least one side wall to form a sealed capsule. Shell comprises an aerosol-generating substrate and a susceptor material for heating the aerosol-generating substrate in the shell. System comprises a power supply connected to a load circuit comprising an inductor for inductive coupling with a susceptor material in a shell, and an aerosol-generating device comprising a mouthpiece and a piercing element for piercing the fragile cap of the capsule. Due to arrangement of aerosol-forming substrate and susceptor material inside capsule, possibility of direct heating of aerosol-forming substrate is provided. Heat is generated directly at the location of the aerosol-forming substrate, namely inside the capsule.

EFFECT: preventing overheating of the aerosol-forming substrate and thus preventing the substrate from burning and reducing the formation of combustion products.

26 cl, 7 dwg

Description

The invention relates to a capsule for use in an aerosol generating system and to an aerosol generating system.

Systems are known that generate an aerosol containing capsules. One particular system is disclosed in international patent publication WO 2009/079641. This system contains a capsule containing a shell enclosing a viscous vaporizable material. The shell is sealed with a cap that can be pierced when the capsule is inserted into the aerosol generating device contained in the system to allow air to pass through the capsule during use. The device includes a heater configured to heat the outer surface of the shell to a temperature of up to approximately 200 degrees Celsius. In such systems, the heater is located close to the outer wall of the device. This may result in high external temperatures, which may cause discomfort to the user holding the device. Additionally, the time to first puff on the device has been found to be up to 30 seconds or more. Thus, the known aerosol-generating system with capsule heating has a number of disadvantages. Therefore, it is an object of the present invention to overcome these disadvantages and to provide a capsule for an aerosol generating system and an aerosol generating system with improved heating efficiency.

According to an aspect of the present invention, there is provided a capsule for use in an aerosol generating system, preferably for use in a portable system, particularly for use in a hand-held system. The capsule contains a shell containing a base and at least one side wall extending from the base. The capsule further comprises a lid sealed to said at least one side wall to form a sealed capsule. The shell includes an aerosol-generating substrate and a susceptor material for heating the aerosol-generating substrate in the shell. In this regard, the expressions “the shell encloses a susceptor material” and “the shell encloses an aerosol-forming substrate” should be understood to mean that the aerosol-forming substrate and the susceptor material are located in the capsule shell.

By placing the aerosol-forming substrate and the susceptor material inside the capsule, it is possible to directly heat the aerosol-forming substrate. Heat is generated directly at the location of the aerosol-forming substrate, namely inside the capsule. It is also possible to reduce the amount of substrate due to efficient use of the substrate. As a result, wasteful material consumption or costs are reduced. In addition, it is possible to prevent overheating of the aerosol-forming substrate, and thus it is possible to prevent burning of the substrate and reduce the formation of combustion products.

Power consumption is reduced, allowing the maximum temperature typically required in the heater to heat the capsule to be reduced to ensure a minimum temperature of the aerosol-forming substrate in the capsule.

Improved heat control allows the aerosol-forming substrate to be heated more quickly, thereby reducing ramp-up time and reducing the energy required to prepare the device for use. Heat loss is reduced and the amount of thermal energy can be reduced, which may be particularly beneficial in terms of extending the operating time of the device or in terms of the battery capacity or battery size of the electronic heating device.

By heating the substance inside the capsule, the degree of increase in the external temperature of the aerosol-generating device, in particular a portable device held in the hand, is also reduced. In this way, it is possible to improve the user experience while at the same time allowing for an increase in operating temperature. Thanks to the latter, greater freedom is provided in the choice of materials suitable for aerosol formation.

The aerosol-forming substrate is preferably a substrate capable of releasing volatile compounds that can form an aerosol. These volatile compounds are released as a result of heating the aerosol-forming substrate.

The aerosol-forming substrate may be solid or liquid or contain both solid and liquid components. In a preferred embodiment, the aerosol-forming substrate is solid.

The aerosol-forming substrate may contain nicotine. The nicotine-containing aerosol-forming substrate may be a nicotine salt matrix. The aerosol-forming substrate may contain material of plant origin. The aerosol-forming substrate may contain tobacco, and the tobacco-containing material preferably contains tobacco volatile aromatic compounds that are released from the aerosol-forming substrate when heated. The aerosol-forming substrate may comprise homogenized tobacco material.

Homogenized tobacco material can be formed by agglomerating tobacco into particles. The homogenized tobacco material, if present, may contain an aerosol former of no less than 5% by weight on a dry weight basis, and preferably from 5% to 30% by weight on a dry weight basis. The aerosol-forming substrate may alternatively comprise a non-tobacco material. The aerosol-forming substrate may comprise homogenized material of plant origin.

The aerosol-forming substrate may contain at least one aerosol former. The aerosol former may be any suitable known compound or mixture of compounds that, when used, promotes the formation of a dense and stable aerosol and is substantially resistant to thermal degradation at the operating temperature of the aerosol generating device.

The aerosol former may also have humectant properties that help maintain a desired level of humidity in the aerosol-forming substrate when the substrate consists of a tobacco-based product containing tobacco particles. In particular, some aerosol formers are hygroscopic material that functions as a humectant, i.e. a material that helps maintain the moisture content of the substrate containing the humectant.

Suitable aerosol formers may be selected from the following: polyols, glycol ethers, polyol esters, esters and fatty acids, and may contain one or more of the following compounds: glycerol, erythritol, 1,3-butylene glycol, tetraethylene glycol, triethylene glycol, triethyl citrate , propylene carbonate, ethyl laurate, triacetin, meso-erythritol, diacetin-based mixture, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenylacetate, ethyl vanillate, tributyrin, lauryl acetate, lauric acid, myristic acid and propylene glycol.

One or more aerosol formers may be mixed to obtain an advantage due to one or more properties of the aerosol formers being mixed. For example, triacetin can be combined with glycerin and water to take advantage of triacetin's ability to transfer the active components and moisturizing properties of glycerin.

Thanks to the increased efficiency and the very direct heating of the aerosol-forming substrate, it is possible to achieve higher operating temperatures. The higher operating temperature allows the use of glycerin as an aerosol former, which provides an improved aerosol compared to the aerosol formers used in prior art systems.

The aerosol-forming substrate may contain other additives and ingredients, such as nicotine or flavorings.

The aerosol-forming substrate preferably contains nicotine and at least one aerosol former.

As used herein, the term "susceptor" refers to a material that is capable of converting electromagnetic energy into heat. When a susceptor is placed in an alternating electromagnetic field, eddy currents are usually induced in it and hysteresis losses occur, which leads to heating of the susceptor. Since the susceptor is located in thermal contact or close thermal proximity to the aerosol-forming substrate, the substrate is heated by the susceptor such that an aerosol is formed. Preferably, the susceptor is in direct physical contact with the aerosol-forming substrate.

The susceptor may be made of any material that can be inductively heated to a temperature sufficient to produce an aerosol from the aerosol-forming substrate. Preferred susceptors contain metal or carbon. A preferred susceptor may contain or consist of a ferromagnetic material, such as ferritic iron, a ferromagnetic alloy, such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. A suitable susceptor may be or contain aluminum.

Preferred susceptors are metal susceptors, for example stainless steel. However, susceptor materials may also contain or be made from graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloys (austenitic nickel-chromium superalloys), metallized films, ceramics such as zirconium, transition metals , such as Fe, Co, Ni, or metalloid components, such as B, C, Si, P, Al.

The susceptor preferably contains more than 5%, preferably more than 20%, preferably more than 50% or 90% ferromagnetic or paramagnetic materials. Preferred susceptors can be heated to temperatures in excess of 250 degrees Celsius. Suitable susceptors may comprise a non-metallic core with a metal layer located on the non-metallic core, for example with metal tracks formed on the surface of the ceramic core.

The susceptor can be solid, hollow or porous. Preferably, the susceptor is solid.

The susceptor may be a carrier for a liquid aerosol-forming substrate. For example, a liquid aerosol-forming substrate may be loaded onto or into the susceptor. For example, the susceptor may be a sponge-like material, such as a metal sponge.

The susceptor can, in principle, have any shape or profile. If the susceptor has a profile of a constant cross-section, for example a circular cross-section, its preferred width or diameter is from 1 millimeter to 5 millimeters. If the susceptor profile is in the form of a sheet or strip, the sheet or strip is preferably rectangular in shape with a width preferably from 2 millimeters to 8 millimeters, more preferably from 3 millimeters to 5 millimeters, for example 4 millimeters, and a thickness preferably from 0.03 millimeters to 0 .15 millimeters, more preferably from 0.05 millimeters to 0.09 millimeters, for example 0.07 millimeters.

If the susceptor is in the form of a plurality of particles distributed preferably uniformly in the aerosol-forming substrate, these susceptor particles are typically present in the form of a susceptor powder, and they may have a size in the range of 5 micrometers to 100 micrometers, more preferably in the range of 10 micrometers to 80 micrometers, for example they can range in size from 20 micrometers to 50 micrometers.

Preferably, the susceptor material is present in the form of a strip, rod, thread, particle, corrugated or folded sheet or mesh. Several strips, rods, threads or particles or fragments of sheets or meshes may be encapsulated.

Preferably, the aerosol-forming substrate is in the form of particles, strips, corrugated or folded sheets, pellets or viscous material. Several particles or stripes may be enclosed within the capsule shell. A pellet may be compressed or compressed individual fragments of an aerosol-forming substrate, such as a compressed plurality of particles or strips.

The aerosol-forming substrate and the susceptor material may be separately located in the shell. For example, flats or beads of susceptor material may be spaced between the aerosol-forming substrate. The susceptor material may also be secured in place, for example, by compressing the aerosol-forming substrate and the susceptor material.

The susceptor material may be incorporated into or coated with the aerosol-generating substrate, for example, during a process for making the aerosol-generating substrate. For example, the susceptor particles may be incorporated into the aerosol-generating suspension, or the susceptor material may be coated with the aerosol-generating suspension.

The aerosol-generating substrate may be present, for example, in the form of particles, such as granules or beads, containing a susceptor core coated with the aerosol-generating substrate. Such particles preferably have a maximum size of 6 millimeters, more preferably a maximum size of 4 millimeters, even more preferably a maximum size of 2 millimeters. The aerosol generating substrate may be present, for example, in the form of a sheet containing a susceptor material coated with the aerosol generating substrate. In such embodiments, the susceptor is preferably present in the form of a sheet, such as foil, mesh or web, coated with an aerosol generating substrate.

The sheet of aerosol generating substrate, whether or not containing a susceptor material, may be corrugated, folded, or it may, for example, be cut into strips and then inserted into the enclosure before sealing the enclosure.

If the susceptor is present in the form of a plurality of particles coated with an aerosol-generating substrate, these susceptor particles, such as pellets or grains, may have a size of from 0.2 mm to 2.4 mm, preferably from 0.2 mm to 1.7 mm , more preferably from 0.3 mm to 1.2 mm. The susceptor particles to be coated, such as flakes, may have a maximum length of 0.2 mm to 4.5 mm, preferably 0.4 mm to 3 mm, more preferably 0.5 mm to 2 mm. The thickness of the susceptor scales may be from 0.02 mm to 1.8 mm, preferably from 0.05 mm to 0.7 mm, more preferably from 0.05 mm to 0.3 mm.

The sheet of aerosol generating substrate, for example containing tobacco material and an aerosol generating agent, may have a thickness of from 0.1 millimeter to 2 millimeters, preferably from 0.3 millimeter to 1.5 millimeters, for example 0.8 millimeters. The aerosol generating substrate sheet may vary in thickness by up to approximately 30 percent due to manufacturing tolerances.

A sheet of aerosol generating substrate, in particular a sheet of homogenized tobacco material, can, for example, be crushed or cut into strips having a width of from 0.2 mm to 2 mm, more preferably from 0.4 mm to 1.2 mm. The width of the strips can be, for example, 0.9 mm.

Alternatively, the aerosol generating substrate, in particular homogenized tobacco material, can be formed into spheres using spheronization. The average diameter of said spheres is preferably from about 0.5 mm to about 4 mm, more preferably from about 0.8 mm to about 3 mm.

As a general rule, whenever a value is mentioned anywhere in this application, it should be understood that the value is disclosed in an unambiguous manner. However, it should also be understood that, for technical reasons, the value does not necessarily represent the exact value. The value may, for example, include a range of values corresponding to the exact value plus or minus 20 percent.

Filling the shell with the aerosol-generating substrate and susceptor material can be accomplished using known filling means. The aerosol-generating substrate and susceptor material can also be filled into sachets, which are then inserted into the shell.

Thus, the capsule may contain a sachet located in the shell. The bag contains a porous container containing an aerosol-generating substrate and a susceptor material.

The bag is preferably formed from a mesh. The mesh is preferably porous to the generated aerosol and allows the aerosol to be released from the bag. The mesh may be formed by any suitable method, for example by weaving the material or by cutting using a pinion or the like, and then stretching the material by applying a force perpendicular to the axis of the pins.

The pouch may be formed from any suitable material capable of withstanding high temperatures during use without burning or introducing unwanted aromas into the aerosol. In particular, the natural fibers sisal and ramie are particularly suitable for pouch formation. Alternatively, the pouch may be formed from ceramic fibers or metal.

The material used to form the pouch may have a thickness from 50 micrometers to about 300 micrometers. By making the bag using thin material, it is possible to reduce material costs and reduce waste. Thicker pouch material, depending on the material used for the pouch, allows for increased insulation effect that can be created by the pouch between the heated susceptor material and the aerosol generating substrate within the pouch on one side and the external environment of the capsule on the other. The fiber size of the material used to form the pouch can range from 10 micrometers to 30 micrometers.

The aerosol generating substrate and susceptor material within the container preferably have a porosity of from 0.2 to 0.35. More preferably, the porosity is from 0.24 to 0.35. Porosity is defined as the volume fraction of empty space inside a container. Thus, a porosity of 100% would mean that the container contains no substrate and susceptor material, and a porosity of 0% would mean that the container is completely filled with substrate and susceptor material without any voids.

The capsule may be filled completely or only partially with the aerosol-generating substrate and susceptor material. The fill level can be selected and adapted to the specific user experience or according to a specific number of puffs.

The capsule is preferably filled with 150 mg to 400 mg of aerosol generating substrate, more preferably 200 mg to 300 mg of aerosol generating substrate, and in a preferred embodiment, 250 mg of aerosol generating substrate.

Preferably, the ratio of susceptor material to aerosol generating substrate is optimized for a particular consumption experience or for a particular aerosol generation mode. The ratio of the amount of susceptor material to the amount of aerosol-generating substrate can vary. However, such ratio is preferably fixed within a certain range.

The ratio of the amount of susceptor material to the amount of aerosol-generating substrate can be, for example, from 1:1 to 1:4, preferably from 1:1.5 to 1:2.5. The indicated ratios are understood as volume ratios.

Keeping said ratios within said range is advantageous for efficient and preferably uniform heating of the aerosol-generating substrate and aerosol formation. Said ratio may be set such that heating provides a sustained delivery of the substance, preferably nicotine, to the user.

As described above, the aerosol generating substrate may be liquid. In such embodiments, the capsule may be equipped with a material with high liquid retention capacity to substantially prevent liquid aerosol generating substrate from leaking out of the capsule during use. The material with high liquid retention capacity may be a sponge-like material. For example, the high retention material may contain one or more of the following: glass, cellulose, ceramic, stainless steel, aluminum, polyethylene (PE), polypropylene, polyethylene terephthalate (PET), poly(cyclohexanedimethylene terephthalate) (PCT), polybutylene terephthalate (PBT) , polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE) and BAREX®.

For example, the retaining material may also be a susceptor, for example made of a sponge-like material.

The capsule may be manufactured using any suitable method. For example, the casing may be manufactured using a deep drawing or molding process. The shell may then be filled with the aerosol-generating substrate by any other suitable means. The shell is then sealed using a lid. The lid may be sealed to the shell using any suitable method, including: an adhesive such as an epoxy adhesive, thermal welding, ultrasonic welding, and laser welding.

Preferably, the lid is frangible. In use, the frangible cap can be pierced or perforated by any suitable piercing element, such as those found in an aerosol generating device, to allow air to pass through the capsule.

The lid is preferably made of a polymer or metal, or it may contain metal. The lid can be laminated to improve sealing ability. Preferably, the lid is made of laminated food grade metal.

Preferably, the capsule containing the shell and the lid is formed from a material containing no or only a limited amount of ferromagnetic or paramagnetic material. In particular, the capsule, shell and lid may contain less than 20 percent, in particular less than 10 percent or less than 5 percent or less than 2 percent ferromagnetic or paramagnetic material.

As used herein, the term “longitudinal” refers to the direction between the proximal or cap end and the opposing distal or base end of the capsule, and also refers to the direction between the proximal or mouth end and the distal end of the aerosol generating device contained in the system of the present invention.

The base of the shell is preferably substantially circular. The capsule base radius is preferably 3 mm to 6 mm, more preferably 4 mm to 5 mm, and in the most preferred embodiment, the base radius is 4.5 mm.

The longitudinal length of at least one side wall is preferably at least 2 times the radius of the base. A shell of this size provides the advantage of being able to provide sufficient volume within the capsule to accommodate sufficient aerosol-generating substrate to provide a suitable sensation to the user.

The longitudinal length of the capsule is preferably from 7 mm to 13 mm, more preferably from 9 mm to 11 mm, and in a particularly preferred embodiment the longitudinal length of the capsule is 10.2 mm.

The shell preferably has a wall thickness of 0.1 mm to 0.5 mm, more preferably 0.2 mm to 0.4 mm, and in a particularly preferred embodiment the wall thickness of the shell is 0.3 mm.

By making the shell with thin walls, it is possible to reduce material costs and reduce waste when disposing of the capsule.

The shell is preferably formed as a single unit. The material used to form the shell may be metal. Alternatively, the material used to form the shell may be a polymer, such as any suitable polymer capable of withstanding the operating temperature of the susceptor material. The capsule may contain or be made from thermal insulating material.

The capsule or parts of the capsule may be formed from one or more suitable materials. Suitable materials include, but are not limited to, polyetheretherketone (PEEK), polyimides such as Kapton®, polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), polystyrene (PS), fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), epoxy resins, polyurethane resins, vinyl resins, metals such as stainless steel, paper or cardboard.

Suitable materials may be food-compatible materials, such as FDA-approved materials for medical instruments and devices.

The capsule, shell, or cap may be formed from one or more materials that are resistant to the ingredients of the aerosol-generating substrate, such as resistant to nicotine or resistant to the aerosol-forming agent and resistant to the susceptor material contained in the capsule.

The capsule, shell, and lid may be coated with one or more barrier materials that are resistant to the ingredients of the aerosol-generating substrate and resistant to the susceptor material contained in the capsule.

According to yet another aspect of the present invention, an aerosol generating system is provided, preferably a portable system, particularly a hand-held system. The aerosol generating system includes a capsule containing a shell having a base and at least one side wall extending from the base. The capsule further comprises a lid sealed to said at least one side wall to form a sealed capsule. The shell includes an aerosol-generating substrate and a susceptor material for heating the aerosol-generating substrate within the shell. Preferably, the system contains a capsule according to the present invention described herein.

The system further includes a power source connected to the load circuit. The load circuit contains an inductor for inductive coupling with the susceptor material inside the shell.

The inductor may include one or more coils that generate a pulsating electromagnetic field inductively coupled to the sensing material in the capsule. A coil or coils may surround a capsule receiving cavity that is formed in the aerosol generating device and into which the capsule is placed when the system is in use. Preferably, the inductor is part of the device body. For example, one or more inductor coils can be integrated in a very compact manner within the body of the device.

When activated, high frequency alternating current flows through wire coils that form part of the inductor. When the capsule is correctly positioned in said capsule receiving cavity, the susceptor material in the capsule is located within said pulsating electromagnetic field. Under the influence of a pulsating electromagnetic field, eddy currents or hysteresis losses occur inside the susceptor material, which heats up as a result. The heated susceptor material heats the aerosol-generating substrate in the capsule to a temperature sufficient to generate an aerosol, for example to approximately 180-220 degrees Celsius.

The aerosol is extruded from the capsule in the direction of flow through the mouthpiece and removed from the aerosol generating device through the mouthpiece.

Preferably, the load circuit of the aerosol generating system according to the present invention includes one inductor. This provides the advantage of simplicity in the design of the device, the electronic circuitry of the device and its operation. In addition, it is possible to adapt aerosol generating devices intended for use with capsules to induction heating. Such devices may be equipped, for example, with an electronic circuit and a load circuit containing an inductor. This allows such devices to be manufactured using less power than conventionally heated devices, such as those containing Kapton® heaters, and provides all the benefits of contact heating (e.g., no interference fit of the capsule into the cavity is required, allowing for greater manufacturing tolerances and separation of the electronic circuit from the heating element).

The aerosol generating system may comprise a thermal insulating layer at least partially surrounding the aerosol generating substrate and susceptor material contained in the capsule. The thermal insulation layer may, for example, be at least partially located around the capsule. Preferably, the thermal insulation layer may be positioned such that it extends around said at least one side wall and base of the shell.

Since the capsule shell is not required to be in thermal contact with the heater and transfer heat from it to the contents of the capsule, it is possible to include a thermal insulation layer within the capsule shell. For example, the shell may be at least partially made of or contain thermal insulating material. In such embodiments, the shell is preferably made entirely of thermal insulating material. Thus, the thermal insulation layer is a layer of material that is separate from or integral with the capsule.

Preferably, the thermal insulation layer is located in the aerosol generating device with which the capsule is used, and preferably it at least partially surrounds the capsule receiving cavity formed in the device. Thus, thermal insulation is provided in the device regardless of the capsule design used with the device.

Thanks to thermal insulation, the heat generated in the capsule is retained in that capsule. It is possible to reduce or eliminate heat loss to the environment due to thermal conductivity. In addition, it is possible to limit or prevent heating of the body of the aerosol generating device.

The thermal insulation layer can be located in the device body, for example, between the inductor and the capsule. It may also be located on the outside of the inductor, for example at least partially surrounding the inductor.

Preferably, the thermal insulation layer is located at least partially between said at least one side wall of the shell and the inductor. In this way, heat generated in the capsule and possibly transferred through the side wall of the shell is prevented from escaping further into the external environment. In particular, heat transfer in a radial direction to the device body is prevented or limited, and thus other areas of the device, in particular the outer surface of the device body that is touched by the user, are not allowed to heat up.

By eliminating the need for an external heater such as a Kapton® heater in the aerosol generating system of the present invention, it is possible to either save the space required for such heaters in prior art aerosol generating devices used in the system of the present invention or to use it space for thermal insulation without the need for additional space.

Thermal conductivity is the ability of a material to conduct heat. Heat transfer occurs at a lower rate in materials with low thermal conductivity than in materials with high thermal conductivity. The thermal conductivity of a material may depend on temperature.

The thermal insulation materials used in the present invention for thermal insulation, in particular for the shell or other parts of the capsule, preferably have a thermal conductivity of less than 1 Watt per (meter x Kelvin), preferably less than 0.1 Watt per (meter x Kelvin), for example from 1 up to 0.01 watt per (meter x Kelvin).

The aerosol generating device contained in the system according to the present invention may include a piercing element. The piercing element is configured to destroy, for example pierce or perforate, the capsule cover.

The aerosol generating device may include a mouthpiece, preferably comprising at least one air inlet and at least one air outlet. The piercing element preferably includes at least one first channel extending between the at least one air inlet hole and a distal end of the piercing element.

The mouthpiece preferably further comprises at least one second channel extending between the distal end of the piercing element and the at least one air outlet. Therefore, the mouthpiece is preferably positioned such that, in use, when the user takes a puff on the mouthpiece, air flows through an air path extending from said at least one air inlet port, through said at least one first channel, a capsule portion, and said at least one at least one second channel and exits from said at least one outlet.

The presence of such channels allows for improved airflow through the device and allows for easier delivery of the aerosol to the user.

The present invention is further described with respect to embodiments thereof, illustrated by the following drawings, in which:

in fig. 1 shows an example of a capsule;

in fig. 2-4 show various options for filling an induction-heatable capsule;

in fig. 5 shows cross sections of an induction-heatable ball with one of two coatings;

in fig. 6 shows cross sections of an induction-heatable flake with one of two coatings;

in fig. 7 is a schematic cross-section of an induction-heatable aerosol generating system.

In fig. 1 shows a capsule 1 enclosing an active substrate 2 containing an aerosol-generating substrate and a susceptor material for use with a device capable of inductively heating the susceptor material of the active substrate 2 and capable of vaporizing the aerosol-generating substrate. Capsule 1 includes a shell 10, which is sealed by a cap 11. Shell 10 includes a flange 12 for attaching cap 11 to shell 10. Shell 10 includes a base 101 and a side wall 100. The shell 10 of capsule 1 or the entire capsule 1 can be made of various materials , including, but not limited to, metals, rigid plastics, flexible plastics, paper, construction paper, cardboard and wax paper. Preferably, the shell as well as the cover 11 are formed from a material containing no or a limited amount of ferromagnetic material or paramagnetic material. In particular, the shell and cover may contain less than 20 percent, in particular less than 10 percent or less than 5 percent or less than 2 percent of ferromagnetic or paramagnetic material.

The shell 10 of the capsule 1 typically contains a food-compatible material since, in most cases, the capsule 1 must be used with a device for inhalation of an aerosol generated by evaporation of an aerosol-generating substrate. Examples of some food-compatible materials include polyethylene terephthalate (PET), amorphous polyethylene terephthalate (APET), high-density polyethylene (HDPE), polyvinyl chloride (PVC), low-density polyethylene (LDPE), polypropylene, polystyrene, polycarbonate and many types of paper products. In some cases, particularly if the material is paper, the shell 10 may be lined with the material or food-compatible material to prevent the aerosol-generating substrate from drying out and to protect the active substrate 2.

The shell 10 of the capsule 1 may be closed using, for example, a heat-sealable closure film to form a completely enclosed and airtight capsule 1. A sealed capsule provides the advantage of being able to keep the contents fresh and preventing the active material contained within the capsule 1 from spilling out during transport or handling by the user.

Preferably, the capsule 1 is formed and profiled for easy insertion into the cavity of an induction heating device and, preferably, for a tight fit inside the cavity of a device, such as a device according to the present invention described herein.

The cover 11 of the capsule 1 can also be made of various materials. Typically the cap contains food-compatible material. The cap 11 can be sealed to the capsule 1 after filling the capsule 1 with the active substrate 2. Those skilled in the art know many methods for sealing the cap 11 to the shell 10 of the capsule 1. One example of a method for sealing the cap to the shell of a capsule containing a flange 12 is is a thermal welding. Preferably, the cap 11 of the capsule 1 is considered food compatible up to a temperature of at least about 350 degrees Celsius. Cover 11 may be a commercially available film that is designed for use with conventional oven-cooked foods and is often referred to as "dual oven film" (microwave and conventional oven). Dual oven films typically contain a PET (polyethylene terephthalate) base layer and a heat sealable APET (amorphous polyethylene terephthalate) layer. In this case, the thermally sealable layer of APET is brought into contact with the flange 12 of the shell 10 of the capsule 1. Such closure films allow them to be easily pre-metallized or amalgamated to improve the barrier properties of the film against moisture, oxygen and other gases.

The material of the capsule 1, in particular the shell 10, can serve to maintain the freshness of the contents and increase the shelf life of the capsule. The capsule or cap or shell also provides the opportunity to improve the visual appeal of the capsule 1 and its subjective perception. The capsule material may also allow for improved printing and visibility of product information, such as brand or flavor designation.

The capsule 1 may have holes or ventilation openings (not shown) in the capsule. These openings may allow the contents of the capsule 1 to communicate with the environment. The capsule 1 may also be composed of a material, or preferably include a lid, that allows it to be perforated or opened when pressed into a device capable of vaporizing the contents of the capsule 1. For example, if the capsule 1 is heated to a certain temperature, its contents evaporate and the hole or holes , created by the device, allow the evaporated contents to escape from the heated capsule 1. The capsule 1 may also include a lid 11 or seal, which can be opened, for example, torn off immediately before inserting the capsule 1 into the device.

Preferably, the capsule 1 is intended for single use and can be replaced with a new one after use. The type of product contained within the capsule 1 may be indicated by a marking on the capsule, and may also be indicated by the color, size, or shape of the capsule 1.

The device or capsule 1 according to the present invention may use any material that can be aerosolized and inhaled by the user. Such materials may include, but are not limited to, materials containing tobacco, natural or artificial flavors, coffee powder or coffee beans, mint, chamomile, lemon, honey, tea leaves, cocoa and other plant-based non-tobacco alternatives. Compounds can be used that can evaporate (or volatilize) at a relatively low temperature and, preferably, without the formation of harmful degradation products. Examples of compounds include, but are not limited to, menthol, caffeine, taurine and nicotine.

Preferably, the capsule 1 is filled with tobacco or tobacco material. Here, tobacco or tobacco material is defined as any combination of natural and synthetic materials containing tobacco. The capsule may be prepared using dried tobacco, an aerosol forming agent such as glycerin or propylene glycol, flavoring agents and a susceptor material. For example, the tobacco may be cut into small pieces (eg, less than 2 millimeters in diameter, preferably less than 1 millimeter), adding other ingredients and mixing until a uniform consistency is achieved. The active substrate may also be processed to a paste-like consistency, for example with a tobacco particle size of less than 1 millimeter and a particulate susceptor material. Such a paste-like substrate or suspension makes it possible to facilitate filling of the capsule 1.

The tobacco-containing suspension can also be applied and dried to form a sheet, so-called. cast sheet. The dried sheet may be inserted into the capsule in a corrugated and folded manner, while the susceptor material may be combined with the cast sheet either before or after the cast sheet is inserted into the capsule.

The tobacco sheet, for example a cast sheet, may have a preferred thickness ranging from about 0.5 millimeters to about 1.5 millimeters, such as 1 millimeter.

The cast sheet may also be processed, for example by cutting the sheet into small pieces or strips, for example 0.5 millimeters to 1.5 millimeters wide.

The tobacco suspension may also be directly applied to a sheet of susceptor material such that, upon drying of the aerosol-generating substrate, an active substrate is formed from the susceptor sheet coated with the aerosol-generating substrate. Such a sheet of active substrate can then be cut, assembled or folded and inserted into the capsule.

Active substrate volumes include, for example, approximately 0.25 cubic centimeter of active substrate per capsule 1.

In fig. 2-fig. 4 schematically shows tubular capsules 1 filled with various examples of active substrate.

In fig. 2 shows several strips of aerosol generating substrate 20 and a strip of susceptor material 30, for example a strip of stainless steel foil, filling the inside of capsule 1. Depending on the required ratio of aerosol generating substrate and susceptor material, more than one strip of susceptor material can be provided 30. Depending on the desired consumption experience, it is possible to increase or decrease the amount of aerosol generated or the number of puffs that should be available from one capsule 2, as well as the number of strips of aerosol generating substrate 20. The strip of aerosol generating substrate 20 can have a width , for example, from about 0.8 millimeters to 1 millimeter, while its length can be, for example, from 4 millimeters to 10 millimeters. The strip of susceptor material 30 may be approximately 2 to 4 millimeters in width with the same length as the strip of aerosol generating substrate 20.

In fig. 3 shows a capsule 1 filled with a plurality of strips of aerosol-generating substrate. The susceptor material is provided in the form of a plurality of beads, for example ferromagnetic beads. Susceptor beads may have preferred diameters ranging from 0.3 millimeters to 2.5 millimeters.

In fig. 4 shows the active substrate provided in the form of strips 21 containing a susceptor material 32. The susceptor material is provided in the form of particles that are embedded in the aerosol generating substrate. Susceptor particles may have a preferred size in the range of 20 micrometers to 50 micrometers.

Preferably, the susceptor particles are included within the aerosol-generating substrate during the manufacture of the active substrate. Such substrates enable a highly homogeneous and uniform distribution of the susceptor material in the aerosol-generating substrate.

The active substrate 2 may also be provided in the form of a plurality of particles having a susceptor core and a coating of an aerosol generating substrate.

In fig. 5 and fig. 6 shows four examples of particles of active substrate 2 in the form of balls (Fig. 5) and in the form of flakes (Fig. 6).

In fig. 5 shows a cross-section of a granule-shaped susceptor core particle 33 coated with one or two coatings 22, 23 of an aerosol-generating substrate. In this case, the first coating 22 is coated with a second coating 23. The aerosol generating substrate of the first coating 22 and the second coating 23 may be the same or it may be different, for example different from one or more of the following: composition, density, porosity, coating thickness.

The balls shown in FIG. 5 are capable of induction heating and are ready to be filled into the capsule 1 in the required quantity, for example from several dozen beads to a maximum of 200 beads per capsule.

Preferably, the susceptor granule 33 is a metal granule made of a metal or a metal alloy, such as austenitic or martensitic stainless steel. Preferably, the first and second aerosol generating substrate coatings 22, 23 are tobacco-containing substrate coatings. In the embodiment of FIG. 5, the thickness of the second coating 23 is approximately half the thickness of the first coating 22.

The sizes of particles, as well as coatings, can be determined by the average diameter of the circle. The susceptor granules as well as the end granules 2 often do not have a perfectly round shape, so that for the susceptor granules 33 and the end granules an average diameter of 55, 56 or an average coating thickness of 51, 52 is determined.

The average diameter of the susceptor granule 33 may range from 0.1 millimeter to 4 millimeters, preferably from 0.3 millimeter to 2.5 millimeters.

The average thickness 51 of the first coating 22 of the aerosol generating substrate may range from 0.05 millimeters to 4.8 millimeters, preferably from 0.1 millimeters to 2.5 millimeters.

Thus, the average diameter 55 of a pellet comprising a single aerosol generating substrate coating 22 may range from 0.2 millimeters to a maximum of 6 millimeters, preferably from 0.5 millimeters to 4 millimeters.

The average thickness 52 of the second coating 23 of the aerosol-generating substrate may range from 0.05 millimeters to 4 millimeters, preferably from 0.1 millimeters to 1.3 millimeters.

Thus, the average diameter 56 of a granule containing two coatings 20, 21 of aerosol generating substrate can be from 0.3 millimeters to a maximum of 6 millimeters, preferably from 0.7 millimeters to 4 millimeters.

Although the maximum particle size is 6 millimeters, preferably 4 millimeters, even more preferably 2 millimeters, the average diameter 55 of a particle having one substrate coating is typically smaller than the average diameter 56 of a particle having two substrate coatings.

When using a suspension containing tobacco and an aerosol generating agent as a coating of an aerosol generating substrate, it is preferable to use a fluidized jet granulation method to mass produce particles. In the case of using a low moisture slurry, powder granulation methods may preferably be used to produce the particles. Preferably, rotary coating granulators are used to produce the granules.

In fig. 6 shows cross-sections of a flake-shaped susceptor particle 34 that is coated with one or two coatings 24, 25 of an aerosol-generating substrate. The first coating 24 is covered with a second coating 25 of aerosol generating substrate. A plurality of induction-heatable coated flakes as shown in FIG. 1 may be used in the capsule of the present invention. 6.

The diameter of the susceptor flake 34 can be from 0.2 millimeters to 4.5 millimeters, preferably from 0.5 millimeters to 2 millimeters. The thickness of the susceptor flake 34 may be from 0.02 millimeters to 1.8 millimeters, preferably from 0.05 millimeters to 0.3 millimeters.

The thickness 61, 62 of the first and second aerosol generating substrate coatings 24, 25 may be in the same ranges and in the same preferred ranges as the thickness of the above-described coatings in the case of beads.

Thus, the diameter of a flake coated with a single aerosol-generating coating may range from 0.3 millimeters to a maximum of 6 millimeters, preferably from 0.7 millimeters to 4 millimeters. The thickness of the flake coated with the aerosol-generating coating alone may range from 0.12 millimeters to a maximum of 6 millimeters, preferably from 0.25 millimeters to 4 millimeters.

The diameter of the flake coated with the two aerosol-generating coatings may range from 0.4 millimeters to a maximum of 6 millimeters, preferably from 0.9 millimeters to 4 millimeters. The thickness of the flake 1 coated with the two aerosol-generating coatings may be in the range from 0.22 millimeters to 6 millimeters, preferably from 0.45 millimeters to 4 millimeters.

In fig. 7 shows cross sections of an inductively heated aerosol generating system 8 comprising the aerosol generating device 7 and the capsule 1 described above. The aerosol generating device 7 includes an outer housing 70 configured to accommodate a power source 700, such as a rechargeable battery, an electronic control circuit 701, and an inductor 702, such as an inductor. The housing 70 further includes a cavity 703 in which the capsule 1 is located. The inductor 702 is built into the proximal portion of the housing 70 surrounding the cavity 703 and the capsule 1 located in the cavity 703.

The aerosol generating device 7 further includes a mouthpiece 71 capable of being attached to the proximal end of the housing 70. The mouthpiece 71 includes a piercing section 710 directed towards the cavity 703. The mouthpiece 71 further contains two air channels located in this mouthpiece - an inlet channel 711 and an outlet channel 712.

When the capsule 1 is placed in the cavity 703 of the housing 70, it is possible to inductively heat the susceptor material of the active substrate 2 enclosed in the capsule 1 by means of an inductor coil 702.

In use, the user inserts the capsule 1 inside the cavity 703 of the aerosol generating device 7 and then attaches the mouthpiece 71 to the body 70. As a result of attaching the mouthpiece, the piercing portion 710 pierces the lid of the capsule 1 and an air path is formed extending from said inlet through the capsule 1 to said outlet. holes. An air path portion 714 entering the capsule 1 and an air path portion 715 exiting the capsule 1 are shown by arrows. The user then activates the device 7, for example by pressing a button (not shown). When the device is activated, power is supplied to the inductor 702 from the power source 700 using the electronic control circuit 701. When the temperature of the contents of the capsule 1 reaches an operating temperature of, for example, from about 180 degrees Celsius to about 220 degrees Celsius, it is possible to inform the user via an indicator (not shown) that the device is ready for use and can take puffs on the mouthpiece 71. When the user takes a puff on the mouthpiece, air flows into the air inlet port, passes through the channel 711 inside the mouthpiece 71 into the capsule 1, captures the vaporized aerosol generating substrate and then exits the capsule 1 through the outlet channel 712 in the mouthpiece 71.

Claims (26)

1. A handheld induction heated aerosol generating system comprising: a capsule containing a shell having a base and at least one side wall extending from the base, the capsule further comprising a frangible cap sealed to said at least one side wall for forming a sealed capsule, the shell comprising an aerosol-generating substrate and a susceptor material for heating the aerosol-generating substrate in the shell; a power source connected to a load circuit containing an inductor for inductively coupling with the susceptor material in the shell; and an aerosol generating device comprising a mouthpiece and a piercing element for piercing a frangible capsule cap. 2. The system of claim 1, comprising a thermally insulating layer at least partially surrounding an aerosol-generating substrate and a susceptor material encapsulated. 3. The system according to claim 1 or 2, in which the aerosol generating device contains an inductor and a device body containing a cavity for housing the capsule. 4. The system according to claim 3, in which the device body contains a thermal insulation layer. 5. The system according to any of the previous paragraphs, in which the inductor surrounds the cavity. 6. The system according to any one of paragraphs. 2-5, in which the thermal insulation layer is located between the capsule and the inductor. 7. The system according to any one of paragraphs. 2-5, in which a thermal insulation layer is included in the capsule shell. 8. The system according to any one of paragraphs. 2-7, in which the thermal conductivity of the thermal insulation layer is less than 1 watt per (meter × Kelvin). 9. A system as claimed in any of the preceding paragraphs, wherein the inductor comprises one or more coils. 10. The system of any one of the preceding claims, wherein the aerosol generating substrate comprises tobacco material. 11. A system as claimed in any one of the preceding claims, wherein the mouthpiece comprises at least one air inlet and at least one air outlet, and the piercing element comprises at least one first channel extending between said at least one air inlet. and a distal end of the piercing element, the mouthpiece further comprising at least one second passage extending between the distal end of the piercing element and the at least one air outlet such that, in use, when the user takes a puff on the mouthpiece, air flows through the air path extending from said at least one air inlet through said at least one first channel, a capsule portion and said at least one second channel, and exits from said at least one outlet. 12. Capsule for use in an aerosol generating system according to any one of paragraphs. 1-11, comprising a shell having a base and at least one side wall extending from the base, the capsule further comprising a frangible cap sealed to said at least one side wall to form a sealed capsule, and the shell enclosing an aerosol generating agent. substrate and susceptor material for heating the aerosol-generating substrate in the shell, wherein the aerosol-forming substrate and susceptor material are separately located in the capsule, and the ratio of the amount of susceptor material to the amount of aerosol-generating substrate is from 1:1 to 1:4. 13. The capsule according to claim 12, wherein the susceptor material is present in the form of a strip, rod, thread, particles, corrugated or folded sheet or mesh. 14. The capsule of claim 12 or 13, wherein the aerosol generating substrate is present in the form of particles, strips, corrugated or folded sheet, pellets or viscous material. 15. Capsule according to any one of paragraphs. 12-14, wherein the aerosol generating substrate contains nicotine and an aerosol generating agent. 16. Capsule according to any one of paragraphs. 12-15, in which the susceptor material is coated with an aerosol-generating substrate. 17. The capsule of claim 16, wherein the susceptor material is coated with two aerosol-generating coatings that differ in any one or more of the following: composition, density, porosity, coating thickness. 18. Capsule according to any one of paragraphs. 12-17, containing a bag located in a shell and containing a porous container, and the aerosol generating substrate and susceptor material are enclosed in the specified porous container. 19. Capsule according to any one of paragraphs. 12-18, in which the shell contains thermal insulation material. 20. Capsule according to any one of paragraphs. 12-19, which is airtight. 21. Capsule according to any one of paragraphs. 12-20, in which the aerosol-generating substrate and susceptor material have a porosity from 0.2 to 0.35. 22. Capsule according to any one of paragraphs. 12-21, which is filled with an aerosol-generating substrate in an amount of 150 to 400 mg. 23. The capsule of claim 14, wherein the aerosol-forming substrate pellet is a compacted or compressed plurality of individual fragments of the aerosol-forming substrate. 24. Capsule according to any one of paragraphs. 12-23, wherein the casing includes a flange for attaching the frangible cap to the casing. 25. The capsule of claim 24, wherein the flange is an outwardly directed flange. 26. Capsule according to any one of paragraphs. 12-25, in which the shell does not contain ferromagnetic or paramagnetic material.