WO2025056611A1

WO2025056611A1 - Aerosol forming article

Info

Publication number: WO2025056611A1
Application number: PCT/EP2024/075376
Authority: WO
Inventors: Walid Abi AOUN; Marcus Hartley
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-09-12
Filing date: 2024-09-11
Publication date: 2025-03-20
Anticipated expiration: 2026-03-12
Also published as: GB202313877D0

Abstract

An aerosol forming article comprising a layered structure, the layered structure comprising: a heating layer; and an aerosol generating material layer comprising aerosol generating material positioned on a first side of the heating layer, the heating layer configured to heat the aerosol generating material, wherein a second side of the heating layer comprises an exposed region, wherein the exposed region is at least partially aligned with at least a portion of the aerosol generating material.

Description

AEROSOL FORMING ARTICLE

Technical Field

The present invention relates to an article for forming an aerosol and an aerosol provision system.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles that burn tobacco by creating products that release compounds without burning. Examples of such products are heating devices which release compounds by heating, but not burning, the material. The material may be for example tobacco or other non-tobacco products, which may or may not contain nicotine.

Summary

In accordance with the first aspect, there is provided an aerosol forming article, the article comprising a layered structure, the layered structure comprising a heating layer and an aerosol generating material layer comprising aerosol generating material positioned on a first side of the heating layer, the heating layer configured to heat the aerosol generating material, wherein a second side of the heating layer comprises an exposed region, wherein the exposed region is at least partially aligned with at least a portion of the aerosol generating material.

The exposed region may be completely aligned with the aerosol generating material.

The heating layer may be an outer layer such that the entire second side forms the exposed region.

The layered structure may comprise a support layer, the support layer positioned on the second side of the heating layer, wherein the support layer comprises a cut-out aligned with the exposed region of the heating layer.

The support layer may comprise a frame surrounding the cut-out.

The frame may be aligned with a region of the heating layer that does not comprise aerosol generating material.

The support layer may be formed of paper or cardboard.

The layered structure may comprise an additional heating layer opposite the first side of the heating layer, such that an airflow path is defined between the heating layer and additional heating layer.

The additional heating layer may comprise aerosol generating material on a first side of the additional heating layer. A second side of the additional heating layer may comprise an additional exposed region, wherein the additional exposed region is at least partially aligned with at least a portion of the aerosol generating material.

The heating layer may be substantially planar.

The layered structure may comprise at least one intermediate layer between the heating layer and additional heating layer.

The aerosol generating material may be positioned in two or more discrete portions on the heating layer.

According to a second aspect, there is provided an aerosol provision system comprising the aerosol forming article of the first aspect, and an aerosol provision device configured to receive the aerosol forming article.

Brief Description of the Drawings

Embodiments will now be described, by way of example only, and with reference to the accompanying drawings in which:

Fig. 1 shows a cross-sectional side view of an aerosol provision device and an article;

Fig. 2 shows a cross-sectional side view of the aerosol provision device receiving the article;

Fig. 3 shows a heating layer and an aerosol generating material layer which form part of the article;

Fig. 4 shows a variety of possible support layers which may form part of the article;

Fig. 5 shows a support layer positioned on the heating layer

Fig. 6 shows an intermediate layer which may form part of the article; and

Fig. 7 shows a mouth end view of the article.

Detailed Description

As used herein, the term “aerosol-generating material” is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. Aerosol-generating material may include any plant based material, such as tobacco-containing material and may, for example, include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Aerosol-generating material also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. Aerosol-generating material may for example be in the form of a solid, a liquid, a gel, a wax or the like. Aerosol-generating material may for example also be a combination or a blend of materials. Aerosol-generating material may also be known as “smokable material”.

The aerosol-generating material may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating material may comprise or be an “amorphous solid”. The amorphous solid may be a “monolithic solid”. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The aerosol-generating material may comprise an aerosol-generating film. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet. The sheet may be a crimped sheet. The aerosol-generating sheet or shredded sheet may be substantially tobacco free.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and an article, typically a consumable for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosolmodifying agent.

An aerosol generating device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article. With reference to Fig. 1 and Fig. 2, an aerosol provision system 10 comprises an aerosol provision device 100 for generating aerosol from an aerosol generating material. The aerosol provision system 10 further comprises a replaceable article 200 (also referred to as an aerosol forming article 200) comprising the aerosol generating material. In broad outline, the aerosol provision device 100 may be used to heat the article 200 to generate an aerosol or other inhalable medium, which is inhaled by a user of the device 100. Though Fig. 1 and Fig. 2 show the same aerosol provision device 100 and article 200, several reference numerals are omitted from Fig. 1 or Fig. 2 for clarity.

The aerosol provision device 100 comprises a housing 102. The housing 102 houses various components of the aerosol provision device 100.

The aerosol provision device 100 comprises an aerosol generator 104. The aerosol generator 104 comprises a heating arrangement 106. The heating arrangement 106 is configured to receive the article 200 inside it.

The external heating arrangement 106 is a hollow body 106. The heating arrangement 106 has a rectangular cross-section. The heating arrangement 106 comprises an inductive element 106a The inductive element is configured to produce a varying magnetic field. The inductive element 106a is at least one coil 106a.

Induction heating is a process of heating an electrically conducting heating element (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor (heating element) suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive element and the susceptor, allowing for enhanced freedom in construction and application.

The heating arrangement 106 extends away from the housing 102. In the present example, the heating arrangement 106 is not surrounded by the housing 102. The heating arrangement may have a housing distinct from the housing 102. In other examples, the external heating arrangement 106 is covered by the housing 102.

An article receptacle 111 is formed between the internal heating arrangement 108 and the external heating arrangement 106.

The aerosol provision device 100 comprises a power source 114 for supplying power to the aerosol generator 104. The aerosol provision device 100 comprises a controller 116. The power source 114 is in the housing 102. The controller 116 is in the housing 102. The power source supplies electrical power to the aerosol generator, and the aerosol generator converts the supplied electrical energy into heat energy for heating the aerosol-generating material. The power source may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery.

The power source 114 is electrically coupled to the aerosol generator 104 to supply electrical power when required and under control of a controller 116 to heat the aerosol generating material. The controller 116 may be configured to activate and deactivate the aerosol generator 104 based on a user input. The controller 116 is in the housing 102.

The article 200 comprises aerosol generating material (not shown in Fig. 1). The article 200 comprises an air passage 204 (also referred to as an airflow path 701). The article 200 comprises a mouth end 208. The mouth end 208 is received in the user’s mouth in use. The article comprises a susceptor material (not shown in Fig. 1). As described below, the article 200 comprises a layered structure.

In use, the article 200 is received in the article receptacle 111 , as shown in Fig. 2. The heating arrangement 106 extends around the article 200. The coil 106a surrounds the susceptor of article 200. The coil 106a induces a varying magnetic field in the susceptor, which causes heating of the susceptor. The susceptor in turn heats the aerosol generating material.

An inlet flow path 118 to the article 200 permits air to flow from outside the aerosol provision system 10 to the article 200. The inlet flow path 118 is between the heating arrangement 106 and the article 200. In other examples, air flows from an air inlet (e.g. an aperture) at the base of the article receptacle 111.

When a user inhales on the article 200, air flows between the external heating arrangement 106 and the article 200, through the inlet flow path 118. The air enters the article 200 through a distal end (opposite to the mouth end 208) of the article 200. The air is drawn through the air passage 204, past the aerosol generating material, which forms an aerosol from the heated aerosol generating material. The aerosol exits the mouth end 208 to be inhaled by the user.

With reference to Fig. 3, the aerosol forming article 200 comprises a heating layer 301 and an aerosol generating material layer 302, which form part of the layered structure of the article. The aerosol generating material layer 302 comprises aerosol generating material 302 that is positioned on a first side of the heating layer 301. The aerosol generating material 302 is formed of two or more discrete portions of aerosol generating material on the heating layer 301. More specifically, the aerosol generating material is formed of five discrete portions of aerosol generating material.

The aerosol generating material layer 302 is divided into the discrete portions to prevent gluing the surface when the heating layer 301 is combined with other components of the aerosol forming article 200. Additionally, the discrete portions may be easily sequentially heated (e.g. one by one) during an aerosol generation session. If multiple coils 106a are present in the heating arrangement 106, these may be configured to individually heat a discrete portion of the aerosol generating material 302 and provide the sequential heating effect.

In the present example, the aerosol generating material 302 is located in 5 rounded square portions which are equally spaced along a section of the heating layer 301.

In alternative embodiments, the aerosol generating material 302 may be distributed in a different number of discrete portions and in different locations on the first side of the heating layer 301.

The second side of the heating layer 301 does not have any aerosol generating material 302 positioned on it.

In the present example, the aerosol generating material 302 is an amorphous solid.

The heating layer 301 is substantially planar. The first side of the heating layer 301 is substantially rectangular, comprising a mouth end 208 and a distal end 303. The heating layer 301 has substantially squared edges at the distal end 303, and substantially curved edges at the mouth end 208.

The heating layer 301 comprises a single layer of material. The heating layer 301 is formed entirely of the same material.

The heating layer 301 acts as a susceptor. In the present example, the heating layer 301 is formed of an aluminium foil material. In other examples, the heating layer 301 may be formed of a different material, for example another metal or a metal alloy. With reference to Fig. 4a to 4f, the aerosol forming article 200 comprises a support layer 400. The support layer 400 comprises a frame 401 and one or more cut outs 402, wherein the frame 401 is configured to surround the cut outs 402.

A cut out 402 is an area of the support layer 400 in which no material is present. Material is present at the frame 401.

Fig. 4a, 4b, 4c, 4d, 4e and 4f show some example configurations of the location of the cut outs 402 relative to the frames 401 . Fig. 4a shows triangular cut outs 402 arranged along the length of the support layer 400. Fig. 4b shows V-shaped cut outs 402 arranged along a portion of the support layer 400. Fig. 4c shows small circular cut outs 402 arranged in a 3 x 17 array along a portion of the support layer 400. Fig. 4d shows large circular cut outs 402 arranged in a single line along a portion of the support layer 400. Fig. 4e shows irregularly sized circular cut outs 402 positioned in a portion of the support layer 400. Fig. 4f shows rounded square cut outs 402 arranged in a single line along a portion of the support layer 400.

In alternative embodiments, the cut outs 402 may have different dimensions and be positioned differently on the support layer 400.

The total combined area of the cut outs 402 on the heating layer 400 may be at least equal to the area of aerosol generating material 302 on the heating layer 400. The area of aerosol generating material 302 may produce the required amount of aerosol per puff.

The configuration and dimensions of the cut outs 402 on the heating layer 400 for a specific device may be chosen based on various factors, for example ease of manufacturing.

The support layer 400 comprises a single layer of material. The support layer 400 is formed entirely of the same material. In the present example, the support layer 400 is formed of paper or cardboard. The support layer 400 provides structural support to the heating layer 301 . The support layer 400 provides structural support to the article 200.

With reference to Fig. 5, the support layer 400 is positioned on the second side of the heating layer 301. The heating layer 301 and support layer 400 together form a bilaminate. The support layer 400 is configured to provide additional rigidity to the heating layer. 301 .

The support layer 400 is configured such that the second side of the heating layer 301 comprises an exposed region in positions aligned with the cut outs 402, such that the exposed region is at least partially aligned with at least a portion of the aerosol generating material 302. In this scenario, an exposed region is defined as a region where the second side of the heating layer 301 is not covered by an external material.

In the present example, the cut outs 402 are located in positions similar to those of Fig. 4a and the exposed regions of the heating layer 301 are therefore also located in these positions. In alternative embodiments, the cut outs 402 may be located in alternative positions, and the exposed regions of the heating layer 301 may therefore also be located in different positions.

In some embodiments, the aerosol generating material 302 may be completely aligned with the exposed region, for example, if a support layer 400 configured similarly to that in Fig. 4f was used e.g. all of the aerosol generating material 302 may be aligned with the exposed region. The exposed region may cover a bigger area than the aerosol generating material 302.

In some embodiments, the frame 401 of the support layer 400 is aligned with a region of the heating layer 301 that does not comprise aerosol generating material 302.

The cut outs 402 may mean that the thermal mass of the support layer 400 is reduced. This may mean that less energy is required to increase the temperature of the aerosol generating material layer 302, using the heating arrangement 106, with less heat being transferred to the support layer 400. This means aerosol can be produced from the aerosol generating material 302 using less power from the power source 114, and the overall efficiency of the aerosol provision device 100 can be increased. A support layer 400 with a reduced thermal mass may also mean that faster aerosolisation of the aerosol generating material 302 is possible.

In some embodiments, the support layer 400 may not be present in the aerosol forming article 200, such that the second side of the heating layer 301 is an outer layer of the aerosol forming article 200 and the entire second side of the heating layer 301 forms the exposed region.

With reference to Fig. 6, the aerosol forming article 200 comprises an intermediate layer 600. The intermediate layer 600 comprises side walls 601 and an intermediate layer cut out 602, wherein the cut out 602 is located between the side walls 601 .

In alternative embodiments, the intermediate layer 600 may have a configuration with more than one intermediate layer cut out 602.

With reference to Fig. 7, the layered structure of the aerosol forming article 200 is illustrated. The layered structure comprises a heating layer 301a, an additional heating layer 301 b, an aerosol generating material layer 302a, an additional aerosol generating material layer 302b, a support layer 400a, an additional support layer 400b, and an intermediate layer 600. The heating layer 301a and the additional heating layer 301b are identical to that shown in Fig. 3. The aerosol generating material layer 302a and additional aerosol generating material layer 302b are identical to that shown in Fig. 3. The support layer 400a and the additional support layer 400b are identical to that shown in Fig. 4a - 4f. Repeated description of identical components is omitted.

The aerosol generating material layer 302a is positioned on the first side of the heating layer 301a in a configuration identical to Fig. 3. The support layer 400a is positioned on the second side of the heating layer 301a in a configuration identical to Fig. 5.

The additional aerosol generating material layer 302b is positioned on the first side of the additional heating layer 301 b in a configuration identical to Fig. 3. The additional support layer 400b is positioned on the second side of the additional heating layer 301 b in a configuration identical to Fig. 5.

The additional heating layer 301 b is positioned opposite the first side of the heating layer 301a such that an airflow path 701 is defined between the heating layer 301a and additional heating layer 301b.

The first side of the heating layer 301a and first side of the additional heating layer 301 b face towards each other. The first side of the heating layer 301a and first side of the additional heating layer 301 b are aligned such that the regions of aerosol generating material 302a 302b are also aligned.

The intermediate layer 600 is positioned so that it is adjacent to and aligned with the heating layer 301a and the additional heating layer 301 b.

The airflow path 701 is formed in the intermediate layer cut out 602 of the intermediate layer 600 and passes the aerosol generating material 302a 302b.

The airflow path 701 allows aerosol produced during heating of the aerosol generating material 302a 302b to travel through the aerosol forming article 200 and leave via the mouth end 208 to be inhaled by the user.

In some embodiments, more than one intermediate layer 600 may be used adjacent to the heating layer 301a and additional heating layer 301b.

In some embodiments, the intermediate layer 600 may have a configuration which requires more than one intermediate layer 600 to be used in the layered structure of the aerosol forming article 200, so that an airflow path 701 is defined.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. An aerosol forming article comprising a layered structure, the layered structure comprising: a heating layer; and an aerosol generating material layer comprising aerosol generating material positioned on a first side of the heating layer, the heating layer configured to heat the aerosol generating material, wherein a second side of the heating layer comprises an exposed region, wherein the exposed region is at least partially aligned with at least a portion of the aerosol generating material.

2. An aerosol forming article according to claim 1, wherein the aerosol generating material is completely aligned with the exposed region.

3. An aerosol forming article according to claims 1 or 2, wherein the heating layer is an outer layer such that the entire second side forms the exposed region.

4. An aerosol forming article according to claims 1 to 3, wherein the layered structure comprises a support layer, the support layer positioned on the second side of the heating layer, wherein the support layer comprises at least one cut-out aligned with the exposed region of the heating layer.

5. An aerosol forming article according to claim 4, wherein the support layer comprises a frame surrounding the at least one cut-out.

6. An aerosol forming article according to claim 5, wherein the frame is aligned with a region of the heating layer that does not comprise aerosol generating material.

7. An aerosol forming article according to claims 4 to 6, wherein the support layer is formed of paper or cardboard.

8. An aerosol forming article according to claims 1 to 7, wherein the layered structure comprises an additional heating layer opposite the first side of the heating layer, such that an airflow path is defined between the heating layer and additional heating layer.

9. An aerosol forming article according to claim 8, wherein the additional heating layer comprises aerosol generating material on a first side of the additional heating layer.

10. An aerosol forming material according to claims 8 or 9, wherein a second side of the additional heating layer comprises an additional exposed region, wherein the additional exposed region is at least partially aligned with at least a portion of the aerosol generating material.

11. An aerosol forming material according to claims 1 to 10, wherein the heating layer is substantially planar.

12. An aerosol forming article according to claims 1 to 11, wherein the layered structure comprises at least one intermediate layer between the heating layer and the additional heating layer.

13. An aerosol forming article according to claims 1 to 12, wherein the aerosol generating material is positioned in two or more discrete portions on the heating layer.

14. An aerosol provision system comprising an aerosol forming article of claims 1 to 13 and an aerosol provision device configured to receive the aerosol forming article.