Note: Descriptions are shown in the official language in which they were submitted.
WO 2023/099696
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PLANAR CONSUMABLE FOR AEROSOL-GENERATING DEVICE
The present invention relates to a consumable for an aerosol-generating
device.
It is known to provide an aerosol-generating device for generating an
inhalable vapor.
Such devices may heat aerosol-forming substrate contained in a consumable to a
temperature
at which one or more components of the aerosol-forming substrate are
volatilised without
burning the aerosol-forming substrate. The consumable may have a shape for
insertion of the
aerosol-generating article into a cavity, such as a heating chamber, of the
aerosol-generating
device. A heating element may be arranged in or around the heating chamber for
heating the
aerosol-forming substrate once the aerosol-generating article is inserted into
the heating
chamber of the aerosol-generating device.
It would be desirable to have a consumable for an aerosol-generating device
with
improved airflow through the consumable. It would be desirable to have a
consumable for an
aerosol-generating device with improved heating of an aerosol-forming
substrate contained in
the consumable. It would be desirable to have a consumable for an aerosol-
generating device
in which all the aerosol-forming substrate contained in the consumable is
heated to an optimal
temperature.
According to an embodiment of the invention there is provided a consumable for
an
aerosol-generating device. The consumable may comprise a first planar
substrate layer of
aerosol-forming substrate. The consumable may further comprise a second planar
substrate
layer of aerosol-forming substrate. The consumable may further comprise a
planar porous
layer allowing airflow through the porous layer in the planar extension
direction of the porous
layer. The porous layer may be arranged between the first and second substrate
layers.
According to an embodiment of the invention there is provided a consumable for
an
aerosol-generating device. The consumable comprises a first planar substrate
layer of aerosol-
forming substrate. The consumable further comprises a second planar substrate
layer of
aerosol-forming substrate. The consumable further comprises a planar porous
layer allowing
airflow through the porous layer in the planar extension direction of the
porous layer. The
porous layer is arranged between the first and second substrate layers.
The consumable improves airflow through the consumable, particularly by
providing
the planar porous layer allowing airflow therethrough.
The planar porous layer may be arranged as a central layer in the consumable.
The
porous layer is preferably arranged in the planar extension plane of the
consumable.
The porous layer preferably enables lateral airflow through the consumable.
The heating of the aerosol-forming substrate contained in the consumable is
improved,
particularly by arranging the aerosol-forming substrate in the form of two
planar layers. A
heating element as described in more detail below may be arranged next to the
planar layers
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of aerosol-forming substrate such that all of the aerosol-forming substrate in
the planar layers
is heated. This prevents uneven heating of aerosol-forming substrate. Further,
this prevents
aerosol-forming substrate to be heated to a non-sufficient temperature and
therefore prevents
unused aerosol-forming substrate.
The length of the consumable is preferably larger than the thickness of the
consumable.
The ratio of length to thickness of the consumable may be larger than two,
preferably larger
than three, more preferably larger than four, most preferably larger than
five. The width of the
consumable is preferably larger than the thickness of the consumable. The
ratio of width to
thickness of the consumable may be larger than two, preferably larger than
three, more
preferably larger than four, most preferably larger than five.
The consumable may be flat. Preferably, the consumable is not bent. The
consumable
preferably extends in a plane.
The length of the consumable may be slightly larger than the width of the
consumable.
The consumable may have a rectangular cross-sectional shape in the extension
plane of the
consumable. The consumable may further have a rectangular cross-sectional
shape in a plane
perpendicular to the extension plane of the consumable.
Alternatively, the length of the consumable may be similar or identical to the
width of
the consumable. In this case, the consumable may have a square cross-sectional
shape in the
extension plane of the consumable. The consumable may further have a
rectangular cross-
sectional shape in a plane perpendicular to the extension plane of the
consumable.
The first substrate layer may be arranged directly adjacent a first surface of
the porous
layer and the second substrate layer may be arranged directly adjacent a
second opposite
surface of the porous layer. In other words, the porous layer may be
sandwiched between the
first and second substrate layers.
The surface area of the surface of the first substrate layer facing the porous
layer may
be identical to the surface area of the surface of the porous layer facing the
first substrate
layer. The surface area of the surface of the second substrate layer facing
the porous layer
may be identical to the surface area of the surface of the porous layer facing
the second
substrate layer.
The first substrate layer may have a similar or identical length than the
porous layer.
The first substrate layer may have a similar or identical width than the
porous layer.
One or both of the first substrate layer and the second substrate layer may
have a
length of between 10 millimeter and 35 millimeter, preferably between 10
millimeter and 25
millimeter, most preferably around 11 millimeter.
One or both of the first substrate layer and the second substrate layer may
have a
thickness of between 0.3 millimeter and 3 millimeter, preferably between 0.4
millimeter and 2
millimeter, most preferably around 0.5 millimeter.
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One or both of the first substrate layer and the second substrate layer have a
width of
between 2 millimeter and 8 millimeter, preferably between 3 millimeter and 5
millimeter.
The porous layer may have a length of between 10 millimeter and 35 millimeter,
preferably between 10 millimeter and 25 millimeter, most preferably around 11
millimeter.
The porous layer may have a thickness of between 0.3 millimeter and 3
millimeter,
preferably between 0.4 millimeter and 2 millimeter, most preferably between
0.5 millimeter and
1 millimeter.
The porous layer may have a width of between 2 millimeter and 8 millimeter,
preferably
between 3 millimeter and 5 millimeter.
The second substrate layer may have a similar or identical length than the
porous layer.
The second substrate layer may have a similar or identical width than the
porous layer.
The first substrate layer may have a similar or identical thickness than the
porous layer.
The second substrate layer may have a similar or identical thickness than the
porous layer.
Alternatively, one or both the first substrate layer and the second substrate
layer have a
thickness that is smaller than the thickness of the porous layer.
The length of one or more of the first substrate layer, the second substrate
layer and
the porous layer may be measured in the planar extension direction of the
respective layer.
The width of one or more of the first substrate layer, the second substrate
layer and the porous
layer may be measured in the planar extension direction of the respective
layer. The width is
measured in a direction perpendicular to the thickness. The thickness of one
or more of the
first substrate layer, the second substrate layer and the porous layer may be
measured
perpendicular to the planar extension direction of the respective layer. The
thickness is
measured in a direction perpendicular to the length direction and to the width
direction.
A ratio between the thickness of the first substrate layer and the thickness
of the second
substrate layer may be between 0,1 and 10, preferably between 0,3 and 3, more
preferably
between 0,7 and 1,5, most preferably around 1.
A ratio between the thickness of one or both of the first planar substrate
layer and the
second planar substrate layer and the thickness of the porous layer may be
between 0,2 and
10, preferably between 0,6 and 6, more preferably between 1 and 3, most
preferably around
2.
The first substrate layer may have the same cross-sectional shape in the
extension
plane of the consumable than the porous layer. The first substrate layer may
have the same
cross-sectional shape in the extension plane of the consumable than the second
substrate
layer. The second substrate layer may have the same cross-sectional shape in
the extension
plane of the consumable than the porous layer.
The first substrate layer may have the same cross-sectional shape in a plane
perpendicular to the extension plane of the consumable than the porous layer.
The first
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substrate layer may have the same cross-sectional shape in a plane
perpendicular to the
extension plane of the consumable than the second substrate layer. The second
substrate
layer may have the same cross-sectional shape in a plane perpendicular to the
extension plane
of the consumable than the porous layer.
The porous layer may comprise cellulose acetate. The porous layer may consist
of
cellulose acetate. The porous layer may comprise a high porosity acetate tow
fiber-based, or
other cellulosic based fiber compound. The material of the porous layer may
have a cross-
sectional porosity.
As used herein, the term "porosity" refers to a fraction of void space in a
porous body.
In more detail, the term "porosity" is used herein with reference to the
"cross-sectional porosity"
of one such body, that is, the fraction of void space in a cross-sectional
area of the porous
body, for example a cross-section of the planar porous layer or of the first
planar substrate
layer or of the second planar substrate layer. The cross-sectional porosity is
the area fraction
of void space in a transverse cross-sectional area of the respective layer.
The transverse
cross-sectional area of the respective layer is the area of the respective
layer in a plane that is
perpendicular to the longitudinal axis of the respective layer.
The porosity of the porous layer in the direction of the extension plane of
the
consumable may be higher than the porosity of the porous layer in a direction
perpendicular
to the extension plane of the consumable.
The porosity of one or both of the first substrate layer and the second
substrate layer
in the direction of the extension plane of the consumable may be higher than
the porosity of
the porous layer in a direction perpendicular to the extension plane of the
consumable.
The aerosol-forming substrate of one or both of the first substrate layer and
the second
substrate layer may be a sensorial media. The aerosol-forming substrate may
comprise a
sensorial media compound, NCP, HTP or Herbals or cut-filler tobacco.
The aerosol-forming substrate of the first substrate layer may be different
from the
aerosol-forming substrate of the second substrate layer. Exemplarily, the
first substrate layer
may be a nicotine containing substrate while the second substrate layer may be
a flavour
containing substrate.
The porous layer may have a higher porosity than the aerosol-forming
substrate.
The porous layer may have a cross-sectional porosity of between 0.3 and 0.95,
preferably between 0.5 and 0.9. The porous layer may have a cross-sectional
porosity of at
least 0.15, more preferably at least 0.2.
The first substrate layer may have a cross-sectional porosity of between 0.10
and 0.45.
The first substrate layer may have a cross-sectional porosity of at least
0.15, more preferably
at least 0.2. The first substrate layer may have a cross-sectional porosity of
less than or equal
to 0.4, more preferably less than or equal to 0.35, most preferable or less
than or equal to 0.25.
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The first substrate layer may have a cross-sectional porosity of between 0.15
and 0.40,
preferably between 0.15 and 0.35, more preferably between 0.15 and 0.25. In
other
embodiments, the first substrate layer may have a cross-sectional porosity of
between 0.20
and 0.40, preferably between 0.20 and 0.35, more preferably between 0.20 and
0.25.
The second substrate layer may have a cross-sectional porosity of between 0.10
and
0.45. The second substrate layer may have a cross-sectional porosity of at
least 0.15, more
preferably at least 0.2. The second substrate layer may have a cross-sectional
porosity of less
than or equal to 0.4, more preferably less than or equal to 0.35, most
preferable or less than
or equal to 0.25. The second substrate layer may have a cross-sectional
porosity of between
0.15 and 0.40, preferably between 0.15 and 0.35, more preferably between 0.15
and 0.25. In
other embodiments, the second substrate layer may have a cross-sectional
porosity of
between 0.20 and 0.40, preferably between 0.20 and 0.35, more preferably
between 0.20 and
0.25.
The porous layer may have a cross-sectional porosity of at least 120 percent,
preferably
at least 130 percent, more preferably at least 140 percent, more preferably at
least 150
percent, more preferably at least 175 percent, more preferably at least 200
percent, more
preferably at least 250 percent, more preferably at least 300 percent, more
preferably at least
400 percent, more preferably at least 500 percent, more preferably at least
600 percent, of the
cross-sectional porosity of one or both of the fist substrate layer and the
second substrate
layer.
The porous layer may have a cross-sectional porosity of between 130 percent
and 600
percent, preferably between 130 percent and 500 percent, more preferably
between 130
percent and 400 percent, more preferably between 130 percent and 300 percent,
more
preferably between 130 percent and 200 percent, more preferably between 140
percent and
600 percent, more preferably between 140 percent and 500 percent, more
preferably between
140 percent and 400 percent, more preferably between 140 percent and 300
percent, more
preferably between 140 percent and 200 percent, more preferably between 150
percent and
600 percent, more preferably between 150 percent and 500 percent, more
preferably between
150 percent and 400 percent, more preferably between 150 percent and 300
percent, more
preferably between 150 percent and 200 percent, of the cross-sectional
porosity of one or both
of the fist substrate layer and the second substrate layer.
The porous layer may have a cross-sectional porosity of up to 0.99. The porous
layer
may have a cross-sectional porosity of less than 0.95, preferably of less than
0.90, more
preferably of less than 0.85. The porous layer may have a cross-sectional
porosity of at least
0.3, preferably of at least 0.35, more preferably of at least 0.4, more
preferably of at least 0.45.
The porous layer may have a cross-sectional porosity of between 0.3 and 0.95,
preferably
between 0.35 and 0.95, more preferably between 0.4 and 0.95, more preferably
between 0.5
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and 0.95. In other embodiments, the porous layer may have a cross-sectional
porosity of
between 0.3 and 0.90, preferably between 0.35 and 0.90, more preferably
between 0.4 and
0.90, more preferably between 0.5 and 0.90. In other embodiments, the porous
layer may have
a cross-sectional porosity of between 0.3 and 0.85, preferably between 0.35
and 0.85, more
preferably between 0.4 and 0.85, more preferably between 0.5 and 0.85.
Preferably the cross-sectional porosity is determined by obtaining a digital
image of a
transverse cross-sectional area of the respective layer and determining the
area fraction of
voids of the transverse area. Further details relating to the measurement of
cross-sectional
porosity in a porous body can be found in the publication of international
patent application
WO 2016/023965 in the name of the present applicant.
The porous layer may have a resistance to draw of between 10 millimeter H20
and 65
millimeter H20, preferably between 30 millimeter H20 and 60 millimeter H20.
A resistance to draw of the porous layer may be lower than 50 %, preferably
lower than
30 cVo, more preferably lower than 10 c)/0, of a resistance to draw of one or
both of the first
substrate layer and the second substrate layer.
The aerosol-forming substrate may comprise tobacco. The aerosol-forming
substrate
may comprise an aerosol former. The aerosol-forming substrate may be solid.
The aerosol-generating substrate may comprise an aerosol-former. The aerosol-
generating substrate preferably comprises hornogenised tobacco material, an
aerosol-former
and water. Providing homogenised tobacco material may improve aerosol
generation, the
nicotine content and the flavour profile of the aerosol generated during
heating of the aerosol-
generating article. Specifically, the process of making homogenised tobacco
involves grinding
tobacco leaf, which more effectively enables the release of nicotine and
flavours upon heating.
The aerosol-generating substrate may further comprise a flavourant between
about 0.1
percent and about 10 percent by weight. The flavourant may be any suitable
flavourant known
in the art, such as menthol.
The aerosol-former preferably comprises at least one polyhydric alcohol. In a
preferred
embodiment, the aerosol-former comprises at least one of: triethylene glycol;
1,3-butanediol;
propylene glycol; and glycerine.
The consumable may be planar or pouch-shaped.
The consumable may further comprise an outer layer made of a paper wrapper. In
case
of a planar consumable, the paper wrapper may comprise a first paper wrapper
layer and a
second paper wrapper layer. The first paper wrapper layer may be arranged on
the outer
surface of the first substrate layer. The second paper wrapper layer may be
arranged on the
outer surface of the second substrate layer. The consumable may consist of the
porous layer,
the first substrate layer, the second substrate layer, the first paper wrapper
layer and the
second paper wrapper layer.
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In case of a pouch-shaped consumable, a single paper wrapper layer may be
arranged
fully surrounding the consumable. More specifically, a single paper wrapper
layer may be
provided covering the large outer surfaces and at least two side surfaces of
the consumable
or covering the large outer surfaces and all side surfaces of the consumable.
The invention further relates to an aerosol-generating system comprising the
consumable as described herein and an aerosol-generating device. The aerosol-
generating
device may comprise a cavity for receiving the consumable.
The invention further relates to an aerosol-generating system comprising the
consumable as described herein and an aerosol-generating device. The aerosol-
generating
device comprises a cavity for receiving the consumable.
The cavity may have a rectangular cross-section. The cavity may be shaped such
that
the consumable can be nestled into the cavity. The inner volume of the cavity
may correspond
to the volume of the consumable.
The aerosol-generating device may comprise a heating element, preferably an
induction heating element.
The heating element may comprise a first planar heater and a second planar
heater.
The first planar heater may be arranged adjacent a first sidewall of the
cavity. The second
planar heater may be arranged adjacent a second opposite sidewall of the
cavity.
The first planar heater may at least partly form or completely form the first
sidewall of
the cavity. The second planar heater may at least partly form or completely
form the second
sidewall of the cavity.
When the consumable is received in the cavity of the aerosol-generating
device, the
first substrate layer of the consumable may be arranged adjacent the first
planar heater of the
heating element. The first planar heater of the heating element may then be
configured to heat
the aerosol-forming substrate of the first substrate layer of the consumable.
When the consumable is received in the cavity of the aerosol-generating
device, the
second substrate layer of the consumable may be arranged adjacent the second
planar heater
of the heating element. The second planar heater of the heating element may
then be
configured to heat the aerosol-forming substrate of the second substrate layer
of the
consumable.
The aerosol-generating device may comprise an airflow channel. The airflow
channel
may be arranged to allow airflow into a base of the cavity. The airflow
channel may be arranged
abutting the porous layer of the consumable, when the consumable is received
in the cavity to
allow airflow into the porous layer of the consumable.
When the consumable is received in the cavity, air may flow centrally through
the
porous layer and the vaporized substrate from the first and second substrate
layers may be
entrained in the airflow and delivered towards the user for inhalation.
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Downstream of the cavity, the aerosol-generating device may comprise an air
outlet.
The air outlet may be part of or form a mouthpiece. The mouthpiece may be
integrally formed
with the aerosol-generating device. Alternatively, the mouthpiece may be
removably
attachable to the aerosol-generating device.
One or both of the first planar heater and the second planar heater may be
susceptors.
The aerosol-generating device may further comprise an induction coil for
heating one or both
of the first planar heater and the second planar heater.
The aerosol-generating device may comprise electric circuitry. The electric
circuitry
may comprise a microprocessor, which may be a programillimeterable
microprocessor. The
microprocessor may be part of a controller. The electric circuitry may
comprise further
electronic components. The electric circuitry may be configured to regulate a
supply of power
to one or both of the first planar heater and the second planar heater. Power
may be supplied
to one or both of the first planar heater and the second planar heater
continuously following
activation of the aerosol-generating device or may be supplied intermittently,
such as on a puff-
by-puff basis. The power may be supplied to one or both of the first planar
heater and the
second planar heater in the form of pulses of electrical current. The electric
circuitry may be
configured to monitor the electrical resistance of one or both of the first
planar heater and the
second planar heater, and preferably to control the supply of power to one or
both of the first
planar heater and the second planar heater dependent on the electrical
resistance of one or
both of the first planar heater and the second planar heater.
The aerosol-generating device may comprise a power supply, typically a
battery, within
a main body of the aerosol-generating device. In one embodiment, the power
supply is a
Lithium-ion battery. Alternatively, the power supply may be a Nickel-metal
hydride battery, a
Nickel cadmium battery, or a Lithium based battery, for example a Lithium-
Cobalt, a Lithium-
Iron-Phosphate, Lithium Titanate or a Lithium-Polymer battery. As an
alternative, the power
supply may be another form of charge storage device such as a capacitor. The
power supply
may require recharging and may have a capacity that enables to store enough
energy for one
or more usage experiences; for example, the power supply may have sufficient
capacity to
continuously generate aerosol for a period of around six minutes or for a
period of a multiple
of six minutes. In another example, the power supply may have sufficient
capacity to provide
a predetermined number of puffs or discrete activations of one or both of the
first planar heater
and the second planar heater.
The invention further relates to a consumable for an aerosol-generating
device, the
consumable may comprise a first planar substrate layer of aerosol-forming
substrate. The
consumable may comprise a second planar substrate layer of aerosol-forming
substrate. The
consumable may comprise a first planar porous layer allowing airflow through
the first porous
layer in the planar extension direction of the first porous layer. The
consumable may comprise
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a second planar porous layer allowing airflow through the second porous layer
in the planar
extension direction of the second porous layer and a planar heater. The heater
may be
arranged between the first and second substrate layers. The heater and the
first and second
substrate layers may be arranged between the first and second porous layers.
The invention further relates to a consumable for an aerosol-generating
device, the
consumable comprises a first planar substrate layer of aerosol-forming
substrate. The
consumable comprises a second planar substrate layer of aerosol-forming
substrate. The
consumable comprises a first planar porous layer allowing airflow through the
first porous layer
in the planar extension direction of the first porous layer. The consumable
comprises a second
planar porous layer allowing airflow through the second porous layer in the
planar extension
direction of the second porous layer and a planar heater. The heater is
arranged between the
first and second substrate layers. The heater and the first and second
substrate layers are
arranged between the first and second porous layers.
Preferably, the first planar substrate layer is distinct from the second
planar substrate
layer. Preferably, the first planar porous layer is distinct from the second
planar porous layer.
Preferably, one or more of the first planar substrate layer, the second planar
substrate
layer, the first planar porous layer and the second planar porous layer has a
constant
thickness.
The consumable may not comprise a single central porous layer. Instead, the
planar
heater may form the central layer of the consumable. The central planar heater
may be
sandwiched between the first substrate layer and the second substrate layer.
Outside of the
first substrate layer and the second substrate layer, the first porous layer
and the second
porous layer may be arranged. Thus, the first substrate layer and the second
substrate layers
may be sandwiched between the first porous layer and the second porous layer.
Air may not centrally flow through the consumable in one embodiment. Rather,
two
separate air flows may be created through the first and second porous layers.
The disclosure herein concerning the dimensions and materials of the first and
second
substrate layers applies to this embodiment as well. Similarly, the disclosure
of the materials
and dimensions of the porous layer described above apply to the first and
second porous layers
described for this embodiment with a single difference. In the early
embodiment, the thickness
of the singer porous layer is most preferably 1 millimeter. In the current
embodiment, the
thickness of each of the first porous layer and the second porous layer is
most preferably 0.5
millimeter.
The heater may be a susceptor. This has the advantage that the heater may be
heated
by an aerosol-generating device without the need for any electrical connection
to the
consumable. The aerosol-generating device may for this purpose comprise an
induction coil
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for generating an alternating magnetic field in the susceptor, when the
consumable is received
in the cavity of the aerosol-generating device.
The consumable may further comprise an outer layer made of a paper wrapper.
Similar
to the initially described embodiment, the paper wrapper may comprise a first
paper wrapper
layer and a second paper wrapper layer. The first paper wrapper layer may be
arranged
outside of the first porous layer. The second paper wrapper layer may be
arranged outside the
second paper wrapper layer. In case the consumable is planar, the outer large
surfaces of the
consumable may be covered by the first paper wrapper layer and the second
paper wrapper
layer. Alternatively, the consumable may be a pouch-shaped consumable. In this
case, the
paper wrapper may fully cover the two large surfaces of the consumable and at
least two side
surfaces of the consumable or at the two large surfaces of the consumable and
all side
surfaces of the consumable.
As used herein, an 'aerosol-generating device' relates to a device that
interacts with an
aerosol-forming substrate to generate an aerosol. The aerosol-forming
substrate may be part
of an aerosol-generating article, for example part of a smoking article. An
aerosol-generating
device may be a smoking device that interacts with an aerosol-forming
substrate of an aerosol-
generating article to generate an aerosol that is directly inhalable into a
user's lungs thorough
the user's mouth. An aerosol-generating device may be a holder. The device may
be an
electrically heated smoking device. The aerosol-generating device may comprise
a housing,
electric circuitry, a power supply, a heating chamber and a heating element.
As used herein, the term 'consumable' refers to an article comprising an
aerosol-
forming substrate that is capable of releasing volatile compounds that can
form an aerosol.
For example, a consumable may be a smoking article that generates an aerosol
that is directly
inhalable into a user's lungs through the user's mouth. A consumable may be
disposable.
As used herein, the terms 'upstream', 'downstream', 'proximal', 'distal',
'front' and 'rear',
are used to describe the relative positions of components, or portions of
components, of the
aerosol-generating device in relation to the direction in which a user draws
on the aerosol-
generating device during use thereof.
The heater may be configured as an induction heater. The induction heater may
comprise an induction coil and a susceptor. In general, a susceptor is a
material that is capable
of generating heat, when penetrated by an alternating magnetic field. When
located in an
alternating magnetic field. If the susceptor is conductive, then typically
eddy currents are
induced by the alternating magnetic field. If the susceptor is magnetic, then
typically another
effect that contributes to the heating is commonly referred to hysteresis
losses. Hysteresis
losses occur mainly due to the movement of the magnetic domain blocks within
the susceptor,
because the magnetic orientation of these will align with the magnetic
induction field, which
alternates. Another effect contributing to the hysteresis loss is when the
magnetic domains will
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grow or shrink within the susceptor. Commonly all these changes in the
susceptor that happen
on a nano-scale or below are referred to as "hysteresis losses", because they
produce heat in
the susceptor. Hence, if the susceptor is both magnetic and electrically
conductive, both
hysteresis losses and the generation of eddy currents will contribute to the
heating of the
susceptor. If the susceptor is magnetic, but not conductive, then hysteresis
losses will be the
only means by which the susceptor will heat, when penetrated by an alternating
magnetic field.
According to the invention, the susceptor may be electrically conductive or
magnetic or both
electrically conductive and magnetic. An alternating magnetic field generated
by one or several
induction coils heat the susceptor, which then transfers the heat to the
aerosol-forming
substrate, such that an aerosol is formed. The heat transfer may be mainly by
conduction of
heat. Such a transfer of heat is best, if the susceptor is in close thermal
contact with the
aerosol-forming substrate.
The susceptor may be formed from any material that can be inductively heated
to a
temperature sufficient to generate an aerosol from the aerosol-forming
substrate. A preferred
susceptor may comprise or consist of a ferromagnetic material or fern-magnetic
material, for
example a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or
stainless steel. A
suitable susceptor may be, or comprise, aluminium. Preferred susceptors may be
heated to a
temperature in excess of 250 degrees Celsius.
Preferred susceptors are metal susceptors, for example stainless steel.
However,
susceptor materials may also comprise or be made of graphite, molybdenum,
silicon carbide,
aluminum, niobium, Inconel alloys (austenite nickel-chromium-based
superalloys), metallized
films, ceramics such as for example zirconia, transition metals such as for
example iron, cobalt,
nickel, or metalloids components such as for example boron, carbon, silicon,
phosphorus,
aluminium.
Below, there is provided a non-exhaustive list of non-limiting examples. Any
one or
more of the features of these examples may be combined with any one or more
features of
another example, embodiment, or aspect described herein.
Example Ex1: A consumable for an aerosol-generating device, the consumable
comprising:
a first planar substrate layer of aerosol-forming substrate;
a second planar substrate layer of aerosol-forming substrate; and
a planar porous layer allowing airflow through the porous layer in the planar
extension
direction of the porous layer,
wherein the porous layer is arranged between the first and second substrate
layers.
Example Ex2: The consumable according to example Ex1, wherein the first
substrate
layer is arranged directly adjacent a first surface of the porous layer and
the second substrate
layer is arranged directly adjacent a second opposite surface of the porous
layer.
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Example Ex3: The consumable according to any of the preceding examples,
wherein
the porous layer is sandwiched between the first and second substrate layers.
Example Ex4: The consumable according to any of the preceding examples,
wherein
the porous layer comprises cellulose acetate, preferably wherein the porous
layer consists of
cellulose acetate.
Example Ex5: The consumable according to any of the preceding examples,
wherein
the porous layer has a higher porosity than the aerosol-forming substrate.
Example Ex6: The consumable according to any of the preceding examples,
wherein
the porous layer has a porosity of between 50 percent and 90 percent in the
planar extension
direction of the porous layer, preferably between 60 percent and 80 percent in
the planar
extension direction of the porous layer, more preferably between 65 percent
and 75 percent in
the planar extension direction of the porous layer.
Example Ex7: The consumable according to any of the preceding examples,
wherein
the porous layer has a resistance to draw of between 10 millimeter H20 and 65
millimeter H20,
preferably between 30 millimeter H20 and 60 millimeter H20.
Example Ex7.1:
The consumable according to any of the preceding examples,
wherein a resistance to draw of the porous layer is lower than 50 %,
preferably lower than 30
/0, more preferably lower than 10 %, of a resistance to draw of one or both of
the first substrate
layer and the second substrate layer.
Example Ex8: The consumable according to any of the preceding examples,
wherein
the porous layer has a thickness of between 0.3 millimeter to 4.0 millimeter,
preferably between
0.4 millimeter to 3.0 millimeter, more preferably between 0.5 millimeter to
1.0 millimeter.
Example Ex9: The consumable according to any of the preceding examples,
wherein
the porous layer has a length of between 5 millimeter to 35 millimeter,
preferably between 7
millimeter to 25 millimeter, more preferably between 10 millimeter to 15
millimeter.
Example Exl 0:
The consumable according to any of the preceding examples,
wherein the aerosol-forming substrate comprises tobacco.
Example Ex11:
The consumable according to any of the preceding examples,
wherein the aerosol-forming substrate comprises an aerosol former.
Example Ex12: The
consumable according to any of the preceding examples,
wherein the aerosol-forming substrate is solid.
Example Ex13:
The consumable according to any of the preceding examples,
wherein the consumable is planar or pouch-shaped.
Example Ex14:
The consumable according to any of the preceding examples,
wherein the consumable further comprises an outer layer made of a paper
wrapper.
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Example Ex15:
An aerosol-generating system comprising the consumable of
any of the preceding examples and an aerosol-generating device, wherein the
aerosol-
generating device comprises a cavity for receiving the consumable.
Example Ex16:
The aerosol-generating system according to the preceding
example, wherein the cavity has a rectangular cross-section.
Example Ex17:
The aerosol-generating system according to any of the two
preceding examples, wherein the aerosol-generating device comprises a heating
element,
preferably an induction heating element.
Example Ex18:
The aerosol-generating system according to the preceding
example, wherein the heating element comprises a first planar heater and a
second planar
heater, wherein the first planar heater is arranged adjacent a first sidewall
of the cavity, and
wherein the second planar heater is arranged adjacent a second opposite
sidewall of the
cavity.
Example Ex19:
The aerosol-generating system according to any of the four
preceding examples, wherein the aerosol-generating device comprises an airflow
channel,
wherein the airflow channel is arranged to allow airflow into a base of the
cavity, and wherein
the airflow channel is arranged abutting the porous layer of the consumable,
when the
consumable is received in the cavity to allow airflow into the porous layer of
the consumable.
Example Ex20:
A consumable for an aerosol-generating device, the consumable
comprising:
a first planar substrate layer of aerosol-forming substrate;
a second planar substrate layer of aerosol-forming substrate;
a first planar porous layer allowing airflow through the first porous layer in
the planar
extension direction of the first porous layer;
a second planar porous layer allowing airflow through the second porous layer
in the
planar extension direction of the second porous layer; and
a planar heater,
wherein the heater is arranged between the first and second substrate layers,
and
wherein the heater and the first and second substrate layers are arranged
between the first
and second porous layers.
Example Ex21:
The consumable according to the preceding example, wherein
the heater is a susceptor.
Example 22: The consumable according to any of the preceding claims, wherein
the
consumable further comprises an outer layer made of a paper wrapper.
Features described in relation to one embodiment may equally be applied to
other
embodiments of the invention.
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The invention will be further described, by way of example only, with
reference to the
accompanying drawings in which:
Fig. 1 shows a consumable for an aerosol-generating device;
Fig. 2 shows the consumable of Figure 1 in a fully assembled state;
Fig. 3 shows a pouch-shaped consumable;
Fig. 4 shows the consumable received in a cavity of an aerosol-generating
device;
Fig. 5 shows the airflow through the consumable and the cavity;
Fig. 6 shows an embodiment of a consumable with an integrated heater.
A consumable for an aerosol-generating device is shown in Figure 1. The
consumable
comprises a porous layer. The porous layer is the central layer of the
consumable.
The consumable is planar. The porous layer is planar. The porous layer enables
airflow
laterally through the consumable. The porous layer has a rectangular cross-
sectional shape in
an extension plane of the consumable. The consumable as a whole has a
rectangular cross-
sectional shape in an extension plane of the consumable.
The consumable further comprises a first substrate layer. The first substrate
layer
comprises an aerosol-forming substrate. The first substrate layer is arranged
directly adjacent
the porous layer. The first substrate layer has the same cross-sectional shape
in an extension
plane of the consumable as the porous layer. The first substrate layer has the
same length
and width as the porous layer. The first substrate layer is in direct physical
contact with the
porous layer.
The consumable further comprises a second substrate layer. The second
substrate
layer comprises an aerosol-forming substrate. The second substrate layer is
arranged directly
adjacent the porous layer. The second substrate layer has the same cross-
sectional shape in
an extension plane of the consumable as the porous layer. The second substrate
layer has the
same length and width as the porous layer. The second substrate layer is in
direct physical
contact with the porous layer.
The aerosol-forming substrate of the first substrate layer may be identical
with the
aerosol-forming substrate of the second substrate layer. Alternatively, the
aerosol-forming
substrate of the first substrate layer may be different from the aerosol-
forming substrate of the
second substrate layer. Exemplarily, the aerosol-forming substrate of the
first substrate layer
may be a nicotine-containing substrate and the aerosol-forming substrate of
the second
substrate layer may be a flavor-containing substrate.
The porous layer is sandwiched between the first substrate layer and the
second
substrate layer. In other words, the first substrate layer and the second
substrate layer cover
opposite large surfaces of the porous layer.
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The consumable further comprises a first paper wrapper layer and a second
paper
wrapper layer.
The first paper wrapper layer is arranged adjacent the first substrate layer.
The first
paper wrapper layer is arranged on an opposite large surface of the first
substrate layer than
the porous layer. The first paper wrapper layer is an outer layer of the
consumable. The first
paper wrapper layer has the same length and width as the first substrate
layer.
The second paper wrapper layer is arranged adjacent the second substrate
layer. The
second paper wrapper layer is arranged on an opposite large surface of the
second substrate
layer than the porous layer. The second paper wrapper layer is an outer layer
of the
consumable. The second paper wrapper layer has the same length and width as
the second
substrate layer.
The first substrate layer and the second substrate layer and sandwiched
between the
first paper wrapper layer and the second paper wrapper layer.
Figure 2 shows the consumable of Figure 1 in a fully assembled state. The
porous layer
forms the central layer. The large surfaces of the porous layer are covered
with the first and
second substrate layers. The outer large surfaces of the first and second
substrate layers are
covered by the first and second paper wrapper layers. The central porous layer
enables airflow
through the consumable.
Figure 3 shows a different type of paper wrapper to wrap the consumable. In
this
embodiment, the paper wrapper is also covering all side surfaces of the
consumable such that
the consumable is configured as a pouch-shaped consumable. Hence, the paper
wrapper is
configured as a pouch-shaped paper wrapper. This may be realized by providing
oversized
first and second paper wrapper layers and gluing the overlapping parts of the
layers together.
Figure 4 shows the consumable of one of Figures 1 and 2 inserted into a cavity
of an
aerosol-generating device. Of course, also the consumable of Figure 3 could be
inserted into
the cavity of the aerosol-generating device shown in Figure 4.
The aerosol-generating device comprises a first planar heater and a second
planar
heater. The first planar heater es arranged at or forming a side surface of
the cavity into which
the consumable is inserted. The second planar heater es arranged at or forming
an opposite
side surface of the cavity.
When the consumable is received in the cavity, the first substrate layer is
arranged
adjacent the first planar heater. The second substrate layer is arranged
adjacent the second
planar heater.
The aerosol-generating device further comprises an induction coil. The
induction coil is
arranged at least partly surrounding the first planar heater and the second
planar heater. The
first planar heater and the second planar heater are each susceptors. The
induction coil is
configured to heat the first planar heater and the second planar heater.
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Figure 4 further shows thermal insulation chambers to thermally insulate the
cavity of
the aerosol-generating device.
Figure 5 shows the airflow 34 through the consumable and the cavity of the
aerosol-
generating device during operation of the aerosol-generating device. Figure 5
is a sideview of
the cavity in contrast to the top view of the cavity shown in Figure 4.
The airflow 34 comes from a base of the cavity and flows further through the
porous
layer of the consumable. The air flows out of the consumable and out of the
cavity through an
outlet of the cavity. The generated aerosol may then be inhaled by a user.
Figure 5 further shows contacts for contacting the induction coil. A power
supply (not
shown) and a controller (not shown) are part of the aerosol-generating device.
The controller
controls the flow of electrical energy from the power supply to the induction
coil during
operation of the aerosol-generating device.
Figure 6 shows an alternative embodiment of a consumable with an integrated
heater.
In this embodiment, the central layer is not formed by a single porous layer.
Instead, the central
layer is formed by a central planar heater. The central planar heater is a
susceptor.
Similar to the previously described embodiment, the central layer is
sandwiched
between a first substrate layer and a second substrate layer. These substrate
layers are the
same substrate layers as previously described. These substrate layers are
sandwiched
between first and second porous layers. The first and second porous layers are
sandwiched
between a first paper wrapper layer and a second paper wrapper layer. The
paper wrapper
layers are the same as previously described.
In this alternative embodiment, the aerosol-generating device does not need to
be
provided with heaters, since the heater is placed in the consumable. The
aerosol-generating
device will in this case only be equipped with an induction coil as previously
described.
When the consumable of this embodiment is inserted in the cavity of the
aerosol-
generating device, air will flow in two separate paths through the first and
second porous
layers. The first and second porous layers are arranged next to the first
substrate layer and
the second substrate layer, respectively. At the same time, the induction coil
of the aerosol-
generating device will generate an alternating magnetic field such that the
central planar heater
of the consumable is heated. This heat will lead to a vaporization of the
aerosol-forming
substrate of the first substrate layer and of the second substrate layer. This
vaporized aerosol-
forming substrate will be entrained in the air flowing through the first and
second porous layers
and delivered towards a user for inhalation.
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