Aerosol-forming cartridge comprising a tobacco-containing material

Patent metadata

Field	Value
Publication number	US-9943114-B2
Application number	US-201515323803-A
Country	US
Kind code	B2
Filing date	Jul 9, 2015
Priority date	Jul 11, 2014
Publication date	Apr 17, 2018
Grant date	Apr 17, 2018

Abstract

There is provided an aerosol-forming cartridge for an electrically operated aerosol-generating system. The cartridge includes a base layer and at least one aerosol-forming substrate disposed on the base layer and including a tobacco-containing material with volatile tobacco flavor compounds that are releasable from the aerosol-forming substrate. The base layer and the at least one aerosol-forming substrate are in contact at a contact surface, which is substantially planar.

First claim

The invention claimed is:

1. An aerosol-forming cartridge for an electrically operated aerosol-generating system, the cartridge comprising:
a base layer; and
at least one aerosol-forming substrate disposed on the base layer and comprising a tobacco-containing material with volatile tobacco flavour compounds that are releasable from the at least one aerosol-forming substrate,
wherein the base layer and the at least one aerosol-forming substrate are in contact at a first contact surface, which is substantially planar.

2. The aerosol-forming cartridge of claim 1 , wherein one or both of the base layer and the at least one aerosol-forming substrate is substantially flat.

3. The aerosol-forming cartridge of claim 1 ,
wherein the base layer comprises at least one cavity, and
wherein the at least one aerosol-forming substrate is held in the at least one cavity.

4. The aerosol-forming cartridge of claim 1 , wherein the at least one aerosol-forming substrate comprises a plurality of aerosol-forming substrates disposed separately on the base layer.

5. The aerosol-forming cartridge of claim 4 ,
wherein the base layer comprises a plurality of cavities, and
wherein each of the plurality of aerosol-forming substrates is held in a cavity of the plurality of cavities.

6. The aerosol-forming cartridge of claim 1 , further comprising an electric heater including at least one heating element configured to heat the at least one aerosol-forming substrate,
wherein a second contact surface between the electric heater and one or both of the base layer and the at least one aerosol-forming substrate is substantially planar and substantially parallel to the first contact surface between the base layer and the at least one aerosol-forming substrate.

7. The aerosol-forming cartridge of claim 6 ,
wherein the at least one aerosol-forming substrate comprises a plurality of aerosol-forming substrates disposed separately on the base layer, and
wherein the electric heater comprises a plurality of heating elements each configured to heat a different one of the plurality of aerosol-forming substrates.

8. The aerosol-forming cartridge of claim 1 , further comprising an integral mouthpiece portion.

9. The aerosol-forming cartridge of claim 8 , wherein the cartridge is configured such that a resistance-to-draw at a downstream end of the mouthpiece portion is from about 50 mmWG to about 130 mmWG.

10. The aerosol-forming cartridge of claim 8 , wherein the cartridge is configured such that a resistance-to-draw at a downstream end of the mouthpiece portion is from about 95 mmWG to about 105 mmWG.

11. An electrically operated aerosol-forming system, comprising:
an aerosol-forming cartridge comprising:
a base layer, and
at least one aerosol-forming substrate disposed on the base layer and comprising a tobacco-containing material with volatile tobacco flavour compounds that are releasable from the at least one aerosol-forming substrate,
wherein the base layer and the at least one aerosol-forming substrate are in contact at a first contact surface, which is substantially planar;

an electric vaporiser configured to vaporise the at least one aerosol-forming substrate; and
an aerosol-generating device comprising:
a main body defining a slot-shaped receptacle configured to removably receive the aerosol-forming cartridge, and
an electric power supply configured to supply power to the electric vaporiser.

12. A method of manufacturing an aerosol-forming cartridge for an electrically operated aerosol-generating system, the method comprising:
providing a base layer; and
placing at least one aerosol-forming substrate on the base layer such that the base layer and the at least one aerosol-forming substrate are joined at a first contact surface, which is substantially planar,
wherein the at least one aerosol-forming substrate comprises a tobacco-containing material with volatile tobacco flavour compounds, which are released from the at least one aerosol-forming substrate upon heating.

13. The method of claim 12 , further comprising forming at least one cavity in the base layer,
wherein the placing the at least one aerosol-forming substrate on the base layer further comprises placing the at least one aerosol-forming substrate in the at least one cavity.

14. The method of claim 12 , wherein the providing the base layer comprises feeding a web of base layer foil from a bobbin to an assembly line and cutting the web of base layer foil transversely to form individual base layers.

15. The method of claim 12 , further comprising attaching an electric heater to the base layer such that the electric heater and the base layer are in contact at a second contact surface, which is substantially planar and is substantially parallel to the first contact surface between the base layer and the at least one aerosol-forming substrate.

16. The method of claim 15 , wherein the attaching the electric heater comprises feeding a web of electric heater foil from a bobbin to an assembly line and cutting the web of electric heater foil transversely to form individual electric heaters.

17. The method of claim 16 , further comprising forming a plurality of aerosol-forming cartridges in parallel,
wherein the web of electric heater foil has a width from about two times to about 50 times greater than a width of each aerosol-forming cartridge of the plurality of aerosol-forming cartridges.

18. The method of claim 16 , wherein two or more webs of foil from which the aerosol-forming cartridge is made are laminated together.

19. The method of claim 16 , wherein the web of electric heater foil comprises a web of electrically insulating substrate foil to which a plurality of heating elements is attached.

20. The method of claim 19 , further comprising forming a plurality of aerosol-forming cartridges in parallel,
wherein the web of base layer foil has a width from about two times to about 50 times greater than a width of each aerosol-forming cartridge of the plurality of aerosol-forming cartridges.

Assignees

• Philip Morris Products Sa

Inventors

• Batista Rui Nuno

Classifications

• A24F40/46

  Shape or structure of electric heating means · CPC title

• H05B2203/017

  Manufacturing methods or apparatus for heaters · CPC title

• A61M15/06

  Inhaling appliances shaped like cigars, cigarettes or pipes · CPC title

• H05B3/34 Primary

  flexible, e.g. heating nets or webs · CPC title

• A24F47/008 Primary

  Human Necessities · mapped topic