Patent Description:
Different types of aerosol generating assemblies are already known in the art. Generally, such assemblies comprise a storage portion for storing an aerosol forming precursor, which can comprise for example a liquid or a solid. A heating system is formed of one or more electrically activated resistive heating elements arranged to heat said precursor to generate the aerosol. The aerosol is released into a flow path extending between an inlet and outlet of the device. The outlet may be arranged as a mouthpiece, through which a user inhales for delivery of the aerosol.

In some aerosol generating assemblies, the precursor is stored in a removable article, also called cartridge or "pod". The aerosol generating assembly comprises then an aerosol generating device comprising an outside casing which defines a cavity in which the article may be inserted. When the article is assembled into the aerosol generating device, the article is said to be in an operation position and the device is able to generate the aerosol. When the precursor is consumed, the article may be easily removed and replaced.

These consumable articles are usually made of plastic and metallic components. They presents therefore a negative environmental impact.

<CIT> discloses a consumable unit comprising a fluid reservoir configured to operate with a cigarette product. <CIT> and <CIT> also disclose aerosol-generating devices. <CIT> discloses a method for manufacturing a body of semi-conductor ceramics.

One of the aims of the present invention is therefore to provide an aerosol generating article operating with a device to generate aerosol with a reduced environmental impact while presenting an equivalent heating efficiency.

For this purpose, the invention relates to an aerosol generating assembly according to claim <NUM>.

Indeed, using these features, the article is made from ceramic loaded with liquid aerosol forming precursor. By heating the article, aerosol is generated and is released from the semi-conductor ceramic. The aerosol flows then towards the mouthpiece and the user. Such an article presents a limited environmental impact as only the ceramic is consumable contrary to a conventional article made of plastic and metallic materials.

Ceramics have a relatively high thermal mass compared to that of metals. Therefore, it takes a large amount of energy to change the temperature due to the thermal inertia. To overcome this, the ceramic is doped with the electrically conductive agent, which may have a lower thermal mass and is also conductive. The article is then formed of homogenous material whereby the entire reservoir body has the same electrical conductive properties. In other words, the electrical conductivity remains substantially constant from the inside to the external surface of the body. Thanks to the doping, less energy is needed to reach the aimed temperature enabling the generation of the aerosol. Moreover, since the body is evenly conductive, the orientation of the article in the device to ensure electrical connection to the device becomes less important and the freedom of shaping the article is increased. Also using resistive heating keeps the device cost lower allowing a more straightforward design.

According to some embodiments, the semi-conductor ceramic is selected amongst Silicone carbide (SiC) or Molybdenum disilicide (MoSi2).

According to some embodiments, the electrically conductive agent is a doping agent selected amongst Yttrium oxide (Y203), Scandium oxide (Sc2O3), Silicium (Si), Ti2CN and combinations thereof.

According to some embodiments, the ratio between the electrically conductive agent and the ceramic in the reservoir body is comprised between <NUM>% and <NUM>% w/w doping agent.

According to some embodiments, the reservoir body is homogenous.

Thanks to these features, the reservoir body presents less electrical resistivity to heat and generate aerosol with limited electrical energy required.

According to some embodiments, the reservoir body forms at least an air through-low channel.

Thanks to these features, the generated aerosol is released from the ceramic and flows through the article towards the mouthpiece.

According to some embodiments, the reservoir body is cuboid.

According to some embodiments, the reservoir body is hexagonal.

Thanks to these features, the reservoir body presents edges and therefore presents a finite number of ways of placing the article in the corresponding heating chamber to ensure the contact between the reservoir body and the energy connection system.

According to some embodiments, the reservoir body is cylindrical.

Thanks to these features, the article may be more easily inserted in the corresponding heating chamber.

According to some embodiments, the energy connection system is formed by two electrodes arranged in the heating chamber so as to be in contact with the reservoir body on two opposite sides of the reservoir body.

According to some embodiments, said two opposite sides of the reservoir body extend along the article axis or perpendicularly to the article axis.

Thanks to these features, the electrodes make contact with the reservoir body and provide the electrical energy to heat the article and to generate aerosol.

According to some embodiments, the energy connection system is formed by an induction coil.

Thanks to these features, the energy connection system creates an electromagnetic field enabling the electrically conductive agent to generate electrical current when powered by the device and to heat the aerosol forming precursor contained in the reservoir body to produce aerosol.

According to some embodiments, the energy connection system is arranged so as to contact or face the reservoir body on an entire side of the reservoir body.

Thanks to these features, the contact area between the reservoir body and the energy connection system is increased and thus more heat may be provided to the article.

According to some embodiments, the assembly comprising a mouthpiece, the airflow channel being able to guide the generated aerosol released from the semi-conductor ceramic towards the mouthpiece.

According to some embodiments, the reservoir body defines with the heating chamber a gap forming a secondary airflow path, the secondary airflow path being able to guide the generated aerosol released from the semi-conductor ceramic towards the mouthpiece.

Thanks to these features, the secondary airflow path guides the generated aerosol released from the semi-conductor ceramic towards the mouthpiece. When the reservoir body is heated through the energy connection system, the generated aerosol may flow through both the airflow channel and through the gap.

In the context of the present invention, as defined in claim <NUM> (assembly), there is also disclosed an aerosol generating article extending along an article axis and configured to operate with an aerosol generating device; the article comprising a reservoir body being formed of a block of semi-conductor ceramic, in particular Silicone carbide (SiC) ; the semi-conductor ceramic being porous and able to retain a liquid aerosol forming precursor and to release the produced aerosol; the reservoir body being configured to conduct or generate electrical current when powered by the device and to heat the aerosol forming precursor contained in the reservoir body to produce aerosol.

The invention and its advantages will be better understood upon reading the following description, which is given solely by way of non-limiting examples and which is made with reference to the appended drawings, in which:.

As used herein, the term "aerosol generating device" or "device" may include a vaping device to deliver an aerosol to a user, including an aerosol for vaping, by means of a heater element explained in further detail below. The device may be portable. "Portable" may refer to the device being for use when held by a user. The device may be adapted to generate a variable amount of aerosol, e.g. by activating the heater element for a variable amount of time (as opposed to a metered dose of aerosol), which can be controlled by a trigger. The trigger may be user activated, such as a vaping button and/or inhalation sensor. The inhalation sensor may be sensitive to the strength of inhalation as well as the duration of inhalation to enable a variable amount of vapour to be provided (so as to mimic the effect of smoking a conventional combustible smoking article such as a cigarette, cigar or pipe, etc.). The device may include a temperature regulation control to drive the temperature of the heater and/or the heated aerosol generating substance (aerosol pre-cursor) to a specified target temperature and thereafter to maintain the temperature at the target temperature that enables efficient generation of aerosol.

As used herein, the term "aerosol" may include a suspension of vaporizable material as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. Aerosol herein may generally refer to/include a vapour. Aerosol may include one or more components of the vaporizable material.

As used herein, the term "vaporizable material" or "precursor" may refer to a smokable material which may for example comprise nicotine or tobacco and an aerosol former. Tobacco may take the form of various materials such as shredded tobacco, granulated tobacco, tobacco leaf and/or reconstituted tobacco. Suitable aerosol formers include: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, acids such as lactic acid, glycerol derivatives, esters such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin or vegetable glycerin. In some embodiments, the aerosol generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate may also comprise at least one of a gelling agent, a binding agent, a stabilizing agent, and a humectant.

<FIG> and <FIG> show an aerosol generating assembly <NUM> comprising an aerosol generating device <NUM>, called hereinafter device <NUM>, and an aerosol generating article <NUM>, called hereinafter article <NUM>. The device <NUM> and the article <NUM> are shown in <FIG> away from each other. In <FIG>, the device <NUM> is operating with the article <NUM> to generate aerosol.

The device <NUM> comprises a device body extending along a device axis Y. The device body comprises a mouthpiece <NUM> and a housing <NUM> arranged successively along the device axis Y. According to the example of <FIG>, the mouthpiece <NUM> and the housing <NUM> are cooperating together through a pivot connection <NUM>. Particularly, the mouthpiece <NUM> is here designed to switch from an open configuration, shown in <FIG>, to a closed configuration in which the mouthpiece <NUM> is fixed on or received in an insertion opening formed at one of the ends of the housing <NUM>, as shown in <FIG>. In this case, the article <NUM> may be inserted inside the device <NUM> when the mouthpiece <NUM> is in the open configuration. According to another example (not-shown), the mouthpiece <NUM> and the housing <NUM> form two different pieces. According to another example (not-shown), the mouthpiece <NUM> and the housing <NUM> form one unique piece.

The mouthpiece <NUM> delimits a flow outlet (not-shown) through which the generated aerosol flows towards the user when puffing.

The housing <NUM> delimits an internal space of the device <NUM> receiving various elements designed to carry out different functionalities of the device <NUM>. This internal space can for example receive a power supply <NUM>, as a battery, for powering the device <NUM>, a control module for controlling the operation of the device <NUM>, a heating chamber <NUM> for heating the article <NUM>, etc. Among these elements, only the heating chamber <NUM> will be explained in further detail below.

The article <NUM> is configured to conduct or generate electrical current when the article <NUM> is inserted in the heating chamber <NUM> in order to produce aerosol, as it will be explained below. In reference to <FIG>, the article <NUM> extends along an article axis X. The article <NUM> comprises a reservoir body <NUM>. As shown in <FIG>, the reservoir body <NUM> is here cuboid. The reservoir body <NUM> presents then four edges <NUM> and four identical side surfaces which provide a finite number of ways of placing the article <NUM> in the heating chamber <NUM> and therefore ensure a good contact as it will be explained below. In a variant (not shown), the reservoir body <NUM> is hexagonal. The reservoir body <NUM> presents then six edges <NUM> and six identical surfaces.

At least an air through-flow channel <NUM> is arranged in the reservoir body <NUM>. The air through-flow channel <NUM> extends along the article axis X. The air through-flow channel <NUM> extends between the two opposite faces of the reservoir body <NUM> along the article axis X. The air through-flow channel <NUM> presents here a cylindrical shape but may present another shape, as a parallelepiped shape for example. As it will be explained below, the air through-flow channel <NUM> is able to guide the generated aerosol released from the reservoir body <NUM> towards the mouthpiece <NUM>.

The reservoir body <NUM> is formed of a block of semi-conductor ceramic doped with at least an electrically conductive agent. The ceramic is in particular a technical ceramic, which is an inorganic, non-metallic material and which is at least partially crystalline. The ceramic is a semi-conductor meaning that it is a solid material presenting a conductivity between that of an insulator and that of most metals. Its resistivity falls as its temperature rises. Its conducting properties may be altered by introducing impurities, also called "doping", into the crystal structure. In particular, the ceramic is here coupled with other materials which have a lower thermal mass and are also conductive. In other words, the semi-conductor ceramics are already conductive, although very week, and the addition of the doping agent increases the conductivity of the reservoir body <NUM>. Therefore, the reservoir body <NUM> is here conductive thanks to the doping with the electrically conductive agent. The semi-conductor ceramic is selected amongst silicone carbide (SiC) or molybdenum disilicide (MoSi2). The electrically conductive agent is configured to conduct or generate electrical current and to heat the aerosol forming precursor present in the semi-conductor ceramic to produce the aerosol. The electrically conductive agent is a doping agent selected amongst Yttrium oxide (Y2O3), Scandium oxide (Sc2O3), Silicium (Si) or Ti2CN. The density ratio of between the electrically conductive agent and the ceramic in the reservoir body <NUM> is comprised between <NUM>% and <NUM>% w/w. When the semi-conductor ceramic is made of silicon carbide, which presents better conductive proprieties than other ceramics, there is no need of a great amount of electrically conductive agent to obtain a global electrical conductivity enough to enable the generating of aerosol as explained below.

Advantageously, the doping of the ceramic leads to substantially homogenous conductive properties. In other words, the reservoir body <NUM> presents advantageously substantially the same electrical resistivity properties at each point.

The semi-conductor ceramic is porous. The semi-conductor ceramic is able to retain a liquid aerosol forming precursor as defined above. In other words, the semi-conductor ceramic is loaded with the liquid aerosol forming precursor which remains captive essentially by capillarity effect in the pores of the ceramic. The semi-conductor is further able to release the produced aerosol when the article <NUM> is heated by the device <NUM>. In particular, when the liquid aerosol forming precursor is transformed in an aerosol vapour, the vapour is no more captive of the pores and flows out of the reservoir body <NUM> and notably flows in the air through-flow channel <NUM>, towards the mouthpiece <NUM>.

Referring again to <FIG>, the heating chamber <NUM> forms a cup shape adapted to receive the article <NUM>. The heating chamber <NUM> forms here a cuboid shape extending along the device axis Y, complementary of the shape of the article <NUM>. The heating chamber <NUM> is configured to receive the article <NUM> so that the device axis Y and the article axis X are parallel or aligned. The heating chamber <NUM> then comprises four lateral faces <NUM> extending along the device axis Y and two transversal faces <NUM> extending perpendicular to the device axis Y.

The device <NUM> further comprises an energy connection system <NUM> arranged in the heating chamber <NUM>. The power supply <NUM> is configured to power the energy connection system <NUM> to produce aerosol in the article <NUM>. Referring to <FIG> and <FIG>, the energy connection system <NUM> is here formed by two electrodes arranged in the heating chamber <NUM> so as contact the reservoir body <NUM> on two opposite sides of the reservoir body <NUM> transversally to the article axis X. In particular, the two electrodes are arranged on two opposite lateral faces <NUM> of the heating chamber <NUM>. In this example, the power supply <NUM> is configured to provide an electrical current to the electrically conductive agent through the electrodes. The electrically conductive agent is then configured to conduct this electrical current and to heat the aerosol forming precursor contained in the reservoir body <NUM> to produce aerosol.

In an advantageous embodiment, not shown, the energy connection system <NUM> is arranged so as to contact the reservoir body <NUM> on the entire height of the reservoir body <NUM> along the article axis X, in order to increase the contact between the reservoir body <NUM> and the energy connection system <NUM> and thus provide more heat to the article <NUM>. In this case, each electrode extends along the entire height of the associated lateral face <NUM> along the device axis Y.

The operation of the aerosol generating assembly <NUM> will now be described. Initially, it is considered that the article <NUM> is extracted from the device <NUM>, as shown on <FIG>. In order to insert it, the user first opens the heating chamber <NUM> by pivoting the mouthpiece <NUM> around the pivot connection <NUM>.

Then, the user inserts the article <NUM> into the heating chamber <NUM> and the user closes the heating chamber by fixing the mouthpiece <NUM> on the housing <NUM>, as shown on <FIG>.

The reservoir body <NUM> of the article <NUM> is then in contact with the energy connection system <NUM> of the device <NUM>.

Then, the user may activate the operation of the aerosol generating assembly <NUM> by actuating for example an ON button or by performing a puff.

This initiates the providing of electrical current from the power supply <NUM> to the energy connection system <NUM>. The reservoir body <NUM>, and in particular, the electrically conductive agent receives the electrical current. Consequently, the reservoir body <NUM> is heating until reaching a sufficiently high temperature to aerosolize aerosol forming precursor present in the semi-conductor ceramic and to produce the aerosol.

The produced aerosol is released from the semi-conductor ceramic and flows in the air through-flow channel <NUM>, arranged between the two opposite transversal faces <NUM>, towards the mouthpiece <NUM>.

Finally, the aerosol is sucked through the mouthpiece <NUM> and inhaled by the user.

The manufacturing of the article <NUM> will now be described.

First, the semi-conductor ceramic is provided as a powder.

The electrically conductive agent is also provided as a powder.

The powders of ceramic and doping agents are milled in the solvent to help with the mixing. The solvent is in particular ethanol.

The mixture is then sintered in order to compact it and to form a solid mass of material by heat and/or pressure. The reservoir body <NUM> is thus formed.

Finally, liquid aerosol forming precursor is added in the porous reservoir body <NUM>.

<FIG> and <FIG> show an aerosol generating assembly <NUM> according to a second embodiment of the invention.

The aerosol generating assembly <NUM> according to the second embodiment is similar to the aerosol generating assembly <NUM> according to the first embodiment explained above except the features described below.

As visible on <FIG> and <FIG>, the energy connection system <NUM> is here formed by two electrodes arranged in the heating chamber <NUM> so as contact the reservoir body <NUM> on two opposite ends of the reservoir body <NUM> along the article axis X. In particular, the two electrical electrodes are arranged on the two opposite transversal faces <NUM> of the heating chamber <NUM>.

In an advantageous embodiment, not shown, the energy connection system <NUM> is arranged so as to contact the reservoir body <NUM> on the entire width of the reservoir body <NUM> perpendicularly to the article axis X.

In this embodiment, the way of placing the article <NUM> in the heating chamber <NUM> has no influence on the contact between the reservoir body <NUM> and the electrical electrodes. The reservoir body <NUM> may be therefore cuboid, hexagonal or cylindrical. Thus, the reservoir body can be oriented in different manners such as by rotating it by <NUM> degrees around a median axis perpendicular to chamber's axis Y or it can be rotated incrementally about axis Y.

Advantageously, the reservoir body <NUM> defines with the heating chamber <NUM> a gap <NUM> forming a secondary airflow path. In particular, the reservoir body <NUM> presents a transversal section smaller than the transversal section of the heating chamber <NUM>. Therefore, the gap <NUM> is formed between the external surface of the reservoir body <NUM> and the inner surface of the heating chamber <NUM>. The secondary airflow path is able to guide the generated aerosol released from the semi-conductor ceramic towards the mouthpiece <NUM>.

In this embodiment, when the reservoir body <NUM> is heated through the energy connection system <NUM>, the generated aerosol flows through both the air through-flow channel <NUM> and through the gap <NUM>.

Other embodiments of the energy connection system <NUM> are possible.

In particular, the energy connection system <NUM> may be formed by four electrodes arranged on each of the lateral faces <NUM> of the heating chamber <NUM>.

In a variant, the energy connection system <NUM> may be formed by six electrodes arranged on each of the faces <NUM>, <NUM> of the heating chamber <NUM>.

In another variant, the energy connection system <NUM> may formed by an induction coil arranged inside the heating chamber <NUM>. The power supply <NUM> is configured to power the inductive coil which generates then an electromagnetic field. The electrically conductive agent is then configured to generate electrical current when powered by the inductive coil and to heat the aerosol forming precursor contained in the reservoir body <NUM> to produce aerosol.

Claim 1:
An aerosol generating assembly (<NUM>) comprising:
- an aerosol generating article (<NUM>) extending along an article axis (X) and configured to operate with an aerosol generating device (<NUM>);
the article (<NUM>) consisting of a reservoir body (<NUM>) formed of a block of semi-conductor ceramic doped with at least an electrically conductive agent;
the semi-conductor ceramic being porous and able to retain a liquid aerosol forming precursor and to release the produced aerosol;
the electrically conductive agent being configured to conduct or generate electrical current when powered by the device (<NUM>) and to heat the aerosol forming precursor contained in the reservoir body (<NUM>) to produce aerosol; and
- an aerosol generating device (<NUM>), the device (<NUM>) comprising a heating chamber (<NUM>) able to receive the article (<NUM>), the device (<NUM>) further comprising a power supply (<NUM>) and an energy connection system (<NUM>) arranged in the heating chamber (<NUM>), the power supply (<NUM>) being configured to power the energy connection system (<NUM>) to produce aerosol by the article (<NUM>).