CONSUMABLE WITH A DIVIDED RESERVOIR FOR A LIQUID AEROSOL-FORMING SUBSTRATE

Abstract

 Consumable (1) for use in an electrically heated aerosol-generating device (100), the consumable comprising: an aerosol outlet path (10); a reservoir (15) comprising a liquid aerosol-forming substrate; and a heating element (50); wherein the reservoir has an upper domain (20) and a lower domain (30), the upper domain and the lower domain being in fluid connection with each other, wherein the upper domain is divided into a first part (21) and a second part (22) arranged on two opposing sides of the aerosol outlet path such that the two parts are not in direct fluid connection within the upper domain, wherein the aerosol-forming substrate comprised by the lower domain is in fluid connection with the heating element.

Description

Technical field

[0001] The present invention relates to a consumable for use in an electrically heated aerosol-generating device. In particular, the present invention relates to a consumable that comprises a reservoir with a liquid aerosol-forming substrate that is electrically heated to generate an aerosol to be inhaled by a user. The liquid aerosol-forming substrate is electrically heated by a heating element of electrically conductive material, comprised by the consumable. The invention further relates to an aerosol-generating system comprising such a consumable and an aerosol-generating device.

Technical background

[0002] Aerosol-generating devices, such as Electronic-cigarettes (E-cigarettes) or Electronic Nicotine Delivery Systems (ENDS), have become a popular alternative to traditional tobacco combustible products, such as roll-your-own/make-your-own tobacco and ready-made cigarettes. Different types of aerosol-generating devices are presently on the market, which evaporate or vaporize a liquid (known as e-liquid) contained in a reservoir, wherein the liquid may or may not comprises nicotine to generate an aerosol to be inhaled by a user. These liquid-based aerosol-generating devices are convenient for users seeking an instant generation of an inhalable aerosol.

[0003] Among liquid-based aerosol-generating devices some work with a consumable article, a cartridge or a capsule, which is received in the device. The consumable article is typically equipped with a reservoir for the liquid, and a heating element. During usage, e.g. when a user draws on a mouthpiece of the device, liquid is guided from the reservoir towards the heating element, to generate an inhalable aerosol. The heating element could be heated for instance using a coil. Typically, a wick is applied to convey liquid from the reservoir to the heating element.

[0004] The liquids stored in the consumable article are often made from a mixture of propylene glycol (PG), vegetable glycerin (VG), flavorings and/or nicotine.

[0005] Alternatively, vaporizable nicotine containing liquids may be derived directly from tobacco materials, and are known as tobacco liquids, or T-liquids. Such T-liquids may still comprise PG and VG, and tobacco material or particles within the liquid solution. The nicotine present in the liquid then essentially originates from natural tobacco materials.

[0006] T-liquids poses several challenges compared to e-liquids. In particular, the tobacco particles comprised within the liquid adversely affects traditional wicking of the liquid towards a heating element to produce aerosols to be inhaled. In particular, the wick can quickly become clogged by the tobacco. Likewise, solid material build-up occurs on the surface of heater elements upon vaporization of T-liquids due to the solid tobacco material contents of the T-liquids, which significantly affects heating efficiency of the heating elements over time, often requiring regular cleaning or replacement thereof. Thus, traditional e-liquid flow management and vaporization methods are not effective for generating an aerosol from T-liquids.

[0007] Further challenges associated with vaporization of T-liquids are the increased or high viscosity of the liquid due to the solid tobacco content. Accordingly, the liquid may become stuck, which adversely affects usage of the consumable. This calls for improvements of the fluid flow or fluid management of the liquid within a consumable article comprising a T-liquid.

[0008] Therefore, there is a need to improve the structure of tobacco liquid containing consumable articles in order to cope with the challenges posed. In particular, improving the liquid flow bears the potential to further improve usage of the liquid in the consumable article, since less unused liquid may remain.

[0009] Against this background, an object of the present invention is to address one or more or all of the above-mentioned challenges. Particularly, it is an object of the present invention to provide an improved tobacco liquid containing consumable for use in an electrically heated aerosol-generating device. For example, it is an object to provide a consumable which allows for an improved fluid flow or fluid management of a tobacco liquid aerosol-generating substrate within an aerosol-generating consumable. Heating of such tobacco-liquid should be improved to provide an aerosol. Further, clogging of the consumable should be reduced. The distance travelled by the liquid aerosol-generating substrate should be reduced to further reduce clogging. Further, vaporizing should be expedited. It is generally an object to provide a consumable that comprises a reservoir having a structure such that usage of the liquid aerosol-generating substrate is increased.

[0010] These and other objects, which become apparent from the following description, are solved by the subject-matter of the independent claims. Preferred embodiments are subject of the dependent claims, and the skilled person finds hints for other suitable embodiments of the present invention throughout the disclosure of the present application.

Summary of the invention

General aspects of the consumable

[0011] A 1st embodiment of the invention is directed to a consumable for use in an electrically heated aerosol-generating device, the consumable comprising: an aerosol outlet path; a reservoir comprising a liquid aerosol-forming substrate; and a heating element; wherein the reservoir has an upper domain and a lower domain, the upper domain and the lower domain being in fluid connection with each other, wherein the upper domain is divided into a first part and a second part arranged on two opposing sides of the aerosol outlet path such that the two parts are not in direct fluid connection within the upper domain, wherein the aerosol-forming substrate comprised by the lower domain is in fluid connection with the heating element.

[0012] A consumable may be understood as an article or cartridge and may be a composable component to be used in an electrically heated aerosol-generating device. Such an aerosol-generating device may provide for electrically heating the liquid aerosol-forming substrate, to generate an aerosol. As an example, the aerosol-generating device could be heated by induction (inductive) or by resistance (resistive) heating. The consumable may be disposable. In this case it may generally produced in larger numbers than the aerosol-generating devices in which it is received. Therefore, reducing the cost of the consumable may entail significant savings for the manufacturer and the consumer.

[0013] The consumable comprises an aerosol outlet path, which may be understood as a path for guiding the aerosol from an inner portion of the consumable to an outer portion. For instance, the aerosol may be guided to a mouth end of the consumable, such that the user can conveniently inhale the aerosol. As an example, the outlet path may have a cylindrical shape such that the surface to volume ratio is improved so that the generated aerosol may not condense on the aerosol outlet path's wall. The aerosol outlet path may also be understood as a chimney.

[0014] The consumable also comprises a reservoir comprising a liquid aerosol-forming substrate. A reservoir may be understood as a cavity, a storage room or an enclosed space, which may serve for holding the liquid aerosol-forming substrate. The reservoir needs to have means, such as an opening, which allow the liquid aerosol-forming substrate to be released from the reservoir. Before the consumable is used by a user, the reservoir is filled with the liquid aerosol-forming substrate. During ordinary use, the liquid aerosol-forming substrate is guided through the aerosol outlet path after an aerosol has been generated. Gradually, the extent to which the reservoir is filled with the liquid aerosol-forming substrate is reduced.

[0015] The liquid aerosol-forming substrate may comprise propylene glycol (PG), vegetable glycerin (VG) and/or tobacco. The tobacco may be provided in particulate form, such as ground, mixed or other processing technology to provide small dispersible particles. The tobacco may be suspended within the solution with PG and VG. Tobacco comprises nicotine. The nicotine comprised in the tobacco may dissolve into the solution, thereby forming a tobacco-liquid (T-liquid). Indeed, the liquid aerosol-forming substrate is preferably a T-liquid..

[0016] The consumable further comprises a heating element. The heating element is capable of being heated. For instance, the heating element could be heated by resistive or by inductive heating methods. Inductive heating methods provide the advantage that no wires are required that contact the heating element. Therefore, the consumable may be easily received in an aerosol-generating device without the need of extensive electrical connections. The liquid aerosol-forming substrate may be guided from the reservoir to a proximity of the heating element. Preferably, a large extent of the liquid aerosol-forming substrate will already be vaporized at this point by the heat transferred from the heating element to the liquid aerosol-forming substrate. Thereby, clogging of the path of the liquid aerosol-forming substrate to the aerosol outlet path is reduced as compared to when a large part of the liquid aerosol-forming substrate is still in a liquid fluid state when it contacts the heating element. The heating element may have holes such that the liquid aerosol-forming substrate and/or the generated aerosol can easily pass through it to enter the aerosol outlet path.

[0017] Vaporizing the liquid aerosol-forming substrate may be understood as generating an aerosol from the liquid aerosol-forming substrate. The aerosol may be inhaled by a user. When generating the aerosol from the liquid aerosol-forming substrate, the liquid fluid will change its physical state to the gaseous fluid state.

[0018] The reservoir has an upper domain and a lower domain, the upper domain and the lower domain being in fluid connection with each other. A domain may be understood as an individual space, or a space that could be recognized as being different from another space, e.g. another domain. The upper domain and the lower domain may be in fluid connection, allowing fluid to be exchanged. For instance, the domains may have an opening in the form of an annular ring, through which the liquid aerosol-forming substrate can pass. The presence of the upper and the lower domain may have the advantage that both domains can be provided with a specific geometric shape that suits the needs of and improves the fluid management, i.e. guidance of the liquid aerosol-forming substrate. For instance, the lower domain may be shaped such that it contacts the heating element to a large extent, such that heating of the liquid aerosol-generating substrate is facilitated and/or improved. The upper domain does not necessarily have to be in close proximity of the heating element, but may be shaped to improve and/or increase a storage capacity of the liquid aerosol-forming substrate.

[0019] The term "upper" may be understood such that the upper domain of the reservoir is closer to a mouth end of the consumable. The term "lower" may be understood such that the lower domain of the reservoir may be arranged further away from the mouth end than the upper domain. The upper and the lower domain maybe adjacent to each another. The upper domain may follow a mouth end of the consumable, and the lower domain may follow the upper domain with respect to a longitudinal direction of the consumable. When the consumable is received in an aerosol-generating device and the device stands on a ground, the longitudinal direction of the consumable may be in parallel to the axis perpendicular to the ground, e.g. in the direction of gravity. Therefore, the upper domain could be said to be arranged vertically above the lower domain.

[0020] Preferably, there is no sealing between the upper domain and the lower domain of the reservoir, not even before the consumable is used for the first time. Such a sealing may not be necessary since a fluid connection should be provided. The absence of a sealing may have the advantage that less structural components are required.

[0021] The upper domain is divided into a first part and a second part arranged on two opposing sides of the aerosol outlet path such that the two parts are not in direct fluid connection within the upper domain. However, it may be possible to provide for an indirect fluid connection, wherein the liquid aerosol-forming substrate is guided from the first part of the upper domain into the lower domain and then into the second part of the upper domain. The upper domain may also be divided in more than a first and a second part.

[0022] The division into a first and a second part provides the advantage that the flow of the liquid aerosol-forming substrate may be improved. For instance, less friction may occur on internal walls of the upper domain of the reservoir.

[0023] By way of example, the aerosol outlet path may be surrounded by the upper domain of the reservoir, wherein there is a wall formed between the aerosol outlet path and the reservoir. Due to the extension of the outlet path, this wall of the upper domain of the reservoir may come close to the opposing internal surface of the upper domain of the reservoir, e.g. if the width of the device is not much greater than the diameter of the aerosol outlet path. This may lead to a portion of the liquid aerosol-forming substrate getting stuck between the walls. As an example, friction may be increased. For instance, a boundary layer may be developed on the internal surfaces of the upper domain of the reservoir. The boundary layer may adversely affect fluid flow from the upper domain to the lower domain. This is particularly true if the liquid aerosol-forming substrate has a high viscosity, for instance if the liquid aerosol-forming substrate has a viscosity greater than water. For example, the viscosity of the liquid aerosol-forming substrate can be comprised between 0.05 N·s/m2 (Newton-seconds per square meter) and 10 N·s/m2. The inventors found that removing the portion of the upper domain of the reservoir where the inner surfaces come close to each other by a separation of the upper domain in a first and a second part reduces the development of boundary layers. Thereby, most of the liquid aerosol-forming substrate may be consumed and less liquid aerosol-forming substrate may be wasted. Less liquid aerosol-forming substrate may be left unused and/or stuck on internal surfaces of the upper domain of the reservoir.

[0024] By the separation of the upper domain of the reservoir into a first part and a second part of the upper domain of the reservoir, a cross section of the upper domain will have a non-annular shape. In one example, the upper domain is divided into a first part and a second part by one or more walls.

[0025] The aerosol-forming substrate comprised by the lower domain is in fluid connection with the heating element. This may improve heating of the liquid the aerosol-forming substrate. Preferably the heating element has a large surface area. This further improves heating the liquid aerosol-forming substrate. As an example, the heating element may have a cylindrical shape.

The consumable's, reservoir's and outlet path's shape

[0026] According to a 2nd embodiment, in the preceding embodiment, the aerosol outlet path extends from a position inside a housing of the consumable, preferably in proximity of the heating element, to a mouth end of the consumable, and is preferably arranged along the longitudinal axis of the consumable.

[0027] The aerosol outlet path provides for a fluid connection from inside a housing of the consumable to the environment. The aerosol outlet path may extend from the heating element to the outside of the consumable. Exemplarily, the outlet path forms at the end which leads to the environment a mouth end to be received by a user. This mouth end may also be referred to as the mouth end of the consumable. Provision of such an aerosol outlet path facilitates inhaling of the generated aerosol.

[0028] According to a 3rd embodiment, in any one of the preceding embodiments, the upper domain of the reservoir radially encloses the aerosol outlet path.

[0029] Radially enclosing the aerosol outlet path is to be understood as the upper domain substantially covering or is being placed around an overall circular surrounding of the aerosol outlet path. This may save space, thus providing for a compact arrangement of the consumable. It is also possible that the heated aerosol passing the aerosol outlet path beneficially heats up the liquid aerosol-forming substrate located within the upper domain of the reservoir. This may improve fluid flow, since an increased temperature of the liquid aerosol-forming substrate may reduce the viscosity and thereby may reduce its friction. Further, the development of boundary layers may be reduced. It may also be possible that an inner surface of the upper domain of the reservoir is radially adjacent to a substantially cylindrical surface forming the outer surface of the aerosol outlet path of the consumable.

[0030] According to a 4th embodiment, in any one of the preceding embodiments, the upper domain extends over at least 10%, preferably at least 30%, more preferably at least 50%, most preferably at least 60% of the length of the reservoir, and/or wherein the upper domain extends over at most 80%, preferably at most 70%, more preferably at most 60% of the length of the reservoir, wherein the length of the reservoir is measured substantially in parallel to the aerosol outlet path.

[0031] According to a 5th embodiment, in any one of the preceding embodiments, a cross section of the consumable in proximity to a mouth end of the consumable and perpendicular to the longitudinal axis of the aerosol outlet path has an elongate shape, such as an elliptical or rectangular shape.

[0032] An elongate shape is to be understood as a shape which has one two dimensions that are perpendicular to each other, wherein one dimension is larger than the other dimension. An elongate shape typically has one elongate axis, wherein the larger of the two dimensions is aligned with the elongate axis. Such a shape provides the advantage that the width of the device does not have to be much greater than the diameter of the outlet path, even if the upper domain of the reservoir radially encloses the aerosol outlet path. This is because the upper domain in this case still provides sufficient storage space to the left and to the right of the outlet path. The left and the right of the outlet path may be the first and the second part into which the upper domain is divided.

[0033] According to a 6th embodiment, in the preceding embodiment, the elongate shape has a largest dimension and a smallest dimension, wherein the largest dimension is larger than the smallest dimension by a factor of at least 1.0, preferably at least 1.4, more preferably at least 1.6, even more preferably at least 2.0, most preferably by a factor of at least 2.4.

[0034] As an example, a factor of 1.4 is to be understood such that the larger dimension is 1.4 times as large as the smallest dimension. An optimal balance should be struck between providing sufficient storage capacity of the upper domain and reducing the length of the device to a size acceptable for the user.

[0035] According to a 7th embodiment, in any one of the preceding embodiments, a smallest dimension of a cross section of the consumable in proximity of a mouth end of the consumable and perpendicular to the longitudinal axis of the aerosol outlet path is larger than an inner or an outer diameter of the aerosol outlet path in the same plane as the cross section of the consumable in proximity of a mouth end by a factor of at least 1.0, preferably at least 1.1, more preferably at least 1.2, even more preferably at least 1.3, further more preferably at least 1.4, most preferably by a factor of at least 1.5, and/or by a factor of at most 2.0, preferably at most 1.9, more preferably at most 1.8, even more preferably at most 1.7, further more preferably at most 1.6, most preferably by a factor of at most 1.5.

[0036] The proximity to the mouth end should be understood such that the cross section is closer to the mouth end than to the opposing end, or that the cross section is substantially at the mouth end within a range of about between 1% to 10% of the overall length of the consumable. The described smallest dimension should be larger than an inner or an outer diameter of the aerosol outlet path. The inner diameter of the aerosol outlet path represents the diameter of the inner surface of the wall. The outer diameter corresponds to the inner diameter and two times the wall thickness of the aerosol outlet path. The smallest dimension should be larger than an inner or an outer diameter of the aerosol outlet path up to a certain factor. The factor should not be too large, otherwise the device would not be flat enough for user acceptance.

[0037] According to an 8th embodiment, in any one of the preceding embodiments, the lower domain is divided into a first lower domain part and a second lower domain part.

[0038] With this embodiment, the lower domain may be divided similarly as the upper domain. This may be advantageous to further improve fluid flow management. Further, it may particularly advantageous if, for instance, the upper and lower domain have a similar cross section, or substantially the same cross section. For instance, the upper domain and the lower domain may have an annular cross section.

Air chambers

[0039] According to a 9th embodiment, in any one of the preceding embodiments, the consumable comprises one or more air chambers, preferably two air chambers, located between the first part and the second part of the upper domain.

[0040] An air chamber maybe understood as a substantially closed space in which air can be stored or located. The air chambers may also be referred to as air pockets. The air may beneficially increase a thermal insulation of the heated parts against a housing of the consumable. The air chambers are located between the first and the second part of the upper domain. The portions between the first and the second part of the upper domain may be characterized by a small distance between the heated aerosol and the outer side of the consumable. Therefore, it is beneficial to apply air chambers in these portions, which improves and increases thermal insulation.

[0041] According to a 10th embodiment, in the preceding embodiment, the one or more air chambers have one or more upper openings configured to allow air to enter the first part and/or the second part of the upper domain of the reservoir at an upper end of the upper domain, wherein the upper end of the upper domain is located on a mouth end side of the consumable.

[0042] The one or more upper openings are understood as holes or protrusions that establish a fluid connection between the first part of the upper domain and the one or more air chambers and/or a fluid connection between the second part of the upper domain and the one or more air chambers. Preferably, there are two air chambers, and each air chamber may have two upper openings, wherein one upper opening provides for a fluid connection with the first part of the upper domain and the other upper opening provides for a fluid connection with the second part of the upper domain. The one or more upper openings may allow a fluid such as air to enter the first and/or second part. It may be beneficial that the air entering the first and/or second part enters the first and/or second part at an uppermost portion within the first/second part. Air entering the first and/or second part advantageously ensures a pressure balance. During ordinary use, air may enter from an uppermost side of the upper domain, which facilitates fluid movement of the liquid aerosol-forming substrate. For instance, during depletion of the liquid aerosol-forming substrate in the upper domain, a pressure may be reduced therein, which hinders fluid movement to the lower domain. Compensating the pressure loss by way of the one or more upper openings improves the flow in the consumable.

[0043] According to an 11th embodiment, in any one of the 9th or 10th embodiments, the one or more air chambers have one or more lower openings configured to allow ambient air to enter the one or more air chambers, wherein the one or more lower openings are preferably located at a lower end of the one or more air chambers, wherein the lower end of the one or more air chambers is located away from the mouth end side of the consumable.

[0044] This embodiment allows a pressure balance during ordinary use. For instance, ambient or external air may be guided into the one or more air chambers and then into the first and/or second part of the upper domain. The lower openings may be located at a lower end of the one or more air chambers. This may improve the flow of the air through the longitudinal extension of the one or more air chambers. Thereby, cooling of a housing of the consumable may be improved.

[0045] According to a 12th embodiment, in any one of the 9th to 11th embodiments, the one or more air chambers extend along the length of the upper domain of the reservoir or along the length of the upper domain and the lower domain of the reservoir in parallel to the aerosol outlet path, such that they thermally insulate an outer housing of the consumable from the aerosol outlet path.

[0046] The extension of the one or more air chambers along the length of the upper domain may be understood as the one or more air chambers having substantially the same length as the upper domain. The extension is in a direction parallel to the aerosol outlet path, which may be parallel to the longitudinal axis of the consumable. This improves cooling of a housing of the consumable. It may also be possible that the one or more air chambers extend along the length of the upper and the lower domain. Thereby, external air may be guided in proximity to and outside to the heating element. This further improves cooling and reducing a temperature of the consumable's housing. This may also increase the energy efficiency.

[0047] According to a 13th embodiment, in any one of the 9th to 12th embodiments, the one or more air chambers comprise one or more fins which fill at least 20%, preferably at least 40%, more preferably at least 60%, most preferably at least 70% of a cross section of the one or more air chambers, and/or which fill at most 98%, preferably at most 90%, more preferably at most 85%, most preferably at most 80% of a cross section of the one or more air chambers.

[0048] A fin may also be understood as a rib. It may be regarded as a structural part that occupies the otherwise air-filled space of the one or more air chambers. The one or more fins fill a cross section to a certain extent. The cross section may be perpendicular to the longitudinal axis of the aerosol outlet path. The one or more fins should not fill the cross section completely. They should fill an optimal amount of the cross section of the one or more air chambers to improve blockage of the liquid aerosol-forming substrate, which may undesirably enter the one or more air chambers through the one or more upper openings. The one or more fins prevent such a liquid aerosol-forming substrate from accidentally entering the one or more air chambers and from advancing further within the one or more air chambers.

[0049] According to a 14th embodiment, in the preceding embodiment, the one or more fins are arranged circumferentially and in an alternating manner on two opposing sides of the one or more air chambers.

[0050] The circumferential arrangement of the fins prevents that liquid aerosol-forming substrate that has undesirably entered the one or more air chambers advances further within the one or more air chambers. The one or more fins are arranged in an alternating manner. This may be understood as a labyrinth sealing. In this manner, the sealing may be established in a cost-efficient manner.

General sizes/flow directions

[0051] According to a 15th embodiment, in any one of the preceding embodiments, the upper domain of the reservoir comprises at least 60%, preferably at least 70%, more preferably at least 80%, most preferably at least 85% of the overall volume of the reservoir and/or wherein the upper domain of the reservoir comprises at most 95%, preferably at most 90%, more preferably at most 85% of the overall volume of the reservoir.

[0052] The volume of the upper domain of the reservoir should be larger than the volume of the lower domain, to increase the volume to surface ratio to further promote fluid flow. However, the relative volume of the upper domain of the reservoir may not be increased too much, because otherwise the volume of the lower domain may become too small. This may adversely affect heating the liquid aerosol-forming substrate. Further, the liquid aerosol-forming substrate comprised by the lower domain should be in fluid connection with the heating element over a large area to facilitate heating and/or generating an aerosol.

[0053] According to a 16th embodiment, in any one of the preceding embodiments, the consumable is configured such that during ordinary use, the aerosol-forming substrate is guided from the first part and/or the second part of the upper domain of the reservoir to the lower domain of the reservoir and through the heating element, thereby generating an aerosol, to be inhaled by a user through the aerosol outlet path.

[0054] During ordinary use, the liquid aerosol-forming substrate is guided or drawn from the first part and/or the second part of the upper domain to the lower domain, as long as liquid aerosol-forming substrate is left in the upper domain. The liquid aerosol-forming substrate is subsequently guided through the heating element. For instance, there may be holes in the heating element to facilitate guidance through the heating element. Already within the lower domain, the liquid aerosol-forming substrate may become an aerosol due to the heat emitted by the heating element. This may be furthered by an increased surface area of the heating element promoting heating of the liquid aerosol-forming substrate and/or the aerosol. As a consequence, clogging of the flow paths may be decreased. For instance, holes of the heating element may be less susceptible to becoming clogged. Also, it may be the case that the internal walls of the lower domain are closer to each other than the walls of the upper domain. Fluid flow may nevertheless be maintained if the liquid aerosol-forming substrate is already heated in the lower domain. Thereby, its viscosity may be decreased, which prevents liquid aerosol-forming substrate from becoming stuck on the internal walls.

[0055] According to a 17th embodiment, in any one of the preceding embodiments, the aerosol-forming substrate comprises tobacco.

[0056] Nicotine is naturally present in tobacco, such as in tobacco leaves. It may be evaporated from tobacco at temperatures below, for instance 300°C. The tobacco may be plant based. The aerosol-forming substrate may also comprise a tobacco-containing material, which contains volatile tobacco flavor compounds. These compounds maybe released from the aerosol-forming substrate when it is heated. The aerosol-forming substrate may comprise homogenized tobacco material.

[0057] The aerosol-forming substrate may also comprise one or more additional aerosol-formers. An aerosol-former in this sense is any suitable compound or mixture of compounds that may facilitate a generation or formation of a dense and stable aerosol and that may be resistant to thermal degradation at the temperature of operation of the aerosol-generating device. Suitable such aerosol formers include glycerin and propylene glycol. Further examples are polyhydric alcohols, esters of polyhydric alcohols, and aliphatic esters of mono-, di- or polycarboxylic acids. Preferably propylene glycol (PG) and/or vegetable glycerin (VG) are applied in addition to tobacco.

Heating element

[0058] According to an 18th embodiment, in any one of the preceding embodiments, the heating element has two portions on two opposing sides which correspond to the two opposing sides of the first part and the second part of the upper domain in an extension along the aerosol outlet path, wherein the two portions are separated on the two sides substantially perpendicular to the two opposing sides.

[0059] The two portions of the heating element may be susceptible of being heated; e.g., the two portions could provide for eddy currents when they are located within a fluctuating electromatic field. The eddy currents may cause heating of the heating element. Preferably, the portions are separated on two sides. Preferably, these two sides are not susceptible of being heated. This may be beneficial in case no heat is required on these two sides of the heating element. The two portions are located on two opposing sides which correspond to the two opposing sides of the first part and the second part of the upper domain. Thereby, the liquid aerosol-forming substrate may advantageously be heated at portions where heating is required.

[0060] The beneficial effect of heating may be pronounced even more if the lower domain is also separated on sides corresponding to the separation or division of the upper domain. Thereby, heating at the sides facing the liquid aerosol-forming substrate is ensured. This improves heating and reduces unnecessary heating of remaining areas. It also avoids that the housing is unnecessarily heated, which could happen if sides of the heating element were heated that are exposed to or that are facing areas where no liquid aerosol-forming substrate is supposed to be located.

[0061] Despite the separation of the heating element on two sides, the heating element could still be regarded as an integral heating element. However, two portions of the heating element are susceptible of being heated. The remaining sides may not be susceptible of being heated. For instance, the remaining sides of the heating element may comprise material that cannot convert electromagnetic energy into heat when located within a fluctuating electromagnetic field. However, it is also possible to provide the heating element as two separate elements, i.e. not as an integral heating element. For example, the remaining sides of the heating element may be left empty.

[0062] According to a 19th embodiment, in the preceding embodiment, the two portions of the heating element each extend over an angular section of at least 10°, preferably at least 30°, more preferably at least 60°, most preferably at least 90°, and/or over an angular section of at most 120°, preferably at most 110°, more preferably at most 100°, most preferably at most 90°, wherein the two portions are optionally separated by an angular section of at least 10°, preferably at least 30°, more preferably at least 60°, most preferably at least 90°, and/or by an angular section of at most 120°, preferably at most 110°, more preferably at most 100°, most preferably at most 90°.

[0063] With this embodiment, the two portions extend over a certain angular section which improves heating of targeted areas where liquid aerosol-forming substrate is located. Most preferably, the two portions each extend over an angular section of substantially 90°. The two portions are opposite to each other. By way of example, the heating element may have an annular cross section, e.g. the heating element may form a hollow cylinder with a small wall thickness. In such an example, an angular section of substantially 90° is covered by one of the portions, followed for instance by an angular section of substantially 90° in the circumferential direction having no material that could generate heat when it is located in an electromagnetic field. Then another portion of the heating element follows in a circumferential direction having an angular section of substantially 90°, which may once more be followed by an angular section of substantially 90° of material that cannot generate heat. All angles should sum up to 360°.

[0064] According to a 20th embodiment, in any one of the preceding embodiments, the heating element comprises one or more holes through which the aerosol-forming substrate and/or aerosol generated from the aerosol-forming substrate is guided during ordinary use.

[0065] A hole may be an opening that allows fluid to pass or to be guided or to be drawn through it. The one or more holes are such that the liquid aerosol-forming substrate and/or the generated aerosol can easily pass through them to enter the aerosol outlet path. The holes also reduce clogging of the flow paths.

[0066] According to a 21st embodiment, in any one of the preceding embodiments, the heating element has a substantially hollow shape.

[0067] A hollow shape of the heating element allows to guide a fluid through it, e.g. through an empty space surrounded by the heating element. The generated aerosol may pass through the heating element from an outer side through holes and may then be guided through the internal empty space of the heating element and through the aerosol outlet path to a mouth end of the consumable.

[0068] According to a 22nd embodiment, in any one of the preceding embodiments, the heating element has a substantially cylindrical shape or an at least section-wise cylindrical shape.

[0069] A cylindrical shape is beneficial for heating the liquid aerosol-forming substrate uniformly in a circumferential perspective. A cylindrical shape may also be easier to manufacture and easier to assemble with the remaining parts of the consumable. An at least section-wise cylindrical shape is to be understood such that at least one angular section of a circle exists. For instance, the heating element may be shaped as a rectangle with rounded corners. In case the heating element comprises two portions, both portions may extend over a certain angular section.

General features/materials

[0070] According to a 23rd embodiment, in any one of the preceding embodiments, the aerosol-forming substrate has a viscosity which is greater than the viscosity of water by a factor of at least 1.2, preferably at least 1.4, more preferably at least 1.6, most preferably at least 2.0, when measured at a temperature of 20°C.

[0071] The viscosity quantifies the internal frictional force between adjacent layers of fluid that maybe in relative motion. The viscosity of a fluid is a measure of its resistance to deformation at a given rate. As an example, when a viscous fluid is forced, flows or passes through two opposing walls, the fluid flows more quickly near the center of the two opposing walls than near the walls. The viscosity depends on the temperature of the fluid, e.g. the liquid aerosol-forming substrate. The viscosity of the liquid aerosol-forming substrate used according to the present invention is typically higher than that of water. This maybe due to tobacco particles suspended within the solution.

[0072] According to a 24th embodiment, in any one of the preceding embodiments, the heating element comprises electrically conductive material, wherein the heating element is preferably a susceptor.

[0073] An electrically conductive material is capable of converting electromatic energy into heat. The heating element is preferably a susceptor, which refers to a material that comprises electrically conductive material and is capable of converting electromagnetic energy into heat. Potential materials for the heating element may include graphite, molybdenum, silicon carbide, stainless steels, niobium, aluminum and any other conductive elements. Preferably stainless steel with aluminum and mild steel may be applied as materials for the heating element. Advantageously, the heating element is a ferromagnetic element. When located within a fluctuating electromagnetic field, eddy currents induced in the heating element cause heating of the heating element. When the heating element is located in a proximity or in thermal contact with the liquid aerosol-forming substrate, the liquid aerosol-forming substrate is beneficially heated by the heating element.

[0074] The consumable maybe designed to engage with an electrically-operated aerosol-generating device comprising heating means, such as a coil or an induction coil. The heating means generates the fluctuating electromagnetic field for heating the heating element. The heating element may be located within the fluctuating electromagnetic field. During ordinary use, the consumable engages with the aerosol-generating device such that the heating element is located within the fluctuating electromagnetic field generated by the heating means.

[0075] According to a 25th embodiment, in any one of the preceding embodiments, the consumable comprises a wick element substantially surrounding the heating element.

[0076] A wick element may be understood as an element that comprises a capillary material. A capillary material is a material that is capable of transporting liquid aerosol-forming substrate from one side of the material the other by means of capillary action.

[0077] The wick element may be in fluid communication with the heating element. The wick element may also be in fluid connection with the lower domain of the reservoir. The wick element may be arranged to guide or transmit liquid aerosol-forming substrate from the lower domain of the reservoir to the heating element. In particular, the wick element may be arranged to guide liquid aerosol-forming substrate from the lower domain of the reservoir across a large surface of the heating element. The wick element may be attached to the heating element. The wick element may also be formed integrally with the heating element.

[0078] According to a 26th embodiment, in the preceding embodiment, the wick element comprises at least one material of the list comprising ceramic material and cotton material.

[0079] Suitable further materials may comprise rayon. The wick element may comprise porous ceramic materials, which may improve heating. The wick element preferably comprises capillary material with a fibrous or spongy structure. The structure of the capillary material may have one or more holes, bores or tubes, through which the liquid aerosol-forming substrate may be guided by capillary action. If the heating element comprises one or more holes, the capillary material may protrude into the one or more holes of the heating element. This may improve heating of the liquid aerosol-forming substrate. The heating element may be capable to draw liquid aerosol-forming substrate into the holes of the heating element by capillary fluid movement.

[0080] According to a 27th embodiment, in any one of the 25th or 26th embodiments, the consumable is configured such that during ordinary use, the aerosol-forming substrate is guided from the lower domain through the wick element and through the heating element.

[0081] This improves heating of the liquid aerosol-forming substrate and the generation of aerosol to be inhaled by a user. It also prevents leakage of aerosol-forming substrate in a liquid state through the aerosol outlet path.

[0082] According to a 28th embodiment, in any one of the preceding embodiments, the aerosol-forming substrate is electrically heated by induction heating or resistance heating.

[0083] Inductive heating has the advantage that no direct electrical contact needs to be provided between the heating element and the inductor. Resistance heating may also be referred to as joule heating, resistive, or Ohmic heating. The passage of an electric current through a conductor produces heat whose power equals the product of the resistance and the square of the current. Electrodes are required to provide for an electrical contact to the heating element. The electrodes ensure that a voltage differential is applied to the heating element, to induce a current.

Aerosol-generating device and system

[0084] A 29th embodiment of the invention is directed to an aerosol-generating system comprising a consumable according to any one of the 1st to 28th embodiments and an aerosol-generating device comprising a power supply and configured to provide energy to the heating element of the consumable.

[0085] A power supply may be any suitable power supply, for example a DC voltage source, such as a battery, e.g. a lithium iron phosphate battery. The power supply may be located within a body of the aerosol-generating device, or it may be another form of charge storage device such as a capacitor. The power supply may allow for recharging and may have a capacity that allows for storing enough energy for one or more ordinary use cycles. A use cycle may be understood as consuming substantially all of the liquid aerosol-generating substrate stored in the reservoir during ordinary use.

[0086] Preferably, the aerosol-generating device is a portable or handheld aerosol-generating device that is comfortable for a user to hold between the fingers of a single hand. The aerosol-generating device may have a substantially cylindrical shape, or an organic shape that streamlines with or resembles a natural shape that is easy and comfortable to be held in a hand. The consumable may also be a handheld consumable.

[0087] According to a 30th embodiment, in the preceding embodiment, the aerosol-generating device comprises heating means, such as a coil or an induction coil, configured to heat the heating element of the consumable by induction when the power supply is connected to the heating means.

[0088] The heating means may provide for an alternating or fluctuating electromagnetic field. For instance, when the power supply is actuated, a high-frequency alternating current is passed through coils of wire that maybe part of the heating means. The electromagnetic field produced by the heating means may induce a current in the heating element, causing the heating element to heat up. The heating element may be a susceptor.

[0089] The heating element may be arranged on a wall of the consumable's housing that forms the transition to the aerosol outlet path. The heating element is configured to be located adjacent, preferably radially adjacent, to the heating means, such as an inductor coil, when the consumable is received and/or engaged with the aerosol-generating device. During ordinary use, it is advantageous to have the heating element close to the heating means, to improve heating of the heating element by increasing the voltage induced in the heating element.

[0090] According to a 31st embodiment, in the preceding embodiment, the heating means of the aerosol-generating device substantially surround the outside of the consumable when the consumable is received in the aerosol-generating device.

[0091] According to a 32nd embodiment, in any one of the 30th or 31st embodiments, the heating means of the aerosol-generating device are substantially radially adjacent to the heating element when the consumable is received in the aerosol generating device.

Brief description of the figures

[0092] In the following, preferred embodiments are described, by way of example only. Reference is made to the following accompanying figures:

Fig. 1

illustrates a consumable for use in an electrically heated aerosol-generating device according to a general embodiment in a perspective view;

Fig. 2

illustrates a consumable for use in an electrically heated aerosol-generating device and heating means of an aerosol-generating device according to the general embodiment in a side cross sectional view;

Fig. 3

illustrates a consumable for use in an electrically heated aerosol-generating device according to a first exemplary embodiment in a side cross sectional view;

Fig. 4

illustrates a consumable for use in an electrically heated aerosol-generating device according to the first exemplary embodiment in a top cross sectional view;

Fig. 5

illustrates a consumable for use in an electrically heated aerosol-generating device according to the first exemplary embodiment with a different heating element in a top cross sectional view;

Fig. 6

illustrates a consumable for use in an electrically heated aerosol-generating device according to a second exemplary embodiment in a top cross sectional view;

Fig. 7

illustrates a consumable for use in an electrically heated aerosol-generating device according to the second exemplary embodiment with a different heating element in a top cross sectional view;

Fig. 8

illustrates a consumable for use in an electrically heated aerosol-generating device according to a third exemplary embodiment in two side cross sectional views;

Fig. 9

illustrates a consumable for use in an electrically heated aerosol-generating device according to the third exemplary embodiment in a top cross sectional view;

Fig. 10

illustrates an aerosol-generating system according to an exemplary embodiment;

Detailed description of the figures

[0093] In the following, the invention is described with reference to the accompanying figures in more detail. However, the present invention can also be used with any other embodiments not explicitly disclosed hereafter.

[0094] Fig. 1 shows a consumable 1 for use in an electrically heated aerosol-generating device in a perspective view according to a general embodiment of the invention. The subsequent embodiments may be used within this general embodiment. The consumable 1 comprises an outer housing 2 and a mouth end 3 to be received by a user's mouth.

[0095] Fig. 2 shows the consumable 1 of the general embodiment in a side cross sectional view. The consumable comprises an aerosol outlet path 10 and a reservoir 15 comprising a liquid aerosol-forming substrate. The consumable also comprises a heating element 50. The flow path of the liquid aerosol-forming substrate and/or the aerosol is indicated. The aerosol leaves the aerosol outlet path 10 in proximity to or at the mouth end 3. A heating means 102 is also shown, which maybe an inductor such as an inductor coil. The heating means 102 is part of the aerosol-generating device 100 (not shown fully in the figure).

[0096] Fig. 3 shows a consumable 1 for use in an electrically heated aerosol-generating device according to a first exemplary embodiment in a side cross sectional view. This first exemplary embodiment may be a specific embodiment of the consumable of the general embodiment, such that it also comprises a housing as shown in the general embodiment. The consumable 1 comprises an aerosol outlet path 10, a reservoir 15 comprising a liquid aerosol-forming substrate and a heating element 50. The reservoir 15 has an upper domain 20 and a lower domain 30. The upper domain 20 and the lower domain 30 are in fluid connection with each other. Thus, liquid aerosol-forming substrate can flow from the upper domain 20 into the lower domain 30. The upper domain 20 is divided into a first part 21 and a second part 22 arranged on two opposing sides of the aerosol outlet path 10. Thus, the first part 21 and the second part 22 are not in direct fluid connection within the upper domain 20. The aerosol-forming substrate comprised by the lower domain 30 is in fluid connection with the heating element 50. The consumable 1 further comprises a wick element 60. The heating element 50 further comprises one or more holes 51. In this manner, aerosol-forming substrate and/or the generated aerosol from the aerosol-forming substrate can be guided through the heating element during ordinary use.

[0097] Fig. 4 shows a consumable 1 for use in an electrically heated aerosol-generating device according to the first exemplary embodiment in a top cross sectional view. The consumable 1 exhibits the heating element 50, the aerosol outlet path 10, the first part 21 of the upper domain 20 and the second part 22 of the upper domain 20. The consumable 1 is shown in a cross section 5, for instance a cross section 5 of the consumable 1 in proximity to the mouth end of the consumable 1. The cross section 5 is perpendicular to the longitudinal axis of the aerosol outlet path 10. As can be seen, the cross section 5 has an elongate shape. In this example, the cross section 5 has a substantially rectangular shape, i.e. a rectangular shape with rounded corners. The outer circumference of the cross section of the upper domain 20 has an elliptical shape. The aerosol outlet path is located in the center of the reservoir and thereby also in the center of the upper domain of the reservoir. The first part 21 and the second part 22 of the upper domain 20 are on two opposite sides of the aerosol outlet path 10. As can be seen, the first part 21 and the second part 22 are separated by two walls. The walls could be said to be formed by an outer wall of the aerosol outlet path 10 coinciding with a wall of the consumable 1.

[0098] It can be seen that a smallest dimension of a cross section 5 of the consumable 1 in proximity of a mouth end of the consumable 1 and perpendicular to the longitudinal axis of the aerosol outlet path 10 is about the same size as the outer diameter of the aerosol outlet path 10 in the same plane as the cross section 5 of the consumable in proximity of a mouth end. That is because the walls coincide. The inner diameter of the aerosol outlet path 10 is smaller, due to a wall thickness of the aerosol outlet path.

[0099] Thus, it is possible that the smallest dimension of the cross section 5 is greater than the inner diameter of the aerosol outlet path 10, for instance greater by a factor of about 1.1 or 1.2 or even more, but preferably less than by a factor of 2.0 or 1.9.

[0100] In general, this arrangement provides for an improved and facilitated fluid movement within the consumable. In particular, less unused liquid aerosol-forming substrate may remain within the reservoir after usage. Further, the arrangement of the lower domain allows for improved heating of the liquid aerosol-forming substrate.

[0101] Fig. 5 shows a consumable for use in an electrically heated aerosol-generating device in a top cross sectional view according to the first exemplary embodiment with a different heating element 50. The consumable 1 is shown in a cross section 5, for instance a cross section 5 of the consumable 1 in proximity to the mouth end of the consumable 1. In this embodiment, the heating element 50 has two portions on two opposing sides, which correspond to the two opposing sides of the first part 21 and the second part 22 of the upper domain 20 in an extension along the aerosol outlet path 10. The two portions of the heating element 50 are separated on two sides that are substantially perpendicular to the two opposing sides. As can be seen, the two portions of the heating element 50 each extend over an angular section of about 60° to 120° or 70° to 110° or 80° to 100°.

[0102] This is advantageous, because only portions of the consumable 1 or reservoir 15 are heated that demand or necessitate heating. In this manner, the liquid aerosol-forming substrate is sufficiently heated, but not the remaining portions. In particular, heating on the two remaining sides may not be necessary since no liquid aerosol-forming substrate may be located there. This can reduce unnecessary heating of a housing of the consumable.

[0103] Fig. 6 shows a consumable 1 for use in an electrically heated aerosol-generating device in a top cross sectional view according to a second exemplary embodiment. In this embodiment, a cross section of the upper domain 20 of the reservoir has a rectangular outer shape. This is understood in that the outer circumference of the cross section of the upper domain 20 has substantially a rectangular shape. This may be beneficial for manufacturing purposes. The consumable 1 is shown in a cross section 5, for instance a cross section 5 of the consumable 1 in proximity to the mouth end of the consumable 1. The consumable 1 comprises one or more air chambers 40. In particular, it comprises two air chambers 40, which are located between the first part 21 and the second part 22 of the upper domain 20. The air chambers 40 are a substantially closed space, in which air can be stored or located. The air can beneficially increase the thermal insulation of the heated parts against a housing of the consumable 1. Therefore, the housing of the consumable becomes less hot. Further, thermal insulation improves the energy efficiency of the aerosol-generating device (not shown in the figure). In this regard, the portions between the first 21 and the second 22 part of the upper domain 20 are characterized by a small distance between the heated aerosol of the aerosol outlet path 10 and the outer side of the consumable. Thus, the outer side of the consumable might be heated unnecessarily if there are no air chambers 40. Accordingly, the air chambers reduce such heating of the housing of the consumable. This improves user experience, energy management and durability of the applied materials.

[0104] Fig. 7 shows a consumable for use in an electrically heated aerosol-generating device according to the second exemplary embodiment with a different heating element 50 in a top cross sectional view. Similar to the first exemplary embodiment that has a different heating element 50, also the heating element 50 of Fig. 7 has two portions. In particular, the heating element 50 has two portions on two opposing sides which correspond to the two opposing sides of the first part 21 and the second part 22 of the upper domain 20 in an extension along the aerosol outlet path 10. The two portions of the heating element 50 are separated on two sides that are substantially perpendicular to the two opposing sides. It is beneficial that the two sides separating the two portions of the heating element 50 are facing the sides on which the air chambers 40 are arranged. Thus, substantially no heat is transmitted to the air chambers 40, which provides the advantage that the housing of the consumable is not unnecessarily heated. The two portions of the heating element 50 may each extend over a similar angular section as the heating element 50 in Fig. 5. The remainder of the consumable of Fig. 7 corresponds to the consumable of Fig. 6.

[0105] Fig. 8 shows a consumable for use in an electrically heated aerosol-generating device according to a third exemplary embodiment in two side cross sectional views. The left hand part of this figure shows the side cross section view A-A as indicated in Fig. 9. The arrangement of the parts of the consumable 1 is similar to the first and second exemplary embodiment, in particular to the second exemplary embodiment.

[0106] The right hand part of this figure shows the side cross section view B-B as indicated in Fig. 9. As can be seen, the consumable 1 has two air chambers 40 located between the first part 21 and the second part 22 of the upper domain 20, similar to the second exemplary embodiment. The air chambers 40 have one or more upper openings 41; in particular, each air chamber 40 has two upper openings 41 (only shown in Fig. 9). The air chambers 40 can also have more than two or and less than two upper openings 41. Preferably, at least one upper opening 41 is provided such that air can enter the first 21 and the second 22 part of the upper domain 20. The upper openings 41 are located at an upper end of the upper domain 20, which is located on a mouth end 3 side of the consumable 1. The mouth end 3 is exemplarily indicated in Fig. 8. The air chambers 40 also have a lower opening 42, which is located away from the mouth end 3 side of the consumable 1. In particular, each air chamber 40 has one opening 42 to allow external air to enter the air chambers 40.

[0107] The upper 41 and lower 42 openings are advantageous because they allow that air, such as external air, to enter through the lower openings 42 into the air chambers 40. Furthermore, the external air can then enter the first 21 and second 22 part of the upper domain 20 at an uppermost portion within the first 21 and second 22 part, e.g. at a portion close to the mouth end 3 of the consumable 1. This facilitates a pressure balance within the reservoir 15. Accordingly, air can enter from an uppermost side the first 21 and the second 22 part of the upper domain 20, which promotes fluid movement of the liquid aerosol-forming substrate from the upper domain 20 to the lower domain 30, through the wick 60, through the heating element 50 having holes 51, thereby being vaporized, and through the aerosol outlet path 10, to be inhaled by a user at a mouth end 3 of the consumable 1. During ordinary use, the liquid aerosol-forming substrate in the upper domain 20 may be depleted, reduced or consumed. Thus, a pressure may be reduced therein, which hinders fluid movement from the upper domain 20 to the lower domain 30. Thus, balancing the pressure by way of the one or more upper 41 and lower 42 openings improves the fluid flow and thus the user experience. The air circulation through the air chambers 40, i.e. air entering the air chambers 40 through the lower openings 42 and leaving the air chambers 40 through the upper openings 41, further promotes cooling of the housing of the consumable 1. As can be seen in Fig. 8, the one or more air chambers 40 extend along the length of the upper domain 20 of the reservoir 15 and along the length of the lower domain 30 of the reservoir 15 in parallel to the aerosol outlet path 10. Thus, they can thermally insulate the housing 2 of the consumable 1 from the heated or hot aerosol outlet path 10 during ordinary use. It may, however, also possible that the one or more air chambers 40 extend merely along the length of the upper domain 20 of the reservoir 15 in parallel to the aerosol outlet path 10.

[0108] Fig. 8 further shows that air chambers 40 comprise one or more fins 43 that fill at least 20%, preferably at least 40%, more preferably at least 60%, most preferably at least 70% of a cross section of the air chambers 40. In this exemplary embodiment, the fins 43 fill about 60% of a cross section of the air chambers 40. The cross section referred to is the cross section perpendicular to the longitudinal axis of the consumable 1, which could be said to be parallel to the aerosol outlet path 10. The fins 43 are circumferentially arranged in the air chambers 43 and protrude to the inside of the air chambers 43 in an alternating manner. In particular, they protrude in an alternating manner by alternating between the two opposing sides of the air chambers 40. In this exemplary embodiment, there are three fins 43 arranged on a radially outer side of the left air chamber 40 and two fins 43 on a radially inner side of the left air chamber 40. Further, there two three fins 43 arranged on a radially outer side of the right air chamber 40 and three fins 43 on a radially inner side of the right air chamber 40. However, different numbers are possible and are in accordance with the present invention. The one or more fins prevent a liquid aerosol-forming substrate from accidentally entering the air chambers 40. The fins 43 fill an optimal cross section of the air chambers 40 (the cross section is perpendicular to the longitudinal axis of the aerosol outlet path 10) to prevent liquid aerosol-forming substrate that accidentally entered the air chambers 40 through the upper openings 41 from advancing further within the air chambers 40.

[0109] Fig. 9 shows a consumable 1 for use in an electrically heated aerosol-generating device according to the third exemplary embodiment in a top cross sectional view. In this figure the side cross sectional views A-A and B-B are indicated. Further, this figure shows the upper openings 41 of the air chambers 40.

[0110] Fig. 10 shows an aerosol-generating system 200 according to an exemplary embodiment. The system 200 comprises an aerosol-generating device 100 comprising a power supply 101. The device 100 further comprises heating means 102 to provide energy to the heating element 50 of the consumable 1. The system 200 further comprises the consumable 1. The heating means 102 is a coil or an induction coil, configured to heat the heating element 50 of the consumable 1 by induction when the power supply 101 is connected to the heating means 102. The heating means 102 generates a fluctuating electromagnetic field for heating the heating element of the consumable 1. The heating element is located within the fluctuating electromagnetic field and in close proximity to the heating means 102.

[0111] In all of the above mentioned exemplary embodiments, the heating element 50 is typically a susceptor and comprises electrically conducive material. Potential materials for the susceptor are graphite, molybdenum, silicon carbide, stainless steels, niobium, aluminum and any other conductive elements. Alternatively, resistive heating means 102 may be applied.

[0112] In all of the above mentioned exemplary embodiments, the wick element 60 comprises at least one of ceramic material and cotton material. The aerosol-generating device 100 is a portable or handheld aerosol-generating device 100. It is comfortable for a user to hold between the fingers of a single hand. The consumable 1 is also a handheld consumable 1, and the same applies to the aerosol-generating system 200.

List of reference signs

[0113] 

1

consumable

2

housing

3

mouth end

5

cross section

10

aerosol outlet path

15

reservoir

20

upper domain

21

first part of the upper domain

22

second part of the upper domain

30

lower domain

31

first part of the lower domain

32

second part of the lower domain

40

air chambers

41

upper openings

42

lower openings

43

fins

50

heating element

51

holes

60

wick element

100

aerosol-generating device

101

power supply

102

heating means

200

aerosol-generating system

Claims

1. A consumable (1) for use in an electrically heated aerosol-generating device (100), the consumable (1) comprising:

an aerosol outlet path (10);

a reservoir (15) comprising a liquid aerosol-forming substrate; and

a heating element (50);

wherein the reservoir (15) has an upper domain (20) and a lower domain (30), the upper domain (20) and the lower domain (30) being in fluid connection with each other,
wherein the upper domain (20) is divided into a first part (21) and a second part (22) arranged on two opposing sides of the aerosol outlet path (10) such that the two parts are not in direct fluid connection within the upper domain (20), wherein the aerosol-forming substrate comprised by the lower domain (30) is in fluid connection with the heating element (50).

2. The consumable (1) according to the preceding claim, wherein the aerosol outlet path (10) extends from a position inside a housing (2) of the consumable (1), preferably in proximity of the heating element (50), to a mouth end (3) of the consumable (1), and is preferably arranged along the longitudinal axis of the consumable (1).

3. The consumable (1) according to any one of the preceding claims, wherein the upper domain (20) of the reservoir (15) radially encloses the aerosol outlet path (10).

4. The consumable (1) according to any one of the preceding claims, wherein the upper domain (20) extends over at least 10%, preferably at least 30%, more preferably at least 50%, most preferably at least 60% of the length of the reservoir (15), and/or wherein the upper domain (20) extends over at most 80%, preferably at most 70%, more preferably at most 60% of the length of the reservoir (15), wherein the length of the reservoir (15) is measured substantially in parallel to the aerosol outlet path (10).

5. The consumable (1) according to any one of the preceding claims, wherein a cross section (5) of the consumable (1) in proximity to a mouth end (3) of the consumable (1) and perpendicular to the longitudinal axis of the aerosol outlet path (10) has an elongate shape, such as an elliptical or rectangular shape.

6. The consumable (1) according to the preceding claim, wherein the elongate shape has a largest dimension and a smallest dimension, wherein the largest dimension is larger than the smallest dimension by a factor of at least 1.0, preferably at least 1.4, more preferably at least 1.6, even more preferably at least 2.0, most preferably by a factor of at least 2.4.

7. The consumable (1) according to any one of the preceding claims, wherein a smallest dimension of a cross section (5) of the consumable (1) in proximity of a mouth end (3) of the consumable (1) and perpendicular to the longitudinal axis of the aerosol outlet path (10) is larger than an inner or an outer diameter of the aerosol outlet path (10) in the same plane as the cross section (5) of the consumable (1) in proximity of a mouth end (3) by a factor of at least 1.0, preferably at least 1.1, more preferably at least 1.2, even more preferably at least 1.3, further more preferably at least 1.4, most preferably by a factor of at least 1.5, and/or by a factor of at most 2.0, preferably at most 1.9, more preferably at most 1.8, even more preferably at most 1.7, further more preferably at most 1.6, most preferably by a factor of at most 1.5.

8. The consumable (1) according to any one of the preceding claims, comprising one or more air chambers (40), preferably two air chambers (40), located between the first part (21) and the second part (22) of the upper domain (20).

9. The consumable (1) according to the preceding claim, wherein the one or more air chambers (40) have one or more upper openings (41) configured to allow air to enter the first part (21) and/or the second part (22) of the upper domain (20) of the reservoir (15) at an upper end of the upper domain (20), wherein the upper end of the upper domain (20) is located on a mouth end (3) side of the consumable (1).

10. The consumable (1) according to any one of claims 8 or 9, wherein the one or more air chambers (40) have one or more lower openings (42) configured to allow ambient air to enter the one or more air chambers (40),
wherein the one or more lower openings (42) are preferably located at a lower end of the one or more air chambers (40), wherein the lower end of the one or more air chambers (40) is located away from the mouth end (3) side of the consumable (1).

11. The consumable (1) according to any one of claims 8 to 10, wherein the one or more air chambers (40) extend along the length of the upper domain (20) of the reservoir (15) or along the length of the upper domain (20) and the lower domain (30) of the reservoir (15) in parallel to the aerosol outlet path (10), such that they thermally insulate an outer housing (2) of the consumable (1) from the aerosol outlet path (10).

12. The consumable (1) according to any one of claims 8 to 11, wherein the one or more air chambers (40) comprise one or more fins (43) that are filling at least 20%, preferably at least 40%, more preferably at least 60%, most preferably at least 70% of a cross section of the one or more air chambers (40), and/or that are filling at most 98%, preferably at most 90%, more preferably at most 85%, most preferably at most 80% of a cross section of the one or more air chambers (40).

13. The consumable (1) according to the preceding claim, wherein the one or more fins (43) are arranged circumferentially and in an alternating manner on two opposing sides of the one or more air chambers (40).

14. The consumable (1) according to any one of the preceding claims, wherein the heating element (50) has two portions on two opposing sides which correspond to the two opposing sides of the first part (21) and the second part (22) of the upper domain (20) in an extension along the aerosol outlet path (10), wherein the two portions are separated on the two sides substantially perpendicular to the two opposing sides.

15. An aerosol-generating system (200) comprising a consumable (1) according to any one of claims 1 to 14 and an aerosol-generating device (100) comprising a power supply (101) and configured to provide energy to the heating element (50) of the consumable (1).

Drawing