Electrically Conductive Consumable

Abstract

A consumable for an aerosol generating device includes a heating layer of an aerosol substrate formed to be positioned in sandwich between two electrodes of the device. The heating layer of aerosol substrate includes flavorant material and an aerosol forming agent. The layer further includes electrically conductive material in particulate form embedded in the layer, wherein the electrically conductive material is arranged in the heating layer to conduct electrical current between the two electrodes and to heat the aerosol substrate to a temperature sufficient to aerosolize the aerosol forming agent. A method for manufacturing such a consumable, a device for delivering a tobacco aerosol including the consumable, and a method for production of tobacco aerosol with the device are also provided.

Description

The present invention relates to electrically conductive tobacco with a heating layer as a consumable for an aerosol generating device. Furthermore, the invention relates to a method for manufacturing such conductive consumable, to a device aerosol generating device and to a method for production of aerosol from the mentioned consumable.

Many kinds of electric smoking devices are available on the market. The most popular are known as e-cigarettes and vaporize an e-liquid to an inhalable vapor. However, such devices are very vulnerable to leakage of the e-liquid. This is very disadvantageous for users who keep the electric smoking devices in pockets or bags. Alternative devices with solid consumable are available. Such devices consist in heating rather than burning tobacco reconstituted substance wrapped in paper and do not suffer from leakage. However, such devices require a heater to be part of the device and so requires to be properly insulated to avoid high temperature at the surface of the device. The device is relatively complex to assemble and is so relatively expensive.

It is therefore the objective of the invention to provide a conductive consumable for an aerosol generating device, which enables operating an aerosol generating device with a rechargeable, e.g. lithium-ion, battery without requiring a heating system or lighter to be part of the device. Furthermore, the objective of the invention is to provide a method for manufacturing the mentioned conductive consumable, the aerosol generating device for use with the consumable and a method for production of aerosol.

The above-mentioned requirement is met by the object of claim 1. Preferred embodiments are objects of the dependent claims.

A consumable for an aerosol generating device according to the invention comprises a heating element and especially a heating layer of an aerosol substrate formed to be positioned in sandwich between two electrodes of the device. The heating layer of aerosol substrate comprises a flavorant material and an aerosol forming agent.

The consumable is characterized in that the layer further comprises electrically conductive material in particulate form embedded in the layer, wherein the electrically conductive material is arranged in the heating layer to conduct electrical current between the two electrodes and/or to heat the aerosol substrate to a temperature sufficient to aerosolize the aerosol forming agent.

Preferably the flavorant material comprised in the heating layer comprises natural and/or synthetic components which enhance and modify the taste of the generated aerosol. It is conceivable that the flavorant material comprises tobacco material which preferably can be manufactured from different types of tobacco plants. However, it is not essential to add the tobacco material to the flavorant material.

Preferably the consumable is arranged between two electrodes, more preferred the consumable is pressed between the electrodes. The two electrodes preferably represent common electrodes for use as a heater in the aerosol generating device. Preferably the consumable, in particular the heating layer, is formed as a paste or dough. It is advantageous to provide the consumable in this shape at least because of the various storage possibilities.

The consumable in form of the dough is preferably provided or stored as a layer which is rolled up on itself similar to a spiral or a hyperbolic spiral. It is also possible to provide the consumable rolled on a bobbin. Preferably the whole consumable and especially the heating layer of an aerosol substrate is stored in a cartridge which is preferably intended for keeping the consumables fresh. The cartridge is preferably provided with a mechanism to open and close the cartridge. Various closures are available for this purpose. Due to this it is conceivable that the cartridge is refillable with the consumable in particular the heating layer.

The consumable provided as a paste comprises a viscosity of up to 10² mPas (at 20° C.). The—preferably dynamic—viscosity of the consumable preferably decreases with increasing temperature of the electrodes. It is conceivable that the consumable is a non-Newtonian fluid and comprises solid particles. Depending on the composition of used materials of the consumable, an amount of the solid particles varies. Due to this the viscosity and in particular dynamic viscosity of the consumable preferably depends on the ingredients and the amount of the comprised solid particles in the consumable.

Preferably the two electrodes of the aerosol generating device are connected to a voltage source. Also preferably the voltage source supplies the whole aerosol generating device with electrical energy providing a voltage in range of 1 V and 5 V. In a preferred embodiment the voltage source is a lithium-ion battery delivering a value of 3.7 V. Such a voltage source is particularly advantageous for a modern aerosol generating device in view of rechargeability. The heating layer according to the invention appears as a conductor between the electrodes and provides a direct aerosolization of the consumable. Preferably the two electrodes and the heating layer reach a temperature in range of 90 to 230° C. for a sufficient aerosolization of an aerosol forming agent comprised in the consumable.

According to another embodiment, the consumable is characterized in that the electrically conductive material has an electrical conductivity of at least 3·10² S/m (at 20° C.). A value of electrical conductivity may vary depending on the selected electrically conductive material. Preferably the electrically conductive material comprised in the consumable or in the heating layer has the electrical conductivity of 100*10⁶ S/m.

The electrically conductive material is preferably a nontoxic approved additive for use in the tobacco industry. In another embodiment, it is conceivable that the electrically conductive material comprised in the consumable or in the heating layer has the electrical conductivity in range of 3*10² S/m and 3*10⁶ S/m. The electrically conductive material preferably allows the electric current to flow from the first electrode to the second electrode. Preferably the current flows in a transverse direction perpendicular to a thickness of the consumable. In this context the thickness of the consumable means the thickness of the consumable which is arranged between the first and second electrode. Preferably to achieve a sufficient electrical current flow between the electrodes through consumable, in particular through the heating layer, it is necessary to provide an electrically conductive material in an amount of at least 2.5%, and preferably less than 50%, more preferably between 2.5% and 25% of a weight of the consumable.

Additionally or alternatively the required electrical conductivity can be effected by a modulation of the contact surfaces of the electrodes. It is conceivable that the smaller electrodes contact surfaces effect a greater resistance. The smaller electrode contact surfaces preferably comprise a contact surface area in range of 150 mm² and 200 mm². In this case it is possible to increase the quantity of the electrically conductive material in the heating layer. Due to this the electrodes with the large electrode contact surface should be used preferably with a heating layer comprising a lower quantity of the electrically conductive material. Preferably the large electrode contact surfaces comprise a contact surface area in range of 250 mm² and 320 mm². In the preferred embodiment the electrode contact surfaces area are in range of 200 mm² to 250 mm², more preferred comprise 215 mm².

According to another embodiment the consumable is characterized in that the thickness of the heating layer is comprised between 0.5 and 3 mm, preferably between 0.5 and 2 mm and most preferably 0.75 mm. The minimum thickness of the consumable is preferably determined by the heating layer. Preferably the electrical resistance of the consumable is proportional to the thickness of the used heating layer. The thinner the layer, the lower the electrical resistance.

It is conceivable that the thickness of the heating layer corresponds to the thickness of the whole consumable. In this case, the heating layer is preferably not formed as a separated layer but is distributed in the whole consumable. Due to this, the whole consumable comprising electrically conductive material is a heating layer. The maximum thickness of the consumable is preferably determined by a design of the aerosol generating device. There is often little space available in the small aerosol generating devices, so the thickness of the consumable is particularly important. Due to this the preferred thickness of the consumable is particularly advantageous for storage in the cartridge.

The narrow thickness of the consumable enables a greater capacity of the cartridge comprising the consumable. At the same time, less electrical voltage and less heating time is preferably needed to heat the consumable. This allows a user to use a single cartridge with the consumable for a longer period of time. A further advantage for a preferred thickness of the consumable or the heating layer would be a compact winding in the cartridge. This helps to avoid wasteful voids in the cartridge with the consumable.

According to another embodiment the consumable is characterized in that the electrically conductive material is distributed in and on the layer in an amount to allow electricity to flow from one electrode through the thickness of the layer to the other electrode. It is conceivable to coat the consumable or the heating layer with the electrically conductive material to provide the electrical conduction between two electrodes. In some embodiments of the invention, the consumable comprises two heating layers comprising the electrically conductive material.

The heating layers are preferably arrangeable as an upper and lower layer of the consumable thereby creating a layered consumable comprising at least three layers. In this case preferably the heating layers are in contact to the electrodes. Also preferably the consumable comprises electrically conductive material in an intermediate layer thereby ensuring a current flow from one electrode to the other electrode.

In another embodiment the electrically conductive material is distributed in the heating layer particularly homogeneously to allow current to flow from one electrode through the thickness of the heating layer to the other electrode. In this case in particular the whole consumable is the heating layer. However, it is also conceivable to use additional highly enriched layers comprising electrically conductive material.

According to another embodiment the electrically conductive material is randomly distributed inside the heating layer and on a surface area of the heating layer. In particular, preferably the electrically conductive material is randomly distributed inside the consumable and on a surface are of the consumable. The distribution of the conductive material in the consumable or heating layer is preferably described with a Fick's law of diffusion. In case if the conductive material or the heating layer is a solid material, preferably provided in form of the dough, the conductive material is preferably anisotropically distributed inside the heating layer of the consumable. This leads to the formation of areas with a higher and a lower concentration of conductive material inside the heating layer or the consumable.

However, preferably the electrically conductive material inside the heating layer of the consumable is dispersed to the extent that the current flow is ensured. The distribution of the conductive material inside a more liquid consumable, preferably in form of a paste, can advantageously be better compared to the distribution inside the solid consumable. Preferably the conductive material is evenly dispersed inside the liquid consumable. This can be achieved through a liquid electrically conductive material or conductive particles dispersed in a carrier liquid.

According to another embodiment the electrically conductive material is graphite or charcoal particles. The material may take the form of powder, loose or agglomerated particles. It is also conceivable to use other conductive materials which are approved in particular at least in the tobacco industry or food industry.

According to another embodiment the electrically conductive material comprises an amount of 2.5 to 50% wt., preferably between 2.5 and 25 wt. % regarding the heating layer. Preferably the electrically conductive material comprises the amount of 2.5 to 59% wt. regarding to the consumable. Preferably the amount of present carbon or charcoal particles in the consumable or the heating layer depends at least on the thickness of the consumable or the heating layer. It is also conceivable that the amount of present carbon or charcoal particles in the consumable depends on provided pressure between the first and the second electrodes during the heating process. It is possible that the consumable comprises both the carbon and the charcoal particles. In this case the amount of both materials in the heating layer or the consumable is preferably present in range of 5% and 40% wt., also preferred 2.5% and 60% regarding to the consumable. In general, it is conceivable to use a greater amount than 50% wt. of the carbon and/or the charcoal particles in the consumable or the heating layer.

The electrically conductive material may have a hollow structure. The hollow structure can be formed by pores or tubes or another capillary or spongy structure. The advantage of such structure is that it can provide a reserve for aerosol forming agent without softening the consumable.

According to another embodiment the heating layer further comprises a binder, preferably carboxymethyl cellulose (CMC), in an amount between 0.5 and 2.5 wt. % regarding to the consumable or the heating layer. In particular the consumable preferably comprises a binder as CMC in an amount between 0.5 and 2.5 wt. % regarding to the consumable. In an example, the binder is comprised in an amount of about 1.74 wt. % of the total weight of the consumable. It is conceivable to use other binders, for example a mixture of cellulose gum, water and glycerine. Water enables to activate the binder and its amount can vary according the binder selected.

According to another embodiment the aerosol forming agent comprises an amount of less than 25% wt. regarding to the consumable or the heating layer. Preferably, the aerosol forming agent is glycerin and/or propylene glycol. Due to this, it is possible not to add the aerosol forming agent to the consumable or the heating layer. In this case the comprised conductive material, preferably charcoal, needs a higher temperature for aerosolization of the flavorings comprised in the consumable. Especially when using a more solid consumable, it is conceivable to use a low amount of aerosol forming agent or no aerosol forming agent. This helps to avoid unnecessary moisture content in the consumable. However, the aerosol forming agent is particularly advantageous for elasticity of the consumable. The use of aerosol forming agent in the consumable can at least avoid its brittleness. This allows optimal shape of the consumable or heating layer for heating between the two electrodes of the aerosol generating device. In a preferred embodiment, the aerosol forming agent comprises an amount of at least 5 wt. % and less than 25 wt. % regarding the consumable. For example, the aerosol forming agent is glycerin in an amount of about 12.50 wt. %

According to another embodiment the layer further comprises water in an amount comprised between 10 and 49.5 wt. %, preferably between 22.5 and 49.5 wt. % regarding to the consumable. For example, the layer comprises about 36 wt. % of water.

According to another embodiment the tobacco material comprises tobacco in an amount up to 47.5 wt. % regarding to the consumable. Preferably, the tobacco material comprises tobacco in an amount between 25 wt. % and 47.5 wt. % of the total weight of the consumable. Tobacco may be tobacco powder and/or shredded tobacco such as flue-cured tobacco (FCT). In particular a consumer can use the consumable according to the invention which does not comprise a tobacco powder. Preferably the consumable comprising a humectant without tobacco powder is aerosolisable between the electrodes of the aerosol generating device. The humectant preferably comprises flavorings for enhancing the generated aerosol with different flavors. However the tobacco powder provides a special enlarged tobacco taste of the generated aerosol. It is conceivable that the tobacco powder comprised in the consumable or the heating layer sticks to the conductive material, preferably charcoal, thereby providing nicotine to the generated aerosol.

According to another embodiment the tobacco powder has a particle size lower than 1000 microns. The tobacco particles may originate from any part of the tobacco plant, e.g. leaves, stems or roots. The particle size of the tobacco powder is crucial in view of the delivered tobacco taste. It has been found that grinding of the tobacco particles to a smaller particle size could affect the odor. It is believed that some of the odorizing molecules decompose due to the high shear energy.

Furthermore, some odorizing molecules could exit too small tobacco particles during the grinding process or during a later handling process. This would result in a depletion of these odorizing molecules in the tobacco particles and an odorizing composition different with respect to the full tobacco odor. In other embodiments, it is conceivable that the particle size of the tobacco powder used in the heating layer or the consumable is lower than 600 microns or less. The tobacco particles having such a small average particle size are providing a high surface area from which odorizing molecules could leave the particle. Due to this, the small tobacco particles have been found to be important since they provide a full tobacco flavor over a long period.

According to another embodiment the flavored material comprises flue cured tobacco (FCT) in an amount comprised between 1 and 47.5 wt. %. regarding to the consumable. In a preferred example, the flavored material comprises flue cured tobacco (FCT) in an amount of about 25 wt. % of total weight of the consumable. Flue cured tobacco may comprise a blend of tobacco strands and tobacco dust. For example, shredded tobacco may comprise tobacco strands (e.g. tobacco cut filler) of up to about 5-mm long. Preferably the flavored material comprises tobacco material which contain of different types of tobacco. Due to this, it is possible to enhance the consumable with different tobacco tastes using at least fire-cured tobacco and/or flue cured tobacco and/or other plant additives.

Preferably, the ratio of solid-to-liquid ingredients content of the consumable is comprised between 70:30 and 30:70, preferably 60:40 to 40:60, more preferably between 55:45 and 50:50, most preferably 52:48. Due to this, the consumable contains enough aerosol forming agent, may be formed into a sheet without being too brittle while having enough conductive material for conductivity.

The objective is also reached by a method for manufacturing of a consumable comprising the steps of:

• • mixing the flavorant material with the electrically conductive material in particulate form, the aerosol forming agent and water to form a paste or dough,
  • pressing the paste or dough into a layer,
  • and solidifying the heating layer such as by curing and/or drying.

It is conceivable to add to the delivered paste or dough a tobacco powder or tobacco material. The dough or the paste comprising the tobacco material or the tobacco paste preferably delivers a strong tobacco taste. In other embodiments the flavorant material further comprises natural or synthetic flavorings which could enhance the consumable or heating layer or generated aerosol with flavorings such as chocolate, vanilla or menthol.

In particular “mixing” means in this context that the ingredients of the consumable or the heating layer are diffusionable or distributionable. It is conceivable that some ingredients are provided in solid form and other in liquid form. It is also conceivable to soak the solid ingredients with the liquid ingredients to manufacture the consumable or the heating layer. After that it is advantageous to knead the paste or the dough for in particular even distribution of the ingredients. Preferably the electrically conductive material, the flavorant material and at least CFT are provided as solid ingredients of the consumable or the heating layer. Also preferably the aerosol forming agent, the water and at least a binder are provided as liquid ingredients of the consumable. Preferably an optimal proportion of the ingredients for the consumable or the heating layer comprises at least 52% wt. of solid ingredients and at least 48% wt. of liquid ingredients.

Preferably the dough or the paste are pressed into a layer with a thickness of at least 0.5 mm. But it is also possible to press a layer with a thickness of 2 mm or less. However, the electrical resistance of the consumable or the heating layer arranged between two electrodes arises with greater thickness of the layer. In an embodiment with the consumable provided as a paste or dough, it is possible to press the paste or dough to a layer and let this dry. Additionally or alternatively the paste or the dough could be pressed to a supporting layer and/or rolled between two porous wrapping layers. Such wrapping layers could be advantageous for forming and keeping the layered form of the pressed ingredients. The supporting layer and/or the wrapping layers preferably comprise paper or silicon. Thus, a particularly stable form of the heating layer can be achieved.

The objective is also reached by a device for delivering a tobacco aerosol comprising a consumable characterized by a pair of electrodes and a source of electrical energy to supply the electrodes, wherein the electrodes comprising a contact surface are configured to press the layer of the consumable in sandwich along at least a portion of a surface area of the layer. The device for delivering a tobacco aerosol is preferably useable as an aerosol generating device for the consumable according to the invention. It is conceivable that such a device comprises further mechanical, electrical and/or electronical part as common electrical aerosol delivering devices. Due to this, it is possible that the device further comprises a cartridge for storage the consumable. Preferably the cartridge is refillable or replenishable with the consumable.

According to another embodiment the device is characterized in that the portion in contact with the layer is comprised between 10 and 80%, preferably 20-50% of the surface area between the electrodes.

According to another embodiment the electrodes are pressed on the layer with a pressure comprised between 0.5 and 10 bar, preferably 5 bar. In a preferred embodiment the device comprises means for pressure generation. Preferably the means comprise springs for generating a pressure between 0.5 and 10 bar. In the preferred embodiment, the means for pressure generation generate a pressure of 5 bar between two electrodes. Preferably the pressure acts on the electrodes with the surface area of 150-300 mm², for example 215 mm². But it is also possible to generate pressure of at least 5 bar on a larger surface area of the electrodes. However, the surface area of the electrodes depends on the size of the whole device. The electrodes may comprise holes or channels to facilitate the aerosol to flow out of the consumable. For example, each electrode comprises a corrugated and/or apertured contact surface.

The objective is also reached by a method of production of tobacco aerosol comprising the steps of:

• • arranging a heating layer of an aerosol substrate between two electrodes of an aerosol generating device,
  • pressing the electrodes on the heating layer,
  • supplying the electrodes with the current, wherein the heating layer conducts the current between the electrodes,
  • heating the heating layer thereby creating the tobacco aerosol.

Preferably the heating of the heating layer or the consumable is provided through the electrical current which flows from electrode to another electrode of the aerosol generating device. The conductive material comprised in the consumable or the heating layer preferably allows the current flow. Due to this the consumable or the heating layer incinerates between two electrodes of the device thereby creating the inhalable aerosol.

Preferably, the method further comprises guiding the tobacco aerosol through a conduit or an aerosol channel to a mouthpiece outlet. It is conceivable that the conduit or the aerosol channel is connected to the mouthpiece and a heating section of the device. Preferably the heating section of the device comprises the two electrodes and the heating layer arrangement.

In the present patent application, the particle size refers to the mean diameter D90 determined by laser diffraction with a particle size analyzer Malvern 3000 using a dry dispersion method and software v3.62.

Further advantages, objectives and features of the present invention will be described, by way of example only, in the following description with reference to the appended figures. In the figures, like components in different embodiments can exhibit the same reference symbols.

The figures show:

FIG. 1a schematic cross-sectional view of a consumable comprising conductive material between two electrodes with one particle of the conductive material;

FIG. 1b schematic cross-sectional view of a consumable comprising conductive material between two electrodes with two touching particles of the conductive material;

FIG. 1c schematic top view of a consumable comprising conductive material between two electrodes;

FIG. 2 schematic view of a device for delivering aerosol with two electrodes and consumable arranged between the electrodes;

FIG. 3 flow chart of a method for manufacturing a consumable comprising a conductive material;

FIG. 4 flow chart of a method of aerosol production with a device comprising two electrodes and a consumable arranged between the electrodes;

FIG. 5a schematic view of a cartridge comprising consumable arranged as a spiral;

FIG. 5b schematic view of a cartridge comprising consumable arranged as a hyperbolic spiral.

In FIGS. 1a and 1b schematic cross-sectional views of a consumable 1 comprising conductive material 7 between two electrodes 4a, b are shown. In both figures, the shown consumable 1 comprises at least flavorant material 5, electrically conductive material 7 and optionally aerosol forming agent 6. It is conceivable that the consumable 1 further comprises ingredients which form an aerosol substrate (not shown). The flavorant material 5 may be a tobacco material for enhancing the aerosol substrate with an individual tobacco taste and/or may be another flavoring substance which is added additionally or alternatively to the tobacco material. The ingredients, especially the electrically conductive material 7 is provided in particulate form. In particular, the ingredient may be provided as a solid powder comprising particles of the conductive material. Such particulate ingredients are preferably embedded in the heating layer 3 or the consumable 1. However, preferably the consumable 1 is formed as a layer, in particular being or comprising a heating layer 3. Also preferably the layer 3 or the consumable 1 is arranged between two electrodes 4a, b in an aerosol generating device 2 (shown in FIG. 2).

The two electrodes 4a, b are spaced to each other being connected with the consumable 1 or the heating layer 3. Preferably a distance between the electrodes 4a, b is considered as a thickness 8 of the consumable 1. The thickness 8 of the consumable 1 or the heating layer 3 could preferably be in range of 0.5 mm and 5 mm, preferably in the range of 0.5 and 2 mm. In particular, the thickness 8 is dependent on the size of the aerosol generating device 2 (shown in FIG. 2) and a size of the electrodes 4a, b. Especially the handy devices 2 preferably comprise electrodes 4a, b with small average contact surfaces 11. In an example, the contact surfaces 11 comprise an area of 215 mm². But it is also conceivable that the contact surfaces 11 comprise the area in range of 150 mm² and 300 mm². As shown in the FIG. 1a, the contact surfaces 11 of the electrodes 4a, b are in direct contact to the consumable 1 or the heating layer 3. In an example, 70% to 95% of the contact surfaces 11 touch the consumable 1 or the heating layer 3. Preferably the electrodes 4a, b apply pressure to the consumable 1 or the heating layer 3 to reduce the contact resistance between the electrodes and the conductive particles.

The first 4a and the second 4b electrode are supplied with a voltage source 19. In a state of use of the aerosol generating device 2, the electrical current flows from the one electrode 4b through the consumable 1 to the other electrode 4a. In an example, the voltage source 19 is supplied by a rechargeable battery, such as lithium-ion, with a voltage value of 3.7 V. But it is also conceivable to use other electrical energy sources 10 (shown in FIG. 2) for supplying the electrodes 4a, b with energy.

The consumable 1 as shown in FIG. 1a preferably comprises a thickness 8, after compression equal to or lower than the largest dimensions of conductive particles. The conductive material 7 is shown as a particle. It is conceivable that the consumable 1 comprises more than one particle of the conductive material 7. Preferably, the consumable comprises a plurality of particles randomly dispersed in the consumable. For example, the electrically conductive material 7 comprises particles of particle size of about 780 microns. In particular, the electrically conductive material 7 was activated carbon particles under reference Jacobi EcoSorb MB3-10H. It is conceivable that the resistance between the electrodes depends on the size of the particles of the conductive material 7. The electrically conductive material 7 preferably may comprise two contact points 7a with the electrodes 4a, b which are preferably arranged parallel to each other. Preferably the current flows from the one contact point 7a to the other thereby electrically connecting the electrodes 4a, b. In another embodiment (see FIG. 1b), the electrical conductive material 7 comprising at least two particles preferably comprises at least three contact points 7a. Preferably two contact points 7a touch the electrodes 4a, b and the third contact point 7a is a contact point between the particles of the conductive material 7. Of course, an electrically conductive material 7 with both arrangements of FIGS. 1a, 1b in the consumable is also possible. Preferably, the thickness 8 of the consumable is substantially equal to the particle size to ensure contacts points 7a with the electrodes for a plurality of particles. The thickness of the consumable may be 0 to 20% larger than the particle size to ensure contact points after compression of the consumable between the electrodes. For example, the particle size of the electrically conductive particles may be respectively about 250 microns, or 300 microns, or 350 microns, or 400 microns, or 450 microns, or 500 microns, or 550 microns, or 600 microns, or 650 microns, or 700 microns, or 750 microns, or 800 microns and the thickness of the consumable or distance 8 between the electrodes may be respectively between 200 and 250 microns, or between 300 and 360 microns, or between 350 and 420 microns, or between 400 and 480 microns, or between 450 and 540 microns, or between 500 and 600 microns, or between 55 and 660 microns, or between 600 and 720 microns, or between 650 and 780 microns, or between 700 and 840 microns, or between 750 and 900 microns, or between 800 and 960 microns.

The FIGS. 1a and b show in particular preferred embodiments, wherein the resistance at the thickness 8 of the consumable 1 decreases. The current flows better with a thickness 8 of the consumable which allows as few as possible contact points 7a to the electrodes 4a, b. Due to this, the transition resistance is preferably proportional to the thickness 8 and/or to a number of contact points 7a.

FIG. 1c shows a schematic top view of a consumable 1 comprising conductive material 7 between two electrodes 4a, b. As can be seen in the FIG. 1b, the consumable 1 is arranged between the electrodes 4a, b (4b not shown). Preferably the consumable 1 or the heating layer 3 comprises at least one surface area 3a which touches the contact surfaces 11 (not shown) of the electrodes 4a, b. Due to the fact that the consumable 1 is pressed between the electrodes 4a, b, it is conceivable that only a portion of the surface 3b of the consumable 1 is heatable.

FIG. 2 shows a schematic view of a device 2 for delivering aerosol with two electrodes 4a, b and consumable 1 arranged between the electrodes 4a, b. The device 2 further comprises an electrical energy supply 10, a mouthpiece 12, an aerosol channel 13 and a cartridge 14. It is conceivable that the device 2 comprises further mechanical, electrical and/or electric components. Preferably the electrodes 4a, b are supplied with energy comprised in the electrical energy 10 supply. Due to this, the electrodes 4a, b preferably does not need an external voltage source 19 (not shown). But it is also possible that another embodiment of the device 2 comprises a voltage source 19 which supplies only the electrodes with energy (not shown).

Preferably the cartridge 14 comprises the consumable 1. The cartridge 14 is used for storage of the consumable 1. Also preferably the stored consumable 1 in the cartridge 14 is advantageously placed in a space saving way. The cartridge 14 is preferably connected to the electrodes 4a, b for supplying the electrodes 4a, b with fresh, in particular not burned consumable 1. It is conceivable that the cartridge comprises means for pushing the stored consumable 1 forwards to the electrodes 4a, b (not shown). This means could be a manual or electrical propulsion.

The heated consumable 1 which is arranged between two electrodes 4a, b preferably segregates inhalable aerosol 9. Preferably the aerosol 9 is guided through the aerosol channel 13 to the mouthpiece 12 of the device 2. Due to this, it is conceivable that the aerosol channel 13 is connected to the electrodes 4a, b. It is also possible that the electrodes 4a, b are arranged in the aerosol channel 13. In such a case, the aerosol channel 14 might be connected to the cartridge 13.

FIG. 3 shows a flow chart of a method for manufacturing a consumable 1 comprising a conductive material 7. First step of the method for manufacturing the consumable 1 could preferably be mixing 100 the ingredients of an aerosol substrate to provide a smooth mixture. Preferably the ingredients comprise solid and liquid. Also preferably the flavorant material 5, such as a tobacco material or other flavorant substance, and the conductive material 7 are provided in particulate form, preferably as powder. It is advantageous to mix the solid materials before adding liquid ingredients to the solid ingredients. An aerosol forming agent 6 and water are preferably provided as liquid ingredients. It is also conceivable to use binder for a smoother aerosol substrate mixture. It is also conceivable to soak porous conductive particles such as charcoal in a liquid forming agent before mixing with the other ingredients. After mixing 100 the ingredients, an aerosol substrate is obtained in form of dough or paste. The next step of the method for manufacturing is preferably the pressing step 101. Preferably the pressing step 101 comprises mechanical compression of the aerosol substrate for forming a consumable 1 to a layer. It is conceivable that the pressed consumable 1 is arranged between two wrappings after pressing step 101. Such wrappings are preferably useful for rolling or layering the consumable 1. In some embodiments the consumable 1 can be rolled or layered without using the wrappings. The wrapping layers can be paper layers. However, it is advantageous to bring the consumable 1 in a rolled shape for further storage in a cartridge 14. As a last step of the method for manufacturing the consumable could be the solidifying step 102. Preferably the pressed and/or rolled consumable 1 is dried and/or cured during the step 102. It is conceivable to arrange the consumable 1 in the cartridge 14 for further use in the device 2. The consumable 1 should comprise a certain amount of moisture for being elastic enough for further use. Preferably the consumable 1 is gradually rolled out in the further use in the device 2.

FIG. 4 shows a flow chart of a method for aerosol production with a device 2 comprising two electrodes 4a, b and a consumable 1 arranged between the electrodes 4a, b. The first step of the method for aerosol production is preferably arranging 200 the consumable 1 or the heating layer 3 between the electrodes 4a, b of the device 2. It is also conceivable that the consumable 1 is rolled out and guided to the electrodes 4a, b out of the cartridge 14 of the device 2 before arranging 200. The method for aerosol production further comprises a pressing step 201, wherein the electrodes 4a, b are pressed with a pressure amount to the consumable 1. Preferably the electrodes 4a, b are arranged parallel to each other (shown in FIG. 1a) and surround the consumable 1 from two sides or directions. The method further comprises a supplying step 202. The supplying step 202 comprises supplying the electrodes 4a, b with electrical current. Preferably the heating layer 3 or the consumable 1 conducts the current between the two electrodes 4a, b. Due to this, the method comprises a heating step 203. A temperature of the electrodes 4a, b preferably increases thereby heating the consumable 1 or heating layer 3. The inhalable aerosol 9 is generated from the consumable 1 or the heating layer 3 during the heating step 203.

FIG. 5a shows a schematic view of a cartridge 14 comprising consumable 1 arranged as a spiral. Preferably the consumable 1 or the heating layer 3 runs around a curve which emanates from a point (not shown), moving farther away as the consumable 1 revolves around the point. The consumable 1 is preferably arranged or stored in the cartridge 14. It is conceivable that the cartridge 14 is a storage box or another container which keeps the consumable fresh. The cartridge further comprises a leading channel 17 which is connected to the electrodes 4a, b of the device 2. It is also conceivable that the leading channel 17 is connected to the aerosol channel 13 of the device 2, wherein the electrodes 4a, b are arranged at least in part inside the aerosol channel 13. However, the cartridge 14 is preferably detachably connected to the electrodes 4a, b via connecting means 18. This could be useful in case of refill of the cartridge 14 with fresh consumable 1. It is conceivable that the device 2 further comprises a container 15 for used consumable 16. In some embodiments the used consumable 16 is preferably heated at a temperature up to 350 C°, wherein the used consumable 16 comprises a very small or no amount of liquids. If the amount of liquid forming agent is too low, a higher temperature, e.g. 350° C. (close to the combustion of tobacco) may be required to generate aerosol. If a sufficient amount of forming agent is contained in the consumable, the temperature to vaporize enough aerosol can be lowered e.g. below 300° C. The used consumable 16 preferably falls into the container 15 after the fresh consumable 1 is forwarded from the cartridge 14 to the electrodes 4a, b. It is also conceivable to arrange other constructions for storage of used consumable 16 in the device 2.

FIG. 5b shows a schematic view of a cartridge 14 comprising consumable 1 arranged as a hyperbolic spiral. The consumable 1 is preferably arranged in the cartridge 14 as shown in FIG. 5a. Preferably the consumable 1 is wrapped on a wrapper or a fixture (not shown) for a better support of the consumable 1 inside the cartridge 14. However, there many possibilities to arrange the consumable 1 or the heating layer 3 inside the cartridge 14. It is important to arrange the consumable 1 very compact inside the cartridge 14 to provide a long uptime of the cartridge 14 inside the device 2.

The consumable can be stored in alternative forms to the ones of FIGS. 5a, 5b such as a stack of a continuous accordion consumable or separate layers arranged in stack.

The applicant reserves his right to claim all features disclosed in the application document as being an essential feature of the invention, as long as they are new, individually or in combination, in view of the prior art. Furthermore, it is noted that in the figures features are described, which can be advantageous individually. Someone skilled in the art will directly recognize that a specific feature being disclosed in a figure can be advantageous also without the adoption of further features from this figure. Furthermore, someone skilled in the art will recognize that advantages can evolve from a combination of diverse features being disclosed in one or various figures.

LIST OF REFERENCE SYMBOLS

• • 1 consumable
  • 2 aerosol generating device
  • 3 heating layer
  • 3 a surface area of the layer
  • 3 b a portion of the surface of the layer
  • 4 a first electrode
  • 4 b second electrode
  • 5 flavorant material/tobacco material
  • 6 aerosol forming agent
  • 7 electrically conductive material
  • 7 a contact point of the conductive material with the electrode
  • 8 thickness of the heating layer/consumable
  • 9 aerosol
  • 10 electrical energy
  • 11 contact surfaces of the electrodes
  • 12 mouthpiece
  • 13 aerosol channel
  • 14 cartridge
  • 15 container for used consumable
  • 16 used consumable
  • 17 leading channel
  • 18 connecting means
  • 19 voltage source
  • 100 mixing the ingredients of the consumable
  • 101 pressing the dough or the paste to a layer
  • 102 solidifying the heating layer
  • 200 arranging the heating layer/consumable between electrodes
  • 201 pressing the electrodes on the heating layer/consumable
  • 202 supplying the electrodes with electrical current
  • 203 heating the heating layer

Claims

1. A consumable for an aerosol generating device comprising a heating layer of an aerosol substrate formed to be positioned in sandwich between two electrodes of the device, wherein the heating layer of the aerosol substrate comprises flavorant material and an aerosol forming agent, wherein the heating layer further comprises electrically conductive material in particulate form embedded in the heating layer, wherein the electrically conductive material is arranged in the heating layer to conduct electrical current between the two electrodes and to heat the aerosol substrate to a temperature sufficient to aerosolize the aerosol forming agent when the heating layer is positioned between the two electrodes of the device.

2. The consumable according to claim 1, wherein: the electrically conductive material has an electrical conductivity of at least 3*102 S/m (at 20° C.).

3. The consumable according to claim 1, wherein: a thickness of the heating layer is between 0.5 and 3 mm.

4. The consumable according to claim 1, wherein: the electrically conductive material is distributed in and on the heating layer in an amount to allow electricity to flow from one electrode through a thickness of the heating layer to the other electrode when the heating layer is positioned between the two electrodes of the device.

5. The consumable according to claim 1, wherein: the electrically conductive material is randomly distributed inside the heating layer and on a surface area of the heating layer.

6. The consumable according to claim 1, wherein: the electrically conductive material comprises graphite and/or charcoal particles.

7. The consumable according to claim 1, wherein: the electrically conductive material comprises an amount of 2.5 to 50 wt. % regarding to the heating layer.

8. The consumable according to claim 1, wherein: the heating layer further comprises a binder in an amount between 0.5 and 2.5 wt. % regarding to the consumable.

9. The consumable according to claim 1, wherein: the aerosol forming agent comprises an amount of less than 25 wt. % regarding to the consumable.

10. The consumable according to claim 1, wherein: the heating layer further comprises water in an amount between 10 and 49.5 wt. % regarding to the consumable.

11. The consumable according to claim 1, wherein: the flavorant material comprises tobacco in an amount up to 47.5 wt. % regarding to the consumable.

12. The consumable according to claim 11, wherein: the tobacco comprises tobacco powder with a particle size lower than 1000 microns.

13. The consumable according to claim 11, wherein: the tobacco comprises flue cured tobacco in an amount between 1 and 47.5 wt. % regarding to the consumable.

14. A method for manufacturing a consumable for an aerosol generating device, comprising the steps of: mixing flavorant material with electrically conductive material in particulate form, an aerosol forming agent, and water to form a paste or dough,pressing the paste or dough into a heating layer, andsolidifying the heating layer by curing and/or drying.

15. A device for delivering a tobacco aerosol comprising the consumable according to claim 1, comprising: a pair of electrodes and a source of electrical energy to supply the electrodes, wherein the electrodes comprising a contact surface are configured to press the heating layer of the consumable in sandwich along at least a portion of a surface area of the heating layer.

16. The consumable according to claim 1, wherein: a thickness of the heating layer is between 0.5 and 2 mm.

17. The consumable according to claim 1, wherein: the electrically conductive material comprises an amount between 2.5 and 25 wt. % regarding to the heating layer.

18. The consumable according to claim 8, wherein: the binder is CMC.

19. The consumable according to claim 9, wherein: the aerosol forming agent is glycerin and/or propylene glycol.