Aerosol former for biodegradable heat-not-burn and e-cigarettes with related system and method

Abstract

An aerosol former for heat-not-burn and biodegradable e-cigarette includes a sectional member wrapped by a paper material. At least one section is a botanical section connected to more than one e-liquid section when used for heat-not-burn cigarettes, and without the botanical section when used for e-cigarettes. The e-liquid sections include a heated segment and a vapor permeable liquid-flow-inhibiting thermal barrier. Each of the heated segments may include a sandwich structure. The structure may include a porous sponge layer made from a cellulose fiber based non-woven material which is installed inside a base frame aluminum foil structure. Each of the vapor permeable liquid-flow-inhibiting thermal barriers may have a first layer made of a hard non-porous hydrophobic non-woven fiber, and a second outside, external layer made from a hydrophobic cellulose fiber. The second layer forms a limiting surface barrier for the first layer.

What is claimed is: 
     
         1 . A biodegradable aerosol former for heat-not-burn and e-cigarettes comprising:
 a sectional member wrapped by a paper material positioned within a heating device,   
       wherein at least one section of the sectional member is a botanical section and an e-liquid section; 
       wherein the sections of the sectional member are heated by a heating component of the heating device;
 the e-liquid section comprises a heated segment and a vapor permeable liquid-flow-inhibiting thermal barrier, the heated segment comprises a sandwich structure comprising a porous fibrous sponge layer made from a cellulose fiber based non-woven material installed inside a base frame aluminum foil structure, 
 wherein the porous fibrous sponge layer in the heated segment is filled with an e-liquid during or after manufacture of the porous fibrous sponge layer, an amount of e-liquid in the porous fibrous sponge layer being directly related to the porosity of the fibrous sponge and calibrated to a desired heating rate and heating duration, 
 wherein the vapor permeable liquid-flow-inhibiting thermal barrier comprises a first layer of a hard non-porous hydrophobic non-woven fiber, and a second layer of a hydrophobic cellulose fiber on an external surface of the first layer, the second layer forming a limiting surface barrier for the first layer. 
 
     
     
         2 . The aerosol former according to  claim 1 , wherein each of the heated segments is made from one of cellulose, carbon, glass, ceramic fibers, or mixtures thereof, wherein each e-liquid section comprises at least two separate heated segments and wherein each of the heated segments is designed for at least two puffs. 
     
     
         3 . The aerosol former according to  claim 1 , wherein the botanical section is formed from at least one of: beads, strips, shredded pieces, granules, gathered webs, or any combination thereof, wherein the botanical section comprises one or more of: tobacco, hemp, cannabis, tea, mint, rose, menthol, jasmine, lotus leaf, licorice, vetiver, orange blossom, honey suckle, agilawood, sarcandra glabra, chrysanthemum, codyceps sinensis, alfalfa, orange peel, dendrobium, rosemary, kratom, ginseng, rooibos, honeybush, and chestnut, or any combination thereof. 
     
     
         4 . The aerosol former according to  claim 3 , wherein a botanical extract of the botanical section is loaded on to a cellulose substrate made by a paper making process, or by a fiber air laying process followed by fiber entanglement using needle punching, hydroentanglement, stitch bonding, chemical bonding, or any combination thereof, wherein the botanical extract is loaded on to the substrate by dip coating, spray application, or a printing process. 
     
     
         5 . The aerosol former product according to  claim 1 , wherein each thermal barrier has a length between about 2.0 mm and about 10.0 mm. 
     
     
         6 . The aerosol former according to  claim 1 , wherein the sectional member has a length between about 45.0 mm and about 84.0 mm, and diameter between about 3.0 mm and about 8.0 mm. 
     
     
         7 . The aerosol former according to  claim 1 , wherein the sectional member is hollow in the e-liquid section, and has a cooling section and a filter section. 
     
     
         8 . The aerosol former according to  claim 1 , wherein the sectional member comprises at least two heated sections, and wherein the botanical section is heated separately to a first temperature of between about 150.0 and about 250.0 deg C., while the e-liquid section is heated separately to a second temperature of about 300.0 deg C. or less. 
     
     
         9 . The aerosol former according to  claim 1 , wherein the botanical section is heated depending on the botanical type to a temperature such that an active ingredient of the botanical section is activated without significant heat-induced chemical degradation. 
     
     
         10 . The aerosol former according to  claim 1 , wherein the e-liquid section, the botanical section, and the mouthpiece section are wrapped with a paper or polymeric fiber wrap that is of sufficient thickness to maintain structural integrity the aerosol former. 
     
     
         11 . A system of a biodegradable aerosol former for heat-not-burn and e-cigarettes comprising:
 a sectional member wrapped by a paper material;   a heating device for receiving the sectional member, wherein the heating device comprises a body part and a cover part coupled together by an opening device, wherein the body part and the cover part form a longitudinal cavity the receives the sectional member;   wherein the sectional member comprises at least one botanical section and an e-liquid section, wherein the e-liquid section comprises a heated segment and a vapor permeable liquid-flow-inhibiting thermal barrier;   wherein an inner surface of the longitudinal cavity comprises heating components, each heating component is connected to a power source and a control unit, wherein the botanical section is aligned with a single heating component and the heated segment is aligned with a single heating component when the sectional member is positioned within the longitudinal cavity;   the botanical section and heated segments are heated by the heating components in a successive manner, the control unit being configured to provide a heating duration related to a predetermined number of puffs associated with the e-liquid section; the heated segment comprises a porous fibrous sponge layer; a capacity of each e-liquid section is related to a porosity of the porous fibrous sponge layer and a desired heating rate and a heating duration.   
     
     
         12 . The system according to  claim 11 , wherein the heating components are made from nichrome or an iron-chromium-aluminium (FeCrAl) alloy, and each heating component comprises a semi-ring-shaped plate located within the longitudinal cavity. 
     
     
         13 . The system according to  claim 11 , wherein the heating components comprise at least one of resistance, induction, solid state microwave, and infrared type heaters. 
     
     
         14 . A method for providing an aerosol former for biodegradable heat-not-burn and e-cigarettes comprising:
 forming a sectional stick wrapped by a paper material, wherein the sectional stick has at least one botanical section and an e-liquid section, wherein the e-liquid section has a heated segment, the heated segment comprises a sandwich structure including a porous fibrous sponge layer positioned within a base frame aluminum foil structure;   filling the sponge layer of the heated segment by an e-liquid, wherein an e-liquid capacity the sponge layer is related to a porosity of the sponge layer and a desired heating rate, desired heating duration and a desired number of puffs;   positioning the sectional stick within a heating device, the heating device having a longitudinal cavity for receiving the sectional stick, wherein an inner surface of the longitudinal cavity comprises heating components, each heating component is connected to a power source and a control unit, and wherein the botanical section is aligned with a single heating component while the heated segment of the e-liquid section is aligned with a single heating component;   heating the botanical section and heated section during a smoking session, wherein the botanical section and heated section are heated by turning on heating components in succession one after another during a smoke session.   
     
     
         15 . The method according to  claim 14 , wherein filling the sponge layer of the heated segments by an e-liquid comprises filling it for one puff session, wherein one puff session comprises at least two puffs. 
     
     
         16 . The method according to the  claim 14 , further comprising separating the heated segment from the botanical section with a vapor permeable liquid-flow-inhibiting thermal barrier, wherein the vapor permeable liquid-flow-inhibiting thermal barrier blocks heat transfer from the heated segment to the botanical section. 
     
     
         17 . The method according to  claim 14 , wherein heating the botanical section and heated section during a smoking section comprises heating for a predetermined period of time to prevent a dry burn effect. 
     
     
         18 . The method according to  claim 14 , wherein the botanical section is heated simultaneously with the heated segments and at different temperatures to prevent formation of inhalable toxic chemical compounds from the botanical section, the method further comprising heating the botanical section to a temperature depending on a detected botanical type such that an active ingredient of the botanical section is activated without significant heat-induced chemical degradation. 
     
     
         19 . The method according to  claim 14 , further comprising providing at least three vaping modes, wherein a first vaping mode is a botanical mode, a second vaping mode is an e-liquid mode, and a third vaping mode is a mixing mode. 
     
     
         20 . The method according to  claim 14 , further comprising detecting a type of material within the botanical section by the heating device, and generating an appropriate heating protocol based on the detected type of material.