A device for generating aerosols, method of using the device, and method of manufacturing a device for generating aerosols.

Description

1 / 63 “AEROSOL GENERATION DEVICE, METHOD OF USING THE DEVICE AND METHOD OF MANUFACTURING A DEVICE "TO GENERATE AEROSOL" TECHNICAL FIELD

[001] The present invention relates to devices used as alternatives to conventional smoking products, such as electronic cigarettes, vaporization systems and, in particular, devices that heat without burning. BACKGROUND

[002] Heat-without-burn (HNB) devices heat tobacco to temperatures below those that cause combustion to create an inhalable aerosol containing nicotine and other tobacco constituents, which is then made available to the device user. Unlike traditional cigarettes, the goal is not to burn the tobacco, but rather to heat it sufficiently to release the nicotine and other constituents through aerosol production. Lighting and burning the cigarette creates unwanted toxins that can be avoided by using the HNB device. However, there is a fine balance between providing enough heat to effectively release the tobacco constituents in aerosol form and not burning or igniting the tobacco. Current HNB devices have not found this balance, either heating the tobacco to temperatures that produce an inadequate amount of aerosol or overheating the tobacco and producing an unpleasant or burnt flavor profile.Furthermore, the current methodology leaves the internal components of the traditional HNB device contaminated with byproducts from tobacco combustion and accidental combustion.

[003] For the reasons above, it is necessary a Petition 870260066600, dated 06 / 07 / 2026, page 11 / 89 2 / 63 aerosol production device that provides the user with the ability to control the device's power, which will affect the temperature at which the tobacco will be heated by the inductive method to reduce the risk of combustion - even at temperatures that would be sufficient to ignite - while increasing the efficiency and flavor profile of the aerosol produced. SUMMARY

[004] The present invention is directed to a system and method by which a consumable tobacco component is rapidly and incrementally heated by induction, so as to produce an aerosol containing some of its constituents, but not the byproducts most frequently associated with combustion, for example, smoke, ash, tar and other potentially hazardous chemicals. This invention involves the positioning and progressive advancement of heat along a consumable tobacco component using an induction heating element that provides an alternating electromagnetic field around the component.

[005] An object of the present invention is a device in which an induction heating source is provided for use in heating a consumable tobacco component.

[006] Another objective of the present invention is a consumable tobacco component consisting of several individually sealed, hermetically sealed, coated wrappers containing a consumable tobacco preparation and an induction heating source. The wrapper may be an aluminum shell with predefined openings. The wrappers may be coated with a gel that seals the openings until a Petition 870260066600, dated 06 / 07 / 2026, page 12 / 89 3 / 63 Induction heating process melts the gel, cleaning the openings. In some embodiments, the gel may include a flavoring agent that can add aroma or enhance the aroma of the tobacco aerosol.

[007] In some embodiments, several casings are stacked inside a paper tube with spaces between them, formed by excess aluminum packaging at the bottom end of each casing and channels on both sides to allow the aerosol produced to escape. When the inductive heating source is activated, the predefined openings are cleared, and the aroma is combined with the aerosol to travel through the tube and be made available to the device user.

[008] Using these methods and devices, the device needs to heat less mass, can heat up instantly, cool down quickly, and save energy, allowing for greater use between recharging sessions. This contrasts with current known commercially available devices for heating without burning.

[009] Another objective of the present invention is a consumable component containing tobacco, composed of several individually sealed, hermetically sealed coated wrappers and an induction heating source. The wrappers are then coated with a gel that seals them until an induction heating process can melt the gel, clearing the openings. In some embodiments, the gel may include a flavoring agent that can add aroma or enhance the aroma of the consumable tobacco component.

[0010] Another objective of the present invention is to create packaging containing consumables that is easy to replace and minimizes fouling of the inside of the case. Petition 870260066600, dated 06 / 07 / 2026, page 13 / 89 4 / 63 during use, in order to reduce the effort required to clean the case.

[0011] Another objective of the present invention is to move the heating element relative to the susceptor or consumable to heat segments of the consumable independently of other segments.

[0012] Another objective of the invention is to maximize the efficiency of energy use in the device for generating aerosols.

[0013] Another objective of the invention is to control the heat of the heating element to maximize the longevity of the device.

[0014] Another objective is to create the ability to alter the airflow through the device to change the scent or dosage of a consumable. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 shows a side view within an embodiment of the present invention.

[0016] Figure 2A shows a perspective view of an embodiment of the present invention with portions removed to show the interior of the embodiment.

[0017] Figure 2B shows a perspective view of the embodiment shown in Figure 2A with portions cut off and / or removed to reveal internal components.

[0018] Figure 2C shows a cross-sectional view of the embodiment shown in Figure 2A cut along line 2C-2C.

[0019] Figure 2D shows an exploded view of the mode shown in Figure 2A.

[0020] Figure 2E shows a perspective view. Petition 870260066600, dated 06 / 07 / 2026, page 14 / 89 5 / 63 of another embodiment of the present invention with portions cut and / or removed to reveal internal components.

[0021] Figure 3A shows a perspective view of another embodiment of the present invention.

[0022] Figure 3B shows a partially exploded view of the mode shown in Figure 3A.

[0023] Figure 3C shows a perspective view of the embodiment shown in Figure 3A with portions cut and / or removed to reveal internal components.

[0024] Figure 3D shows an enlarged perspective view of a unit containing consumables shown in Figure 3A.

[0025] Figures 4A and 4B show an exploded view of configurations of a unit containing consumables.

[0026] Figure 5A shows a perspective view of another embodiment of the present invention.

[0027] Figure 5B shows a cross-sectional view of the embodiment shown in Figure 5A taken along line 5B-5B.

[0028] Figure 5C shows a perspective view of a package containing consumables from the embodiment shown in Figure 5A.

[0029] Figure 6A shows a perspective view of another embodiment of the present invention.

[0030] Figure 6B shows an exploded view of the mode shown in Figure 6A.

[0031] Figures 7A and 7B show perspective views of other embodiments of the present invention.

[0032] Figure 8A shows a side view of one embodiment of the heating element. Petition 870260066600, dated 06 / 07 / 2026, page 15 / 89 6 / 63

[0033] Figure 8B shows a front view of the heating element shown in Figure 7A.

[0034] Figure 7C shows another embodiment of the present invention.

[0035] Figure 7D shows an exploded view of the mode in Figure 7C.

[0036] Figure 9A shows a side view of an embodiment of the aerosol production device.

[0037] Figure 9B shows a top view of the aerosol production device shown in Figure 8A.

[0038] Figure 9C shows a schematic diagram of one embodiment of the controller and its connection to other components of the present invention.

[0039] Figures 10A-10B show schematic diagrams of the controller's modalities and its connection to other components of the present invention.

[0040] Figure 11 shows a perspective view of one embodiment of a mobile heating element.

[0041] Figures 12A-12D show exploded views, cross-sectional views and perspective views of an embodiment of the present invention using a magnet for alignment.

[0042] Figure 12E shows a perspective view of another embodiment of an alignment mechanism.

[0043] Figures 13A-13B show perspective views of a multi-pin susceptor.

[0044] Figures 13C-D show side cross-sectional views of the embodiments in Figures 13A and 13B, respectively, cut along the longitudinal axis showing the multi-pin susceptor removed and inserted. Petition 870260066600, dated 06 / 07 / 2026, page 16 / 89 7 / 63 in the packaging containing consumables.

[0045] Figures 14A-14C show end views of an embodiment of the packaging containing consumables with the heating element rotating around the packaging containing consumables.

[0046] Figures 15A-15C show end views of an embodiment of the packaging containing consumables having another three-pin susceptor with the heating element rotating around the packaging containing consumables.

[0047] Figures 16A-16D show end views of an embodiment of the packaging containing consumables with a four-pin susceptor with the heating element rotating around the packaging containing consumables.

[0048] Figures 17A-17B show perspective views of an embodiment of a mechanism for rotating the heating element along an eccentric path around the packaging containing consumables.

[0049] Figures 18A-18B show end views of the embodiment in Figures 17A-17B of a mechanism for rotating the heating element along an eccentric path around the package containing consumables.

[0050] Figure 19 shows a perspective view of an embodiment of a mechanism for rotating the heating element along an eccentric path and translating the heating element along the packaging containing consumables.

[0051] Figure 20 shows a perspective view of one embodiment of a mechanism for moving the element of Petition 870260066600, dated 06 / 07 / 2026, p. 17 / 89 8 / 63 heating in relation to the packaging containing consumables.

[0052] Figure 21 shows a schematic diagram of one embodiment of the controller and its connection to other components of the present invention.

[0053] Figure 22 shows an embodiment of a heat sink attached to the heating element, with portions of the heat sink removed to show the heating element.

[0054] Figure 23 shows a cross-sectional view of an airflow controller attached to the packaging containing consumables.

[0055] Figure 24A shows an exploded perspective view of another embodiment of the present invention.

[0056] Figure 24B shows an end view of the embodiment in Figure 24A.

[0057] Figure 24C shows a cross-sectional view taken through line 24C-24C shown in Figure 24B.

[0058] Figures 25A-B show partial cutaway views of the packaging containing consumables in perspective with the susceptor removed to show a configuration inside the packaging containing consumables that uses a susceptor with a hollow pin.

[0059] Figures 25C-D show partial cutaway views of the embodiments in Figures 25A-B, respectively, with the hollow pin susceptor incorporated in a package containing consumables.

[0060] Figure 25E shows a cross-sectional view of the embodiment shown in Figures 25A-D cut along its longitudinal axis to show the airflow. Petition 870260066600, dated 06 / 07 / 2026, page 18 / 89 9 / 63 during use.

[0061] Figure 26A shows a perspective view of another embodiment of the packaging containing consumables before the insertion of a susceptor.

[0062] Figures 26B-C show partial cutaway views of the modality shown in Figure 26A to show the relationship of the internal components before susceptor insertion.

[0063] Figure 26D shows a cross-sectional view of the packaging embodiment containing consumables shown in Figures 26A-C cut along its longitudinal axis.

[0064] Figure 26E shows a partial cross-sectional view of the embodiment shown in Figure 26A after insertion of the susceptor.

[0065] Figure 26F shows the partial cross-sectional view shown in Figure 26E with a heating element wrapped around the packaging containing consumables.

[0066] Figure 26G shows a cross-sectional view of the packaging embodiment containing consumables shown in Figure 26F cut along its longitudinal axis. DETAILED DESCRIPTION OF THE INVENTION

[0067] The detailed description presented below, in connection with the accompanying drawings, is intended to be a description of currently preferred embodiments of the invention and is not intended to represent the only ways in which the present invention may be constructed or used. The description presents the functions and the sequence of steps for the Petition 870260066600, dated 06 / 07 / 2026, page 19 / 89 10 / 63 construction and operation of the invention in connection with the illustrated embodiments. It should be understood, however, that the same equivalent functions and sequences can be performed by different embodiments that are also intended to be encompassed by the spirit and scope of the invention.

[0068] The invention of the present application is a device for generating aerosol from a product containing consumables for inhalation, in a manner that utilizes relatively high heat with minimal burning of the product containing consumables. For the purposes of this application, the term consumable shall be interpreted broadly to encompass any type of pharmaceutical agent, medicine, chemical compound, active agent, constituent and the like, regardless of whether the consumable is used to treat a condition or disease, is for nutrition, is a supplement or is used for recreation. By way of example only, a consumable may include pharmaceuticals, nutritional supplements, over-the-counter medicines, tobacco, cannabis and the like.

[0069] With reference to Figures 1, the device 100 comprises a packaging containing consumables 102 and an aerosol production device 200. The device 100 generates aerosol through a heating-without-burning process, in which a unit containing consumables 104 is heated to a temperature that does not burn the unit containing consumables 104, but releases the consumable from the unit containing consumables in the form of an aerosol product that can be inhaled. Thus, a unit containing consumables 104 is any product containing a consumable that can be released in aerosol form when heated to the appropriate temperature. The present application discusses the application Petition 870260066600, dated 06 / 07 / 2026, page 20 / 89 11 / 63 of the invention applies to a tobacco product to provide a concrete example. The invention, however, is not limited to use with tobacco products. Package containing consumables

[0070] With reference to Figures 2A-6B, the packaging containing consumables 102 is the component that is heated to release the consumable in aerosol form. The packaging containing consumables 102 comprises a unit containing consumables 104, a metal (also called a susceptor) 106 for heating the unit containing consumables 104 through an induction heating system, and an enclosure 108 for containing the unit containing consumables 104 and the susceptor 106. The quality of heating of the packaging containing consumables 102 depends on the consistency of the product. The consistency of the product takes into account several factors such as position, shape, orientation, composition, and other characteristics of the unit containing consumables 104. Other characteristics of the unit containing consumables 104 may include the amount of oxygen contained in the unit. The objective is to maximize the consistency of the product by keeping each of these factors consistent throughout the manufacturing process.

[0071] If the shape of the consumable-containing unit 104 is in direct physical contact with the susceptor 106 with maximum contact area between them, then it can be inferred that the thermal energy induced in the susceptor 106 will be largely transferred to the consumable-containing unit 104. As such, the shape and arrangement of the consumable-containing unit 104 in relation to the susceptor 106 is an important factor. In some embodiments, the consumable-containing unit 104 is generally cylindrical in shape. As such, Petition 870260066600, dated 06 / 07 / 2026, page 21 / 89 12 / 63 the unit containing consumables 104 may have a cross-section of circular or oval shape.

[0072] Furthermore, another objective with regard to the design of the consumables-containing unit 104 is to minimize the amount of air to which the consumables-containing unit 104 is exposed. This eliminates or mitigates the risk of oxidation or combustion during storage or during the heating process. As a result, in certain definitions, it is possible to heat the consumables-containing unit 104 to temperatures that would otherwise cause combustion when used with prior art devices that allow more air exposure.

[0073] As such, in the preferred embodiment, the consumable-containing unit 104 is made from a powdered form of the consumable that is compressed into a pellet or rod. Compression of the consumable reduces the oxygen trapped within the consumable-containing unit 104. In some embodiments, the consumable-containing unit 104 may further comprise an additive, such as a humectant, flavoring, oxygen-displacing filler, or steam-generating substance, and the like. The additive may further assist in the absorption and transfer of thermal energy, as well as eliminate oxygen from the consumable-containing unit 104. In an alternative embodiment, the consumable may be mixed with a substance that does not interfere with the function of the device but displaces air in the interstitial spaces of the consumable and / or surrounds the consumable to isolate it from air.In yet another alternative embodiment, the consumable can be formed into small pellets or another shape that can be encapsulated to further reduce the air available to the user. Petition 870260066600, dated 06 / 07 / 2026, page 22 / 89 13 / 63 consumable.

[0074] As shown in Figures 2A-2D, in the preferred embodiment, the consumable-containing unit 104 can be an elongated unit defining a longitudinal axis L. For example, the consumable-containing unit 104 can be an elongated cylinder or tube having a circular cross-section or an oval cross-section. As such, the consumable-containing unit 104 can be defined by two opposite ends 105, 107 and a side wall 109 between them extending from the first end 105 to the second end 107, which defines the length of the consumable-containing unit 104.

[0075] The susceptor 106 may be similarly elongated and incorporated into the consumable-containing unit 104, preferably along the longitudinal axis L and extending substantially to the length and width (i.e., the diameter) of the consumable-containing unit 104. In consumable-containing units 104 having an oval cross-section, the diameter refers to the major diameter defining the long axis of the oval.

[0076] The susceptor 106 can be extruded by machine. Once extruded, the consumable-containing unit 104 can be compressed around the susceptor 106 along the length of the susceptor 106. Alternatively, the susceptor 106 can be stamped from flat metal material or any other suitable manufacturing method before assembling the consumable-containing unit 104 around the susceptor 106. In some embodiments, as shown in Figure 2E, the susceptor 106 can be made of steel wool. For example, the susceptor 106 can be made of thin Petition 870260066600, dated 06 / 07 / 2026, page 23 / 89 14 / 63 steel wool filaments grouped in the form of a block. As such, the steel wool block comprises numerous thin edges. In some embodiments, the steel wool block may be soaked with, immersed in, or completely filled with additive, such as a wetting agent, flavoring agent, vapor-generating substance, a substance to retard the oxidation of the steel wool (rust), and / or a filler to eliminate air between the steel wool filaments, and the like. As shown in Figure 2E, there may be cuts along the steel wool block to divide the unit containing consumables 104 into discrete segments for individual heating, as described below. Alternatively, individual steel wool blocks may be used, separated by space and / or consumables, so that each block can be heated individually during use.

[0077] The advantages of steel wool include, but are not limited to, easy disposal from an environmental point of view, as it begins to oxidize soon after being heated; and thus, it becomes brittle and degrades easily without dangerous sharp edges. Being composed of iron and carbon, it is relatively non-toxic.

[0078] The susceptor 106 can be made of any metallic material that generates heat when exposed to varying magnetic fields, as in the case of induction heating. Preferably, the metal comprises a ferrous metal. To maximize the efficient heating of the consumable-containing unit 104, the susceptor 106 generally corresponds to the shape of the largest cross-sectional area of ​​the consumable-containing unit 104, so as to maximize the surface area with which the consumable-containing unit 104 Petition 870260066600, dated 06 / 07 / 2026, page 24 / 89 15 / 63 makes contact with susceptor 106, but other configurations may also be used. In embodiments where the consumable-containing unit 104 is an elongated cylinder, the largest cross-sectional area would be defined by dividing the elongated cylinder along the longitudinal axis L along its major diameter, creating a rectangular cross-sectional area. As such, susceptor 106 would also be rectangular with dimensions substantially similar to the dimensions of the cross-sectional area of ​​the elongated cylinder.

[0079] In some embodiments, the susceptor 106 may be a metal plate. In some embodiments, the susceptor 106 may be a metal plate with a plurality of openings 110, such as a mesh screen. Inductive heating appears to be more effective and efficient at the edges of the susceptor 106. A mesh screen creates more edges on the susceptor 106 that can come into contact with the unit containing consumables 104 because the edges define the openings 110.

[0080] Preferably, the susceptor 106 may be a standardized strip with an array of small openings 110 to increase the amount of edges that can be used in an efficient inductive heating process, followed by a larger gap 112 that allows that length of susceptor 106 which will not permit inductive heating, or at least attenuates inductive heating and / or attenuates conduction from the segment being heated. This configuration allows the packaging containing consumables 102 to be heated in discrete segments. The elongated susceptor 106 may be an elongated metal plate having a longitudinal direction, the elongated metal plate comprising sets of openings 110a, 110b and sets Petition 870260066600, dated 06 / 07 / 2026, p. 25 / 89 16 / 63 of gaps 112a, 112b wherein the sets of openings 110a, 110b alternate in series with the sets of gaps 112a, 112b along the longitudinal direction of the elongated metal plate, so that each set of openings 110a, 110b is adjacent to one of the gaps 112a, 112b. Therefore, moving from one end of the susceptor 106 to the opposite end, there is a first set of openings 110a, then a first gap 112a, then a second set of openings 110b, then a second gap 112b and so on. In the area of ​​gaps 112, there is very little metallic material; therefore, there is minimal heat transfer. As such, even if the unit containing consumables 104 is a single unit, it can still be heated in discrete sections. The unit containing consumables 104 and the susceptor 106 are then wrapped in a casing 108.

[0081] In the preferred embodiment, the enclosure 108 may be made of aluminum with pre-drilled openings 120. The consumable-containing unit 104 is placed inside the enclosure 108 to contain the heat generated by the susceptor 106. The openings 120 in the enclosure 108 allow the consumable aerosol to escape when heated. Because the openings 120 create an avenue through which air can enter the enclosure 108 to be exposed to the consumable-containing unit 104, the openings 120 can be temporarily sealed using a coating. The coating is preferably made of a composition that melts at temperatures that create consumable aerosols. Therefore, as the susceptor 106 is heated, due to the lack of air inside the enclosure 108, the consumable-containing unit 104 can be raised to excessively high temperatures without burning. As Petition 870260066600, dated 06 / 07 / 2026, p. 26 / 89 17 / 63 The susceptor 106 reaches high temperatures, and the consumable aerosols that begin to form are unable to escape. When the coating melts and exposes the opening 120, the consumable aerosols are then able to escape from the casing 108 for inhalation. In the preferred embodiment, the coating may be propylene glycol alginate (PGA) gel. The coating may also include a flavoring. Therefore, as the coating melts and the consumable aerosol is released, the flavoring is also released with the consumable aerosol. In some embodiments, the flavoring may be mixed with the additive.

[0082] In some embodiments, the openings 120 may be a plurality of holes or slits. The openings 120 may be formed along the length of the side wall 122 of the enclosure 108, arranged radially around the side wall 122, arranged randomly or uniformly throughout the side wall 122, and the like. In some embodiments, the openings 120 may be a plurality of holes along the opposite ends 124, 126 of the enclosure 108. In some embodiments with the elongated consumables-containing unit 104, the enclosure 108 may also be elongated with the opening 120 in the form of one or more elongated slits that traverse the length of the enclosure parallel to the longitudinal axis L, thus creating a seam. This seam can be folded or crimped, but it still leaves a gap through which consumable aerosols can travel, either along its entire length or in discreet areas.Like the 120 openings described above, the seam can be sealed with a lining.

[0083] The packaging containing consumables 102 may Petition 870260066600, dated 06 / 07 / 2026, page 27 / 89 18 / 63 further comprises a filter tube 140 for encapsulating the unit containing consumables 104, susceptor 106, and the housing 108. The filter tube 140 may be made of filter material to capture any unwanted debris while allowing the consumable aerosol released from the heating of the housing to pass transversely through the filter. The filter tube 140 may enclose the housing 108 and further cover the lined openings 120. Because the filter tube 140 may be made of filter material, the consumable aerosol is able to travel through the filter tube 140. By way of example only, the filter tube may be made of cellulose or cellulose acetate, although any suitable filter material may be used.

[0084] The packaging containing consumables 102 may further comprise a housing 150 for enclosing the filter tube 140. The housing 150 may be a paper tube. The housing 150 is less likely to allow the passage of consumable aerosols. As such, the housing 150 wrapped around the filter tube 140 creates a longitudinal channel through the filter tube 140 through which the consumable aerosol travels, instead of escaping radially out of the filter tube 140. This allows the consumable aerosol to follow the inhalation path towards the user's mouth. One end 152 of the housing 150 may be capped with a terminal cap 154. The terminal cap 154 ​​may be composed of a type of filter material. At the opposite end 156 of the housing 150 is a nozzle 158 which the user draws to pull the heated consumable aerosol out of the casing 108 along the filter tube 140 towards the Petition 870260066600, dated 06 / 07 / 2026, page 28 / 89 19 / 63 nozzle 158 and to the user's mouth. As such, the nozzle 158 can also be a type of filter, similar to that of the terminal cap 154. Where the packaging containing consumables 102 includes a channel through which the consumable aerosol travels, and this channel leads directly to the nozzle 158 which is also part of the packaging containing consumables 102, and the channel is isolated from the case 202, the case 202 will remain free of any residue or byproduct formed during the operation of the device. In this configuration, the case 202 remains clean and does not require the user to periodically clean the case 202.

[0085] In some embodiments, the enclosures 108 may be made of a two-piece unit with a first enclosure section 108a and a second enclosure section 108b. The unit containing consumables 104 may be inserted into the first enclosure section 108a and the second enclosure section 108b may be positioned on top of the first enclosure section 108a to cover the unit containing consumables 104. Pre-configured openings 120 may be formed in the enclosure 108 before encapsulating the unit containing consumables 104.

[0086] Having established the general principles of packaging containing consumables 102, variations achieving the same objectives were also contemplated. For example, in some embodiments, the unit containing consumables 104 may comprise two elongated sections 104a, 104b. The two elongated sections 104a, 104b of the unit containing consumables 104 may be defined by a plane parallel to and cutting through the longitudinal axis L along the diameter. Therefore, the two elongated sections 104a, 104b may Petition 870260066600, dated 06 / 07 / 2026, page 29 / 89 20 / 63 being half-cylinder sections which, when coupled together, form a complete cylindrical unit containing consumables 104.

[0087] In some embodiments, as shown in Figures 3A-3D, the consumable-containing unit 104 may be in the form of a pellet or tablet. Unlike the consumable-containing unit 104, which is an elongated cylinder or tube in which the length of the side wall 109 is much greater than the diameter, in the tablet embodiment, the tablet may be a short cylinder defining a longitudinal axis L, in which the length of the side wall 109 is closer to the diameter size, or shorter than the diameter. The susceptor 106 may have a flat, circular shape to match the shape of the tablet's cross-section when cut transversely, perpendicular to the longitudinal axis L. The consumable-containing unit 104 may be compressed around the susceptor 106. To imitate a cigarette, a plurality of consumable-containing units 104 may be stacked end to end along their longitudinal axes L to form an elongated cylinder.Therefore, each unit containing individual consumables 104 can be heated separately, effectively mimicking the segments of the unit containing consumables 104 having an elongated tubular body.

[0088] Other shapes may also be used, such as square or rectangular shapes with a susceptor 106 having a corresponding shape. The cylindrical shape, however, is preferred because of the ease with which this shape can be used to imitate the shape of a real cigarette.

[0089] In some embodiments, the unit containing consumables 104 may be formed from two sections Petition 870260066600, dated 06 / 07 / 2026, page 30 / 89 21 / 63 Sections 104a and 104b of the consumable-containing unit 104 are combined to form a whole, as shown in Figures 4A and 4B. The two sections 104a and 104b are defined by dividing the consumable-containing unit 104 in half transversely along a plane perpendicular to the longitudinal axis L. The susceptor 106 can be sandwiched between the two sections 104a and 104b. With the susceptor 106 sandwiched between the two sections containing consumables 104a, 104b, the unit containing consumables 104 can be enclosed by the casing 108. This process can be repeated to create a plurality of units containing individual consumables 104 by sandwiching the respective susceptors 106, each individually contained in a respective casing 108. The plurality of units containing consumables 104 can be stacked one on top of the other to create the packaging containing consumables 102, in which each unit containing individual consumables 104 can be heated individually, one at a time.

[0090] In some embodiments, the casing 108 may be wrapped in aluminum around a consumable-containing unit 104. The aluminum may have overbends 130, 132 at opposite ends, as shown in Figure 3D. These overbends 130, 132 create a gap between adjacent consumable-containing units 104 when stacked on top of each other.

[0091] In some embodiments, the enclosure 108 may be of two pieces having a first enclosure section 108a and a second enclosure section 108b which serves as a cover or lid to enclose the unit containing consumables 104 within the first enclosure section 108a, as shown in Figures 4A and 4B. As described Petition 870260066600, dated 06 / 07 / 2026, page 31 / 89 22 / 63 previously, the openings 120 in the casing 108 may be along the side wall 122 or at the ends 124, 126. As described earlier, the susceptor 106 may be any type of metal that is subjected to induced heating, including steel wool, as shown in Figure 4B. In preferred embodiments, numerous edges are created in the susceptor 106 by creating a plurality of holes 110 or by using steel wool filaments compressed together. The steel wool filaments may be of fine to medium grade. As discussed above, the steel wool block may be soaked in, coated with, or filled with additive, flavoring, protectant and / or filler.

[0092] In some embodiments, a plurality of units containing consumables 104 may be contained in a single elongated casing 108, as shown in Figures 5A-6B. The casing 108 may be molded with compartments 111 to receive each individual consumable-containing unit 104. In some embodiments, the individual compartments 111 may be connected to each other by a bridge 121. In some embodiments, the bridge 121 may define a channel 125 that allows fluidic communication from one compartment 111 to another. In some embodiments, the bridge 121 may be crimped to prevent fluidic communication between one compartment 111 and another through the bridge 121. In some embodiments, the elongated casing 108 may be a two-piece assembly divided transversely along the longitudinal axis L, as shown in Figures 6A-6B. The units containing consumables 104 can be placed in compartments 111 of one of the enclosure sections 108a.The second section of the 108b enclosure can then be coupled to... Petition 870260066600, dated 06 / 07 / 2026, page 32 / 89 23 / 63 first enclosure section 108a to cover the units containing consumables 104. The division between the first enclosure section 108a and the second enclosure section 108b can be used as the opening 120. Alternatively, predefined openings 120 can be formed in one or both of the enclosure sections 108a, 108b.

[0093] In some embodiments, as shown in Figure 7A-7D, the casing 108 may be made of material that allows the casing 108 to serve as the susceptor. For example, the casing 108 may be made of steel, or otherwise comprise ferrous metal, or any other metal that can be heated using induction heating. In such an embodiment, an internal susceptor 106 would not need to be incorporated into the unit containing consumables 104. The casing 108 may further comprise a plurality of orifices 120, and be covered with an additive and / or sealant, such as PGA. This embodiment may be transformed into an elongated tube, as shown in Figure 7A, or into tablets or discs, as shown in Figure 7B. The 108 casing can be a two-piece casing with a first casing section 108a and a second casing section 108b, as discussed previously.

[0094] In some embodiments, the enclosure 108 may have transverse slots 123 running across the enclosure 108, generally perpendicular to the longitudinal axis L, as shown in Figures 7C and 7D. The slots 123 create segmentation in the enclosure 108, so that only a small segment of the consumable-containing unit 104 is heated by actuation. The transverse slots 123 may be through holes, which expose the consumable-containing unit. Petition 870260066600, dated 06 / 07 / 2026, page 33 / 89 24 / 63 consumables 104 underneath. In such embodiments, the segments may be filled with a coating or some other plug to seal the orifice, permanently or with a substance that will melt upon heating and allow the aerosol to escape through the slot 123. In some embodiments, the plug may be made of material that can function as a heat sink and / or a substance that is not easily heated by induction to reduce the heating effect on the cross slots 123. In some embodiments, the cross slot 123 may be a recessed portion or an indentation in the casing 108. In other words, the cross slot 123 may be a thinner portion of the casing 108. As such, the cross slot 123 may define a well. The well may be filled with a plug that can function as a heat sink and / or a substance that is not easily heated by induction to reduce heat transfer along the cross slot 123. Induction heating

[0095] Heating of the consumables-containing unit 104 is achieved by an induction heating process that provides contactless heating of a metal, preferably ferrous metal, by positioning the metal in the presence of a variable magnetic field generated by an inductive heating element 160, as shown in Figures 8A-8B. In the preferred embodiment, the inductive heating element 160 is a conductor 162 wound in a coil that generates the magnetic field when current is passed through the coil. The metal susceptor 106 is positioned close enough to the conductor 162 so as to be within Petition 870260066600, dated 06 / 07 / 2026, page 34 / 89 25 / 63 of the magnetic field. In the preferred embodiment, the coil is wrapped in a manner that defines a central cavity 164. This allows the package containing consumables 102 to be inserted into the cavity 164 so that the coil surrounds the susceptor 106 without touching the susceptor 106. The current passed through the coil is alternating current, creating a rapidly alternating magnetic field. The alternating magnetic field can create eddy currents in the susceptor 106, which can generate heat within the susceptor 106. Thus, the package containing consumables 102 is generally heated from the inside out. In embodiments where the casing 108 also serves as a susceptor, the package containing consumables 102 is heated from the outside in.

[0096] In the preferred embodiment, the segments of the package containing consumables 102 must be heated individually. As such, the conductor 162 can also be provided as individual sets of spiral conductors l62a-f, as shown in Figure 8A. Each conductor coil l62a-f can be connected to a controller 166 which can be controlled to activate one conductor coil l62a-f at a time. Although there are six (6) conductor coils l62a-f shown in Figure 8A, larger or smaller coils can be used. In an alternative embodiment, a single conductor coil 162 can be used, with a mechanical mechanism that translates the coil along the package containing consumables 102 to individually heat each segment of the package containing consumables 102.

[0097] Individual l62a-f conductor coils may coincide with discrete segments of the packaging containing consumables 102, as described above, and shown Petition 870260066600, dated 06 / 07 / 2026, page 35 / 89 26 / 63 in Figures 3A-6B. Alternatively, the conducting coils l62a-f may each correspond to a certain length of a continuous consumable package 102, as shown in Figures 2A-2D, 7A and 7D, to heat only that particular length. In preliminary tests of such embodiments, heating along discrete lengths of the consumable package 102 does not appreciably heat adjacent portions of the consumable package 102, as the adjacent unheated consumable appears to act as an insulator. Thus, structures to limit heat transfer may not be necessary, although such structures have been discussed here and may be useful.

[0098] The efficiency of converting electrical energy into thermal heat in susceptor 106 is referred to here as conversion efficiency, and is based on a variety of factors, such as bulk resistivity of the metal, metal dielectric, metal geometry and heat loss, consistency and efficiency of the power source, coil geometry, and losses and overall operating frequency – to identify some of these factors. Device 100 is designed and configured to maximize conversion efficiency. Aerosol production device

[0099] To effect the heating and conversion into an aerosol of the consumable, the housing 150 containing the filter tube 140 wrapped around the consumable-containing unit 104 is positioned within an aerosol production device 200, as shown in Figures 9A-9C. The aerosol production device 200 comprises a case 202 for containing the consumable-containing packaging 102, Petition 870260066600, dated 06 / 07 / 2026, page 36 / 89 27 / 63 the induction heating element 160 to heat the susceptor 106, and a controller 166 to control the induction heating element 160.

[00100] The case 202 was designed for ergonomic use. For ease of naming, the case 202 is described using terms such as front, back, sides, top and bottom. These terms should not be limiting, but used to describe the positions of various components relative to each other. For the purposes of describing the present invention, the front 210 will be the portion of the case 202 that faces the user when used as intended, as described herein. As intended, when the user holds the case 202 for use, the user's fingers wrap around the back 212 of the device 100 with the thumb wrapping around the front 210.

[00101] The case 202 defines a cavity 214 (see Figure 1) in which the components of the device 100 are contained. As such, the case 202 is designed to contain a substantial portion of the packaging containing consumables 102, the controller 166, the inductive heating element 160, and the power source 220. In the preferred embodiment, the upper front part of the case 202 defines an orifice 216. The nozzle portion 158 of the packaging containing consumables 102 projects from the orifice 216, so that the user has access to the packaging containing consumables 102. The nozzle 158 projects sufficiently out of the case 202 to allow the user to place their lips around the nozzle 158 to inhale the consumable aerosol.

[00102] The 202 case is designed to be easy to use and easy to carry. In the preferred embodiment, the 202 case Petition 870260066600, dated 06 / 07 / 2026, page 37 / 89 28 / 63 can have dimensions of approximately 85 mm in height (measurements from top 222 to bottom 224) by 44 mm in depth (measurements from front 210 to back 212) by 22 mm in width (measurements from side 226 to side 228). This can be manufactured by protomolding for high-quality / more resistant plastic parts.

[00103] In some embodiments, the packaging containing consumables 102 may be held in a spacer that allows the packaging containing consumables 102 to be retracted into the case 202 for storage and transport. Due to the configuration of the packaging containing consumables 102, the case 202 does not require a cleaning orifice like other devices in which some combustion is still predominant, creating byproduct residue from combustion. In embodiments where the packaging containing consumables 102 comprises a user nozzle 158 and a filter tube 140, if any byproducts are created during operation, they will remain in the disposable packaging containing consumables 102, which is changed when the user inserts a new packaging containing consumables 102 and the filter tube 140, if necessary, into the case 202. Thus, the interior of the case 202 remains clean during operation.

[00104] In the preferred embodiment, the top 222 of the case 202 comprises a user interface 230. The positioning of the user interface 230 on the top 222 of the case 202 allows the user to easily check the device status 100 before use. The user could potentially view the user interface 230 even while inhaling. The user interface 230 may be a multi-color (RGB) LED display for device status indication during use. A Petition 870260066600, dated 06 / 07 / 2026, page 38 / 89 A 29 / 63 light tube can be used to provide wide-angle visibility of this display. As an example, the 230 user interface features a 0.96-inch (diagonal) OLED display with a 128x32 aspect ratio and an I2C (or SPI) interface. The 230 user interface is capable of 234 haptic feedback (vibration) and 250 audio feedback (piezoelectric transducer). In some embodiments, a transparent plastic cover (PC or ABS) can be placed over the OLED glass to protect it from damage / scratches.

[00105] The rear part 212 of the case comprises a trigger 232, which is a finger-activated (grip) button for turning the device on / starting the blow. Preferably, the trigger 232 is adjacent to the top 212. In this configuration, the user can hold the case 202 as intended with their index finger on or near the trigger 232 for convenient actuation. In some embodiments, a locking mechanism may be provided in the trigger 232 either mechanically or through electrical interlocking that requires the case 202 to be opened before the trigger 232 is electrically actuated. In some embodiments, a haptic feedback motor 234 may be mechanically coupled to the trigger 232 to improve the user's recognition of haptic feedback during operation. Actuation of the trigger 232 drives the induction heating element 160 to heat the susceptor 106.

[00106] Device 100 is powered by a 220 battery. Preferably, the 220 battery is a two-cell lithium-ion battery pack (connected in series) with a continuous draw capacity of 4A and a rating of 650750mAh. The two-cell pack may include a circuit of Petition 870260066600, dated 06 / 07 / 2026, page 39 / 89 30 / 63 protection. The 220 battery can be charged with a USB Type-C connector 236. The USB Type-C connector 236 can also be used for communications. The controller 166 can also provide battery voltage monitoring 238 to display the battery's charge / discharge status.

[00107] The trigger 232 is operatively connected to the induction coil actuator 240 via the controller 166. The induction coil actuator 240 activates the inductive heating element 160 to heat the susceptor 106. The present invention eliminates the motor-driven coil design of the prior art. The induction coil actuator 240 can provide actuation / multiplexing for multiple coils. For example, the induction coil actuator 240 can provide actuation / multiplexing for 6 or more coils. Each coil is wound around a segment of the packaging containing consumables 102 and can be actuated at least one or more times. Therefore, a segment of the packaging containing consumables 102 can be heated twice, for example. In a device 100 with six coils, the user can extract 12 puffs from the device 100.

[00108] The induction coil drive circuit in the preferred embodiment can be directly controlled by a microprocessor controller 166. A special peripheral in this processor (numerically controlled oscillator) allows generating the frequency drive waveforms with minimal CPU processing overhead. The induction coil circuit can have one or more capacitors connected in parallel, making it a parallel resonant circuit.

[00109] The drive circuit may include Petition 870260066600, dated 06 / 07 / 2026, page 40 / 89 31 / 63 Current monitoring with a peak detector that returns to an analog input on the processor. The function of the peak detector is to capture the maximum current value for any voltage cycle of the drive circuit, providing a stable output voltage for conversion by an analog-to-digital converter (part of the microprocessor chip) and then used in the induction coil drive algorithm.

[00110] The induction coil drive algorithm is implemented in the firmware running on the microprocessor. The resonant frequency of the induction coil and capacitors will be known with reasonable accuracy by design, as follows: resonant frequency (in Hertz) = 1 / (2 * pi * SQRT {L * C}) where: pi = 3.1415..., SQRT indicates the square root of the content between square brackets {...}, L = the measured inductance of the induction coil, and C = the known capacitance of the capacitors connected in parallel.

[00111] There will be manufacturing tolerances for the L and C values ​​(above), which will produce some variation in the actual resonant frequency versus that calculated using the formula above. Additionally, there will be variation in the inductance of the induction coil based on what is located within that coil. In particular, the presence of a ferrous metal within (or in the immediate vicinity of) that coil will result in a certain amount of inductance change, resulting in a small change in Petition 870260066600, dated 06 / 07 / 2026, p. 41 / 89 32 / 63 resonant frequency of the LC circuit.

[00112] The firmware algorithm for driving the induction coil will sweep the operating frequency to the expected maximum frequency range while simultaneously monitoring the current, searching for the frequency where the current consumption is minimal. This minimum value will occur at the resonant frequency. Once this central frequency is found, the algorithm will continue sweeping the frequency by a small amount on either side of the central frequency and adjusting the value of the central frequency as needed to maintain the minimum current value.

[00113] The electronic components are connected to the controller 166. The controller 166 allows processor-based frequency control to optimize the heating of the susceptor 106. The relationship between frequency and temperature rarely correlates directly, largely due to the fact that temperature is a result of frequency, duration, and the way the package containing consumables 102 is configured. The controller 166 can also provide current monitoring to determine power delivery, and peak voltage monitoring across the induction coil to establish resonance. By way of example only, the controller can provide a frequency of approximately 400 kHz to approximately 500 kHz, and preferably 440 kHz, with a three-second preheating cycle to raise the temperature of the susceptor 106 to 400 °C or more in one second.In some modes, the temperature of susceptor 106 can be increased to 550 °C, or more, in one second. In some modes, the temperature can be raised up to... Petition 870260066600, dated 06 / 07 / 2026, p. 42 / 89 33 / 63 800 °C. Thus, the present invention has an effective range of 400-800 °C. In prior art devices, these temperatures burned the consumable, rendering prior art devices ineffective at these temperatures. In the present invention, these high temperatures can still be used to improve aerosol production efficiency and allow for faster heating times.

[00114] Device 100 may also comprise a communications system 242. In the preferred embodiment, Bluetooth low-energy radio may be used to communicate with a peripheral device. The communications system 242 may serially interface with the main processor to communicate information with a telephone, for example. A ready-to-use RF module (pre-certified: FCC, IC, CE, MIC) may also be used. One example utilizes the Laird BL652 module because SmartBasic support allows for rapid application development. The communication system 242 allows the user to program device 100 to suit personal preferences related to aerosol density, amount of aroma released, and the like, by controlling the frequency and 3-stage duty cycle, specifically the preheating stage, heating stage, and deceleration stage of the inductive heating elements 160.The 242 communication system may have one or more USB 236 ports.

[00115] In some modes, a real-time clock / calendar (RTC) with a backup battery may be used to monitor usage information. The RTC can measure and store relevant user data to be used in conjunction with an external application downloaded to a device. Petition 870260066600, dated 06 / 07 / 2026, page 43 / 89 34 / 63 peripheral, like a smartphone.

[00116] In some embodiments, a micro-USB connector (or USB Type-C connector or other suitable connector) may be located on the bottom of the case 202. The support connector with plastic may be provided on all sides to reduce stress on the connector due to cable forces.

[00117] By way of example only, device 100 can be used as follows. The device's power can be turned on by momentarily pressing trigger 232. For example, a brief touch on the trigger (< 1.5 s) can turn on device 100 but does not start the heating cycle. A second brief touch on trigger 232 (< 1 second) during this period will keep device 100 on for a longer period of time and will start Bluetooth advertising if there is no currently active (on) Bluetooth connection with the phone. A longer press of trigger 232 (> 1.5 s) starts the heating cycle. The power on device 100 can remain on for a short period of time after each heating cycle (e.g., 5 s) to display the updated unit status on the OLED user interface 230 before turning off. In some embodiments, device 100 may turn on when the packaging containing consumables 102 is deployed from the case 202.In some configurations, a separate 246 power switch can be used to turn the device on and off.

[00118] When an active connection is found with a smartphone and the custom application is running on the smartphone, the device remains powered on for up to 2 minutes before shutting down. When the battery level is too low to operate, the user interface display Petition 870260066600, dated 06 / 07 / 2026, page 44 / 89 35 / 63 230 flashes several times (showing the battery icon at 0%) before the unit shuts down.

[00119] In some embodiments, the user interface 230 may display a segmented cigarette showing which segments remain (solid fill) versus which segments have been used (dotted outline) as an indicator of how much of the packaging containing consumables 102 still contains consumable products to be released. The user interface 230 may also display an updated battery icon with the current battery status, a charging icon (lightning bolt) when the device is connected, and a Bluetooth icon when there is an active connection with a smartphone. The user interface 230 may show the Bluetooth icon blinking slowly when there is no connection, but the device 100 is advertising.

[00120] The device may also have a 248 indicator to inform the user about the power status. The 248 indicator may be an RGB LED. As an example, the RGB LED may show a green LED lit when the device is first turned on, a red LED flashing during the preheating time, a red LED lit (solid) during the “inhalation” time, and a blue LED flashing during charging. The flashing cycle indicates the relative charge status of the battery (20-100%) in 20% increments (solid blue means full charge). A rapid flash of the blue LED may be displayed when an active Bluetooth connection is detected (the phone is connected to the device and the custom application on the phone is running).

[00121] Tactile feedback can provide information Petition 870260066600, dated 06 / 07 / 2026, page 45 / 89 36 / 63 additional signals to the user during use. For example, 2 short pulses may be signaled immediately when power is turned on (from the finger activation button). A prolonged pulse at the end of the preheating cycle may be signaled to indicate that the devices are referring to inhalation (start of the HNB inhalation cycle). A short pulse may be signaled when USB power is connected or removed for the first time. A short pulse may be signaled when an active Bluetooth connection is established with an active phone application running on the smartphone.

[00122] A Bluetooth connection can be initiated after power is turned on by briefly pressing (< 1.5 s) the finger-pinch button. If no BLE (Bluetooth Low Energy) connection is enabled, devices may begin to slowly advertise (pairing mode) once a second short press is detected after the initial short press that powers on the device. After a connection is established with the smartphone application, the Bluetooth icon on the user interface display 230 may stop flashing and the blue LED will light up (solid). If the device 100 is powered on and has a connection linked to a smartphone, it may begin to advertise to attempt to re-establish that connection with the phone until it powers off. If the connection with this smartphone can be re-established, the unit may remain powered on for up to 2 minutes before powering off. To delete a linked connection, the user can power on the device with a short tap, followed by another short tap.While the BLE icon is flashing, the user can press and hold the trigger 232 until the device 100. Petition 870260066600, dated 06 / 07 / 2026, page 46 / 89 37 / 63 vibrate and the Bluetooth icon disappears.

[00123] Thus, by rigorously controlling the aforementioned conversion efficiency factors and product consistency factors, it is possible to provide controlled heat delivery to the consumable-containing unit 104. This controlled heat delivery involves a microprocessor controller 166 for monitoring the induction heating system 160 to maintain various levels of electrical power supply to the susceptor 106 during controlled time intervals. These properties allow for a user control feature that would permit the selection of certain consumable aromas, as determined by the temperature at which the consumable aerosol is produced.

[00124] In some embodiments, a microprocessor or configurable logic block can be used to control the frequency and power supply of the induction heating system. As shown in Figure 10A, an induction heating system 160 may comprise a coil of wire 162 in parallel with one or more capacitors 260 for and from a self-resonant oscillator. The inductance of the coil 162 in combination with the capacitance of the capacitor(s) 260 largely defines the resonant frequency at which the circuit will operate. In this embodiment, however, a microprocessor / microcontroller 166 can be used to drive the power switches and thus control the oscillation frequency of the circuit. With this approach, the peak voltage and current are used as feedback to allow the microprocessor control program to provide a close fit to find resonance. The benefit of this approach is that it allows Petition 870260066600, dated 06 / 07 / 2026, page 47 / 89 38 / 63 efficient control of the power supplied to the susceptor, switching the oscillation of the circuit synchronously on and off under the control of the microprocessor control program 166 and provides optimal on / off switching of the power control elements driving the induction coil system.

[00125] Based on these concepts, numerous variations were contemplated by the inventors. Thus, as discussed above, the present invention comprises a consumable-containing unit 104, a susceptor 106 incorporated within the consumable-containing unit 104, a heating element 160 configured to at least partially enclose the consumable-containing unit 104, a controller 166 for controlling the heating element 160, and a case 202 for containing the consumable-containing unit 104, the susceptor 106, the heating element 160, and the controller 166. Preferably, the consumable-containing unit 104 is contained with the susceptor 106 in a package containing consumables 102. As such, any description of the relationships between the package containing consumables 102 and other components of the invention may also apply to the consumable-containing unit 104, as some embodiments may not necessarily require packaging of the consumable-containing unit 104.

[00126] In some embodiments, as shown in Figure 10A, the device comprises a self-resonant oscillator to control the inductive heating element 160. The self-resonant oscillator comprises a capacitor 260 operatively connected to the inductive heating element 160 in parallel. In some Petition 870260066600, dated 06 / 07 / 2026, page 48 / 89 39 / 63 modes, as shown in Figure 10B, multiple heating elements 160 can be connected in parallel with their respective capacitors 260a, 260b. Preferably, the heating elements are in the form of a spiral wire l62a, l62b.

[00127] To enable a single package containing consumables 102 to generate aerosol multiple times, multiple heating elements 160 and / or mobile heating elements 160 may be used. Thus, the heating element 160 comprises a plurality of coiled wires l62a, b, wherein each coiled wire may be operatively connected to the controller 166 for independent activation of the other coiled wires.

[00128] In some embodiments, the heating element 160 may be movable. In such embodiments, the packaging containing consumables 102 may be an elongated member defining a first longitudinal axis L, and the heating element 162 may be configured to move axially along the first longitudinal axis L. For example, as shown in Figure 11, the heating element 160 may be fixed to a conveyor 270. The conveyor 270 may be operatively connected to the housing 202 so as to move along the length of the packaging containing consumables 102, while the heating element 160 remains wound around the packaging containing consumables 102. The extension S of the coil (measured as the linear distance from the first turn 272 of the coil to the last turn of the coil 274) may be short enough only to cover a segment of the packaging containing consumables 102. Since the element of Petition 870260066600, dated 06 / 07 / 2026, page 49 / 89 40 / 63 heating 160 has been activated in this segment, the conveyor 270 advances along the package containing consumables 102 along its longitudinal axis L to another segment of the package containing consumables 102. The displacement distance of the conveyor 270 is such that the first turn 272 of the coil is adjacent to where the last turn 274 of the coil previously resided. Thus, a new segment of equal size to the previously heated segment is ready to be heated. This can continue until the conveyor 270 moves from the first end 105 of the package containing consumables 102 to the opposite end 107.

[00129] In embodiments where the package containing consumables 102 contains multiple units containing consumables 104, the extension S of the coil may be approximately the same size as the length of the unit containing consumables 104. The conveyor 270 may be configured to align the coil with a unit containing consumables 104, so that the coil may heat an entire unit containing consumables 104. The conveyor 270 may be configured to move the coil from one unit containing consumables 104 to the next, again allowing a single package containing consumables 102 to be heated multiple times with the aerosol being released each time.

[00130] As shown in Figures 12A-12E, to facilitate proper alignment of the heating element 160 around the packaging containing consumables 102, the device 200 may comprise a packaging aligner. For example, the packaging aligner may be a magnet 280. Preferably, the magnet 280 is a cylindrical magnet that defines a Petition 870260066600, dated 06 / 07 / 2026, page 50 / 89 41 / 63 second longitudinal axis M. In embodiments where the heating element 160 is a cylindrical coil wound around the packaging containing consumables 102, the cylindrical coil defines a third longitudinal axis C. The cylindrical magnet 280 and the heating element 160 are configured to maintain collinear alignment of the second longitudinal axis M with the third longitudinal axis C. Preferably, the cylindrical magnet 280 is a round ring magnet, in which the center is a path for airflow. Preferably, any magnet 280 would be of the rare-earth neodymium type. It would be axially magnetized.

[00131] In the embodiment using a magnet 280 for alignment, one end 105 of the packaging containing consumables 102 may comprise a magnetically attractive element 281. Preferably, the magnetically attractive element 281 is a stamped sheet metal component manufactured at the first end 105 of the packaging containing consumables 102. The cylindrical magnet 280 may be part of the aerosol production device 200, and the packaging containing consumables 102 may have a magnetically attractive element 281 or washer attached to its end 105, such that the packaging containing consumables 102 is pulled towards the magnet 280 affixed to the aerosol production device 200. Other combinations of magnets 280 and magnetically attractive elements 281, in various positions, may be used to achieve the desired alignment.

[00132] In some embodiments, preferably one that uses a package containing consumables 102 with a filter tube 140 and a housing 150, the package aligner may be a receiver 151, such as a close-fitting cylinder. Petition 870260066600, dated 06 / 07 / 2026, p. 51 / 89 42 / 63 (if housing 150 is cylindrical) which can be used to align the packaging containing consumables 102, and the coil 162 can be positioned outside the receiver 151, as shown in Figure 12E. Preferably, the receiver 151 would be made of non-conductive material to avoid induction heating, such as borosilicate glass, quartz glass, Piroceram glass, Robax glass, high-temperature plastics such as Vespel, Torlon, polyimide, PTFE (polytetrafluoroethylene), PEEK (polyetheretherketone) or other suitable materials. Alternatively, the cylinder can be made of a conductive material that has a lower resistivity than the susceptor 106 in the packaging containing consumables 102, which would allow some induction heating of the receiver 151, but not as much as the susceptor 106.Examples of lower resistance materials may include copper, aluminum, and brass, whereas the susceptor 106 is made of high-resistance materials such as iron, steel, tin, carbon, or tungsten, although other materials may be used. In some embodiments, a receiver 151 with a resistivity equal to or greater than that of the susceptor 106 may be used, which will heat the exterior of the package containing consumables 102 when the receiver 151 heats up by induction. The receiver 151 may be attached to the device 200 and properly aligned with the coils 162, just as when the package containing consumables 102 is inserted into the coils 162, the susceptor 106 is properly aligned with the coils 162.

[00133] In some embodiments, housing 150 may function as the receiver. Therefore, instead of a separate receiver 151, housing 150 may have the characteristics Petition 870260066600, dated 06 / 07 / 2026, p. 52 / 89 43 / 63 described above and insertion into coils 162 can function as the alignment process, or the housing can be fixed inside coils 162 and the filter tube 140 containing the unit containing consumables 104 and the susceptor 106 can be inserted into housing 150.

[00134] In some embodiments, multiple activations of a single package containing consumables can be performed with a multi-pin 106 susceptor, as shown in Figures 13A-D. A multi-pin susceptor is a 106 susceptor with two or more 290 pins. In some embodiments, the susceptor may have three 290a, 290b, 290c pins. In some embodiments, the 106 susceptor may have four pins. In some embodiments, the 106 susceptor may have more than four pins. In the preferred embodiment, the multi-pin 106 susceptor has three or four pins.

[00135] The multiple pins 290a, 290b, 290c of the multi-pin susceptor 106 are generally parallel to each other, as shown in Figures 13C and 13D. The multi-pin susceptor 106 is configured and can be incorporated into the package containing consumables 102 in such a way that each pin 290a, 290b, 290c is parallel and equally spaced from the longitudinal axis of the package containing consumables L, and equally spaced from each other along the perimeter of an imaginary circle. Therefore, when viewed in cross-section, as shown in Figures 14AC, the susceptor pins 290a, 290b, 290c are equally spaced from each other around the circular face of the packaging containing consumables 102. This arrangement allows each pin 290a, 290b, 290c to maximize non-overlapping heating zones for each pin when each pin is activated. Petition 870260066600, dated 06 / 07 / 2026, p. 53 / 89 44 / 63 maximum. In other words, when a susceptor pin 290a, 290b, 290c is heated, it radiates heat radially away from susceptor pin 290a, 290b, 290c, creating a circular heating zone with susceptor pin 290a, 290b, 290c at the center. Each susceptor pin 290a, 290b, 290c heats its own circular zone, although some overlap may be unavoidable. Collectively, an entire cross-sectional area of ​​a unit containing consumables 104 can be heated, one cross-sectional segment at a time.

[00136] When the heating element 160 is a cylindrical coil wound around a susceptor 106, the maximum amount of power is transferred to the center of the cylindrical coil. Therefore, when the susceptor 106 is aligned with the center of the cylindrical coil, the susceptor 106 will receive the maximum amount of energy from the electricity passing through the coil. In other words, when the susceptor pin 290a, 290b, 290c is collinear with the cylindrical coil, the susceptor pin 290a, 290b, 290c will receive the maximum amount of energy from the cylindrical coil. Thus, to heat each susceptor pin 290a, 290b, 290c independently, the susceptor pin 290a, 290b, 290c and the center of the coil must be moved relative to each other so that the center of the coil aligns with one of the susceptor pins 290a, 290b, 290c in sequence. This can be achieved by moving the susceptor pin relative to the coil or by moving the coil relative to the susceptor pin, or both.

[00137] In the preferred embodiment, the heating element 160 moves relative to the susceptor 106. By Petition 870260066600, dated 06 / 07 / 2026, p. 54 / 89 45 / 63 example, the cylindrical coil can be wound around the package containing consumables 102 and configured to rotate along an eccentric path, so that during one rotation of the cylindrical coil, each of the pins 290a, 290b, 290c will align with the center of the coil at different times, as shown in Figures 14A-16D.The packaging containing consumables 102 may be an elongated member defining a first longitudinal axis L, wherein the heating element 160 is a coil wound around the packaging containing consumables 102 to form a cylinder defining a second longitudinal axis C, and wherein the heating element 160 is configured to rotate around the packaging containing consumables 102 in an eccentric path such that the second longitudinal axis C aligns collinearly with each of the pins 290a, 290b, 290c of the multi-pin susceptor at some point during the movement of the heating element around the packaging containing consumables 102. Therefore, the multi-pin susceptor 106 is stationary and the coil moves rotationally in an eccentric path such that the center of the coil aligns with the linear axis of each susceptor pin 290a, 290b, 290c, in turns, through rotation.The electrical slip rings would supply power to an eccentric path rotating coil design.

[00138] The rotation of the heating element 160 can be effected by a series of gears 300a, 300b operatively connected to a motor 302. For example, as shown in Figures 17A-B, the heating element 160 can be mounted on a first gear 300a so that the heating element can rotate with the first gear. Petition 870260066600, dated 06 / 07 / 2026, p. 55 / 89 46 / 63 gear 300a. A second gear 300b can be operatively connected to the first gear 300a so that the rotation of the second gear 300b causes the rotation of the first gear 300a. The second gear 300b can be operatively connected to a motor 302 to make the second gear 300b rotate. The heating element 160 is mounted on the first gear 300a in such a way that the rotation of the first gear 300a causes the longitudinal axis C of the heating element 160 to move along an eccentric path instead of causing the heating element to rotate around a fixed, non-movable center. Thus, the center of the heating element 160 can shift to align with the different pins 290a, 290b, 290c.

[00139] In some embodiments, the heating element 160, the gears 300a, 300b and the motor 302 can be mounted on a conveyor 270, as shown in Figure 19. The conveyor 270 allows the heating element, the gears 300a, 300b and the motor 302 to move axially along the length of the package containing consumables 102. The conveyor 270 can be operatively connected to an actuator 306, which is operatively connected to a second motor 304. For example, the actuator 306 can be threaded. The conveyor 270 can have a threaded hole 276 through which the actuator 306 is inserted. Activation of the second motor 304 causes the actuator 306 to rotate. Rotation of actuator 306 causes conveyor 270 to move along actuator 306, as shown by the double arrow in Figure 19.

[00140] In some modalities, instead of doing with Petition 870260066600, dated 06 / 07 / 2026, page 56 / 89 47 / 63 where the heating element 160 rotates along an eccentric path, the heating element 160 can be moved translationally along the XY axis when viewed in cross-section. Therefore, the package containing consumables 102 can be an elongated member defining a longitudinal axis L, and wherein the heating element 160 is configured to move radially relative to the longitudinal axis L when viewed in cross-section to align the center of the coiled heating element 160 with each of the pins 290a, 290b, 290c of the multi-pin susceptor 106, in turns. In the XY axis positioning scenario, coil power can be supplied through a flexible electrical conductor or by moving electrical contacts.

[00141] For example, the heating element 160 can be operatively mounted on a pair of translation plates 310, 312, as shown in Figure 20. Specifically, the heating element 160 can be mounted directly on a first translation plate 310, and the first translation plate 310 can be mounted on a second translation plate 312. The first translation plate 310 can be configured to move in the X or Y direction, and the second translation plate 312 can be configured to move in the Y or X direction, respectively. In the example shown in Figure 20, the first translation plate 310 is configured to move in the X direction, while the second translation plate 312 is configured to move in the Y direction. This configuration can be switched so that the first translation plate 310 is configured to move in the Y direction and the second translation plate 312 is configured to move in the X direction. Petition 870260066600, dated 06 / 07 / 2026, page 57 / 89 48 / 63 The first and second translation plates 310, 312 can be operatively connected to their respective motors, for example, by means of gears, to cause the translation plates to move in the appropriate direction. Between the two translation plates 310, 312, the heating element 160 can be moved so that its longitudinal axis C can align collinearly with any of the pins 290a, 290b, 290c.

[00142] In other arrangements, the coil assembly can move along the linear axis of the susceptor, independently of the rotational or non-rotational motion mechanisms, as discussed above. Therefore, a three-pin susceptor would allow the device to heat a package containing consumables 102 three times in the same linear position, heating the three different pins 290a, 290b, 290c three different times before moving to its next linear position, where it will be able to heat three times again. In a package containing consumables 102 with four linear positions, a package containing consumables must be able to provide 12 distinct blows, i.e., 3 pins times 4 positions along the length of the package containing consumables 102.

[00143] In some embodiments, instead of causing the heating element 160 to move relative to the packaging containing consumables 102, the packaging containing consumables 102 may be moved relative to the heating element. Therefore, the packaging containing consumables 102 is configured to rotate within the heating element 160 in an eccentric path so that the second longitudinal axis C defined by the coils aligns Petition 870260066600, dated 06 / 07 / 2026, pp. 58 / 89 49 / 63 collinearly with each of the pins 290a, 290b, 290c of the multi-pin susceptor at some point during the rotation of the packaging containing consumables 102 within the heating element 160. Alternatively, the packaging containing consumables 102 is configured to move radially within the heating element 160, such that the second longitudinal axis C aligns collinearly with each of the pins of the multi-pin susceptor at some point during the movement of the packaging containing consumables 102 within the heating element 160. In some embodiments, both the packaging containing consumables 102 and the heating element 160 may move.For example, heating element 160 can move linearly along the longitudinal axis of the package containing consumables 102, and the package containing consumables 102 can move in an eccentric or radial path to move susceptor 106 into position relative to heating element 106, so that all consumables are heated sequentially as the user takes individual puffs. Other variations of movement can also be used.

[00144] The motion mechanisms described above are only examples. The mechanism in an XYZ motion scenario can be implemented using a variety of combinations of motors, linear actuators, gears, belts, cams, solenoids, and the like.

[00145] With reference to Figure 21, a closed-loop control of the induction heating system can be based on the detection of a magnetic flux density created by the induction heating system. The systems Petition 870260066600, dated 06 / 07 / 2026, p. 59 / 89 50 / 63 induction heating operates by creating a concentrated alternating magnetic field within the heating element of the induction coil. This field will produce a heating effect in a metal susceptor by virtue of eddy currents and the reversal of magnetic flux (assuming a ferrous receiving material) that occurs in the susceptor material. Induction heating is typically "open-circuit" because there are limited means of monitoring the susceptor temperature within the induction coil while it is operating. Under controlled conditions, the magnetic field external to the induction coil and in reasonable proximity to the coil can be used to determine the flux intensity inside the coil.For example, a small coil 310 can be placed in reasonable proximity to the induction coil type heating element 160 with its axis approximately parallel to the magnetic flux field lines 312 passing through the small coil 310, providing a means of detecting the magnitude of the magnetic flux of the induction coil type heating element 160 present by virtue of the voltage induced across the small coil 310 due to the change in magnetic flux passing through the small coil 310. The magnitude of this external flux can then be calibrated to correlate with the magnetic flux density within the heating element 160 and thus be used as a means of closed-loop control of the induction system to ensure consistent performance in measuring the heating of the susceptor 106. The magnetic flux is symmetrical around the axis of the induction coil. A flux density measurement performed anywhere near the... Petition 870260066600, dated 06 / 07 / 2026, pp. 60 / 89 The 51 / 63 induction coil can be used to extrapolate the magnetic flux density within the heating element, based on characterizing the relative magnitudes of the magnetic flux at each location (within the induction coil and within the parasitic detection coil). In practice, there is no need to quantify this, as flux detection is used to infer the heating rate that will occur in a susceptor 106 present in this magnetic field. Thus, the small coil 310 configured in this way functions as a magnetic flux sensor.

[00146] Therefore, in some embodiments, the device may further comprise a magnetic flux sensor adjacent to the inductive heating element 160 and configured to measure a magnetic flux created by the inductive heating element 160. The magnetic flux sensor may be operatively connected to the controller 166 to control the activation of the inductive heating element 160 based on the feedback from the magnetic flux sensor.

[00147] In some embodiments, it is desirable to be able to detect whether a unit containing consumables 104, or a portion thereof, has been heated or not. If a unit containing consumables 104 has already been heated, the heating element 160 can heat the next unit containing consumables 104 or the next segment of a unit containing consumables 104, in order to avoid wasting energy on a used portion of the unit containing consumables 104. Therefore, in some embodiments, as shown in Figure 11, a method for detecting the segments of the package containing consumables 102 that have been used is provided in Petition 870260066600, dated 06 / 07 / 2026, pp. 61 / 89 52 / 63 device, allowing the device to autonomously determine the next unused segment available for use. For example, the device may comprise a usage sensor 320 to detect whether a portion of the packaging containing consumables 102 being detected has been heated beyond a predetermined temperature. In some embodiments, the usage sensor 320 may detect visual changes in the packaging containing consumables 102 that are indicative of heating. In some embodiments, the usage sensor 320 may detect thermal changes in the packaging containing consumables 102 that are indicative of heating. In some embodiments, the usage sensor 320 may detect textural changes (i.e., changes in texture) in the packaging containing consumables 102 that are indicative of heating.In some embodiments, the usage sensor 320 may be the controller keeping track of where the heating element 160 is located along the packaging containing consumables 102 and when it has been heated in relation to its movement along the packaging containing consumables 102. For example, the controller may include a memory to store locations of portions of the packaging containing consumables 102 that have been heated to a predetermined temperature.

[00148] In the preferred embodiment, the usage sensor 320 is a photoreflective sensor. The photoreflective sensor can be configured to detect changes in the packaging containing consumables 102 from its original state compared to a state in which the packaging containing consumables 102 has been exposed to significant heat (i.e., beyond normal daytime temperatures). More Petition 870260066600, dated 06 / 07 / 2026, page 62 / 89 53 / 63 preferably, the packaging containing consumables 102 may be composed of a heat-sensitive dye that changes color when heated to a predetermined temperature. This color change can be detected by the photoreflective sensor.

[00149] The thermally sensitive dye can be printed around the outer surface of the packaging containing consumables 102. When a segment of the packaging containing consumables 102 is heated, a band 322 in the nearest vicinity of the heated segment changes color. For example, band 322 can change from white to black. The wear sensor 320 mounted with the heating element 160 has an optic 324 focused just above – or below – the heating element to provide a side view of the packaging containing consumables 102 along the entire range of the movable heating element 160.

[00150] In some embodiments, a limit switch 326 is also installed at one end 105 of the packaging containing consumables 102 and used to detect when the packaging containing consumables 102 is removed from or reinserted into the device. When a packaging containing consumables 102 is reinserted, the device activates the motorized heating element assembly and moves it throughout its range of travel, allowing the usage sensor 320 to detect if any segment has been previously heated by detecting the dark bands 322 of the thermally sensitive dye. Thus, the device may further comprise a limit switch 326 to reset the memory when a new packaging containing consumables 102 is inserted into the compartment.

[00151] In some modalities, to manage the Petition 870260066600, dated 06 / 07 / 2026, pp. 63 / 89 54 / 63 Thermal heat dissipation of the heating element 160, the device may further comprise a heat sink 330 operatively connected to the inductive heating element 160. Induction heating involves the circulation of high currents in the induction coil, resulting in resistive heating in the wire used to form the coil. Thermal heat dissipation takes advantage of materials with high thermal conductivity that are electrically insulating to form heat sinks 330. Preferably, the heat sinks 330 may be formed by injection molding or potting processes. As the preferred embodiment utilizes a cylindrical coil as the heating element 160, the heat sink 330 may also be a cylinder formed around the induction coil, so that it encapsulates the coil as shown in Figure 22.The cylindrical heat sink 330 encapsulates the heating element 160, residing within a vertical cavity inside the case 202, forming a kind of chimney within which air convection occurs. The chimney requires ventilation at the top to support the airflow. This method also eliminates the delimitation of the electromagnetic field, allowing for a highly focused heating method on each segment of the package containing consumables 102. As a result of such focus, it would not be necessary to enclose the unit containing consumables 104 within the package containing consumables 102 in a non-conductive sheet or other similar material; paper or a similar material would suffice.

[00152] In the preferred embodiment, the heat sink 330 is a finned cylinder enclosing the element of Petition 870260066600, dated 06 / 07 / 2026, pp. 64 / 89 55 / 63 Inductive heating 160. The finned cylinder is a cylindrical heat sink with fins 332 projecting laterally away from its outer surface 334. Preferably, each fin 332 extends substantially along the length of the cylinder to provide a substantial surface area from which heat from the heating element 160 can dissipate. The thermally conductive material of the heat sink 330 can be a polymer. The thermally conductive polymer can be a thermosetting, thermoplastic molding, or potting compound. The heat sink 330 can be machined, molded, or formed from these materials. The material can be rigid or elastomeric. Some examples of thermally conductive compounds used in thermally conductive polymers are aluminum nitride, boron nitride, carbon, graphite, and ceramics.In the preferred embodiment, the heating element 160 is an inductive coil enclosed in a finned cylinder made of a thermally conductive polymer that has been molded around the coil, with an open center creating ventilation through a chimney-like effect.

[00153] In some embodiments, as shown in Figure 23, the device may further comprise an airflow controller 340 to provide a means for adjusting the aroma strength of the consumable-containing unit 104 by controlling the airflow that is drawn through the consumable-containing packaging 102. The design of the consumable-containing packaging 102 is such that the amount of vapor / aroma that is introduced into the airflow passages is a function of the duration and intensity of the induction heating and of Petition 870260066600, dated 06 / 07 / 2026, pp. 65 / 89 56 / 63 air pressure differential between the air passage(s) through the packaging containing consumables 102. This pressure differential draws vapor out of the packaging containing consumables 102 and into the airflow. If the airflow at the first end 105 of the packaging containing consumables 102 can be controlled, this pressure differential can be varied, allowing more (or less) vapor to be introduced into the airflow, effectively altering the aroma robustness. This ability to alter aroma robustness is closely integrated with the heating of the packaging containing consumables 102, as it is the increase in the consumable's temperature that produces this vapor. By precise control of the heating process (time and rate) and the airflow through the first end 105 of the packaging containing consumables 102, a wide range of aroma robustness experiences can be produced.

[00154] For example, the airflow controller 340 may comprise an adjustable flow control valve 342, such as a needle valve, butterfly valve, ball valve, or an adjustable opening. Adjustable flow control valves allow the user to control the airflow even during use. However, the airflow controller 340 may also be a membrane 344 with fixed openings, such as a porous or fibrous membrane or element. A membrane 344 may also act as an inlet particle filter. Therefore, flow control mechanisms may or may not be adjustable by the user. In membrane embodiments 344, multiple membranes 344 with different sized openings may be provided. Thus, the user can select the desired opening size and Petition 870260066600, dated 06 / 07 / 2026, pp. 66 / 89 57 / 63 Apply this membrane 344 to the first end 105 of the device. If the user prefers an increase or decrease in airflow, the user can select another membrane 344 with larger or smaller openings, respectively. In some embodiments, the airflow controller 340 can use both a control valve 342 and a membrane 344. For example, the membrane 344 can precede the control valve 342, so as to control the airflow and filter particles before the control valve 342, then the control valve 342 can still control the airflow for fine-tuned airflow control.

[00155] In some embodiments, instead of having the aerosol flow from the consumable-containing unit 104 through the openings 120 of the housing 108 to a filter tube 140, and towards the nozzle 158, the air flows into the susceptor 106, sucks out the active ingredient from the consumable-containing unit 104 to create the aerosol that flows through the susceptor 106 towards the nozzle 158, as shown in Figure 25A-E. In such embodiments, the susceptor 106 may have one or more hollow pins 350 with at least one input 352 along the length of each pin 350 and at least one output 354. Pin 350 comprises a connected end 356 operatively connected to a susceptor base 358, and a free end 360 opposite the susceptor base 358. The hollow pin 350 is connected to the susceptor base 358 at the connected end 356. The output 354 of the hollow pin 350 is located towards the free end 360.For example, the outlet might be at tip 362 of the free end 360, or there might be a plurality of outlets 354 spaced angularly around the perimeter surface of the hollow pin. Petition 870260066600, dated 06 / 07 / 2026, pp. 67 / 89 58 / 63 350 on the free end side, 360.

[00156] In some embodiments, the tip 362 of the free end 360 may be pointed or sharpened to facilitate penetration into the consumable-containing unit 104. The particle size, density, binders, fillers, or any component used in the consumable-containing unit 104 may be modified to allow penetration of susceptor pins 290, 350, and / or piercing needles without causing excessive compression or changes in the density of the consumable-containing unit 104. Changes in the density of the compression packing of the consumable-containing unit 104 may negatively affect the flow of air or vapor through the consumable-containing unit 104.

[00157] Any consumable particulate material that can be pushed completely through the casing 108 after penetration of the susceptor 106 will be held captive in the cavity 368 between the consumables-containing unit 104 and the nozzle 158. As the tips 362 of the pins 290, 350 are sharp, it is unlikely that the consumables will be ejected from the casing 108.

[00158] In some embodiments, the outputs 354 and / or the inputs 352 may be covered with a coating that melts at heated temperatures. In the preferred embodiment, the unit containing consumables 104 is long enough to cover the entire hollow pin 350, except for the output 354.

[00159] The susceptor base 358 may comprise an opening 364 which corresponds to the hollow pin 350. In embodiments with multiple hollow pins 350a-d, each hollow pin 350a-d has its own corresponding opening 364.

[00160] In some modalities, there may be several Petition 870260066600, dated 06 / 07 / 2026, pp. 68 / 89 59 / 63 hollow pins 350a-d. The hollow pins 350a-d can be arranged in a circle, making them compatible with the movable heating element 160 or with the movable consumables container 102. In some embodiments, there may be a single hollow pin 350 with the hollow pin 350 centered on the susceptor base 358. In some embodiments, there may be a central hollow pin 350 surrounded by a plurality of hollow pins 350a-d. Another arrangement of hollow pin 350 may be used.

[00161] Each hollow pin 350 may have at least one input 352 and at least one output 354. Preferably, the hollow pin 350 comprises a plurality of inputs 352 and a plurality of outputs 354. The inputs 352 may be arranged in a series along the length of the hollow pin 350. In some embodiments, the inputs 352 may be arranged circularly around the perimeter of the hollow pin 350. Increasing the number of inputs 352 on a hollow pin 350 increases the number of points through which the generated aerosol can escape from the unit containing consumables 104 and exit the package containing consumables 102. Similarly, there may be a plurality of outputs 354 arranged circularly around the perimeter of a pin 350 on the free-end side 360.

[00162] In some embodiments, the consumable-containing unit 104 does not extend from one end 105 of the packaging containing consumables 102 to the nozzle 158. As such, a cavity 368 exists between the consumable-containing unit 104 and the nozzle 158. This cavity 368 may be filled with thermally conductive material, flavoring, and the like.

[00163] As shown in the cross-sectional view Petition 870260066600, dated 06 / 07 / 2026, pages 69 / 89 60 / 63 of Figure 25E, in use, the susceptor 106 is incorporated into the consumables-containing unit 104. When the susceptor 106 is heated by inductive heating by the heating element 160, the consumables-containing unit releases the aerosol. As the user sucks on the mouthpiece 158, the pressure differential within the consumables-containing container 102 causes the aerosol to enter the hollow pin 350 through the inlet 352 and exit through the outlet 354 (see the arrows showing the airflow). The aerosol then enters the cavity 368 of the consumables-containing container 102 and is filtered through the mouthpiece 158 for inhalation by the user. As such, the enclosure 108 does not need to have any opening 120.

[00164] In some embodiments, as shown in Figures 26A-G, there may be a single hollow pin 350 centrally positioned in the susceptor base 358, with a plurality of pins 290a-d surrounding the hollow pin 350. In such an embodiment, the hollow pin 350 need not be capable of heating by induction heating, although it may be. In this embodiment, the consumable-containing unit 104 may have a central hole 366 through which the hollow pin 350 may be inserted for a tight fit.

[00165] As shown in Figure 26G, in use, when the susceptor pins 290 are heated, the generated aerosol enters through the inlets 352 of the hollow pin 350 and exits through the outlets 354 and the nozzle 158, as shown by the airflow arrows.

[00166] The aerosol produced by the methods and devices described in this document is efficient and reduces the amount of toxic byproducts observed in cigarettes. Petition 870260066600, dated 06 / 07 / 2026, pp. 70 / 89 61 / 63 traditional and other devices for heating without burning. EXAMPLE

[00167] As shown in Figures 24A-C, tests were performed on packages containing consumables 102 that were prepared by compressing powdered tobacco mixed with a humectant and PGA, to form the consumable unit 104, around a susceptor 106, wrapped in a foil covering as the casing 108, inserted into a filter tube 140 in such a way that openings 120 were present on three sides as air channels, covered in standard cigarette paper as the housing 150, capped at one end with a high-flow proximal filter as the mouthpiece 158 and at the other end with a distal filter tip as the end cap 154. The susceptor 106 is in the form of a metal sheet twisted into a spiral. The consumable-containing unit 104 and the casing 108 have triangular cross-sections. Filter tube 140 is a spiral paper tube.

[00168] The test in Durham, North Carolina, was performed with a prototype device that was determined to heat the susceptor to 611 °C (degrees Celsius) by virtue of the calibration of the electrical energy used in the test process.

[00169] The Durham test was performed using a 20-port SM459 linear analytical smoking machine and was carried out by technicians familiar with the equipment and all associated accessories. The technicians placed three packages containing 102 consumables into the smoking machine. Each package containing 102 consumables was then blown 6 times, for a total of 18 blows. The resulting aerosol was then collected in filter blocks. The smoking regimen Petition 870260066600, dated 06 / 07 / 2026, pp. 71 / 89 62 / 63 was a puff every 30 seconds, lasting 2 seconds and with a volume of 55 mL collected using a bell curve profile. Analysis of the collected aerosol determined that 0.570 mg of carbon monoxide (CO) was present in the aerosol from each consumable stick, well below the levels at which combustion would be assumed to have occurred, despite the fact that combustion is generally assumed to occur at temperatures above 350 °C.

[00170] A second set of tests was conducted in Richmond, Virginia. The Richmond tests were performed with a package containing consumables 102 configured in a similar manner and a prototype device that was calibrated to heat a susceptor 106 at three separate settings of 275 °C, 350 °C, and 425 °C. CO data were generated by Enthalpy Analytical (EA) (Richmond, Virginia, USA), LLC, according to EA Method AM-007. Packages containing consumables 102 were smoked using an analytical smoking machine, following the established Canadian intense smoking procedure. The vapor phase of the smoke (i.e., aerosol) was collected in gas sampling bags attached to the smoking machine configured with the requested puff parameters. A non-dispersive infrared absorption (NDIR) method is used to measure the CO concentration in the vapor phase as a percentage by volume (percent vol).Using the number of packages containing consumables (102), the puff count, the puff volume, and the environmental conditions, the percentage of CO₂ was converted to milligrams per package containing consumables (mg / cig).

[00171] Under the calibrated temperature settings, it was determined that no CO was found in the aerosol. Petition 870260066600, dated 06 / 07 / 2026, pp. 72 / 89 63 / 63 produced in each of the configurations, despite the fact that it is generally assumed that combustion will occur at temperatures above 350 °C.

[00172] The tests performed are industry standard tests. In similar industry standard tests, commercially available heat-without-burn products report CO at 0.436 mg / cig. Standard combustible cigarettes indicate CO at 30.2 mg / cig.

[00173] The preceding description of the preferred embodiment of the invention has been presented for illustrative and descriptive purposes. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the invention is not limited by this detailed description, but by the appended claims and claims equivalent to those claims. Petition 870260066600, dated 06 / 07 / 2026, pp. 73 / 89

Claims

1 / 7 CLAIMS 1. Device (100) for generating aerosol, characterized in that it comprises: a) a consumable-containing unit (104) comprising compressed powder; b) a susceptor (106) incorporated in the consumable-containing unit (104), wherein the consumable-containing unit (104) is compressed onto the susceptor (106); c) an inductive heating element (160) configured to at least partially enclose the consumable-containing unit (104); d) a controller (166) for controlling the inductive heating element (160); e) a case (202) for containing the consumable-containing unit (104), the susceptor (106), the inductive heating element (160) and the controller (166).

2. Device (100), according to claim 1, characterized in that the housing (202) comprises: a) a switch operatively connected to the inductive heating element (160) to activate the inductive heating element (160); b) a user interface operatively coupled to the switch and to the inductive heating element (160) to provide status information.

3. Device (100), according to claim 1, characterized in that it further comprises a self-resonant oscillator for controlling the heating element (160).

4. Device (100), according to claim 3, characterized in that the self-resonant oscillator Petition 870260066600, dated 06 / 07 / 2026, page 74 / 89 2 / 7 comprises a capacitor (260) operatively connected to the heating element (160).

5. Device (100), according to claim 1, characterized in that the inductive heating element (160) comprises a plurality of spiral wires (162a, 162b), each spiral wire operatively connected to the controller (166) for independent activation of the other spiral wires (162a, 162b).

6. Device (100), according to claim 1, characterized in that the heating element (160) is movable.

7. Device (100), according to claim 1, characterized in that the consumables-containing unit (104) is an elongated member defining a first longitudinal axis (L), and in which the heating element (160) is configured to move axially along the first longitudinal axis (L).

8. Device (100), according to claim 1, characterized in that the consumable-containing unit (104) defines a first longitudinal axis (L) and the consumable-containing unit (104) comprises a cylindrical magnet (280) at one end of the consumable-containing unit (104), the cylindrical magnet (280) defining a second longitudinal axis (M), wherein the inductive heating element (160) is a cylindrical coil wound around the consumable-containing unit (104), the cylindrical coil defining a third longitudinal axis (C), wherein the cylindrical magnet (280) and the inductive heating element (160) are configured to maintain collinear alignment of the second longitudinal axis (M) with the third longitudinal axis (C).

9. Device (100), according to claim 1, characterized in that the susceptor (106) is a multi-pin susceptor (106).

10. Device (100), according to claim 9, characterized in that the inductive heating element (160) is configured to rotate around the consumables-containing unit (104).

11. Device (100), according to claim 10, characterized in that the multi-pin susceptor (106) comprises a plurality of pins parallel (290, 290a, 290b, 290c) to each other and incorporated in the consumables-containing unit (104).

12. Device (100), according to claim 11, characterized in that the consumables-containing unit (104) defines a first longitudinal axis (L), in which the inductive heating element (160) is configured to move radially relative to the first longitudinal axis (L).

13. Device (100), according to claim 12, characterized in that the inductive heating element (160) defining a second longitudinal axis (M) is configured to rotate around the consumable-containing unit (104) in an eccentric path, such that the second longitudinal axis (M) aligns collinearly with each of the pins (290, 290a, 290b, 290c) of the multi-pin susceptor (106) at some point during the rotational motion of the inductive heating element (160) around the consumable-containing unit (104).

14. Device (100), according to claim Petition 870260066600, dated 06 / 07 / 2026, page 76 / 89 4 / 7 1, characterized in that the susceptor (106) comprises a hollow pin (350).

15. Device (100), according to claim 14, characterized in that the hollow pin (350) comprises an input (352) and an output (354).

16. Device (100), according to claim 1, characterized in that the susceptor (106) is a metal plate comprising a plurality of openings.

17. Device (100), according to claim 16, characterized in that the susceptor (106) is an elongated metal plate having a longitudinal direction, the elongated metal plate comprising sets of openings, and sets of gaps, wherein the sets of openings alternate in series with the sets of gaps along the longitudinal direction of the elongated metal plate, such that each set of openings is adjacent to one of the gaps.

18. Device (100), according to claim 1, characterized in that the susceptor (106) comprises steel wool.

19. Device (100), according to claim 1, characterized in that it further comprises a magnetic flux sensor adjacent to the inductive heating element (160) and configured to measure a magnetic flux created by the heating element.

20. Device (100), according to claim 19, characterized in that the magnetic flux sensor is operatively connected to the controller (166) to control the activation of the inductive heating element (160) based on the return from the magnetic flux sensor. Petition 870260066600, dated 06 / 07 / 2026, p. 77 / 89 5 / 7 21. Device (100), according to claim 1, characterized in that it further comprises a wear sensor (320) for detecting whether a portion of the packaging containing consumables (104) being detected has been heated beyond a predetermined temperature.

22. Device (100), according to claim 21, characterized in that the sensor (320) in use is a photoreflective sensor.

23. Device (100), according to claim 22, characterized in that the consumables-containing unit (104) is contained in a consumables-containing package (102), and the consumables-containing package (102) comprises a heat-sensitive dye that changes color when heated to a predetermined temperature, wherein the color change is detectable by the photoreflective sensor.

24. Device (100), according to claim 1, characterized in that it further comprises a memory for storing locations of the portions of the unit containing consumables (104) that have been heated to the predetermined temperature.

25. Device (100), according to claim 24, characterized in that it further comprises a limit switch (326) for resetting the memory when a new unit containing consumables (104) is inserted into the case (202).

26. Device (100), according to claim 1, characterized in that it further comprises a heat sink (330) operatively connected to the heating element (160).

27. Device (100), according to claim Petition 870260066600, dated 06 / 07 / 2026, page 78 / 89 6 / 7 26, characterized in that the heat sink (330) is a finned cylinder that encloses the heating element (160).

28. Device (100), according to claim 1, characterized in that it further comprises an airflow controller (340).

29. Device (100), according to claim 1, characterized in that it further comprises a packaging aligner containing consumables.

30. Device (100), according to claim 1, characterized in that it further comprises an enclosure enclosing the unit containing consumables (104) and the susceptor (106), wherein the enclosure has a first end and a second end opposite the first end, wherein the enclosure comprises an opening.

31. Device (100), according to claim 30, characterized in that it further comprises a cover for sealing the opening.

32. Device (100), according to claim 30, characterized in that it further comprises a filter configured to enclose the housing.

33. Device (100), according to claim 30, characterized in that it further comprises a plurality of enclosures, wherein the inductive heating element (160) is configured and programmed to selectively heat each enclosure a predetermined number of times to a predetermined temperature selected by a user.

34. Device (100), according to claim 30, characterized in that one of the first or second ends of the enclosure comprises a fold for spacing Petition 870260066600, dated 06 / 07 / 2026, page 79 / 89 7 / 7 adjacent enclosures.

35. Method of using the device (100), as defined in claim 1, characterized in that it comprises applying heat to the consumable-containing unit (104) by heating the susceptor (106) from about 400 degrees Celsius to about 800 degrees Celsius with an induction heating element to release the aerosol form of the consumable from the consumable-containing unit (104).

36. Method of manufacturing a device for generating aerosol, characterized in that it comprises: a) incorporating a susceptor (106) into a consumables-containing unit (104), wherein the consumables-containing unit (104) is compressed over the susceptor (106) against a pellet to minimize oxygen within the pellet; b) enclosing the consumables-containing unit (104) with an inductive heating element (160); and c) placing the consumables-containing unit (104) with the susceptor (106), and the inductive heating element (160) in the case (202).

37. Method according to claim 36, characterized in that the unit containing consumables (104) is mixed with an additive to minimize oxygen within the pellet. Petition 870260066600, dated 06 / 07 / 2026, pp. 80 / 89

Images