Aerosol supply device

Abstract

The present application provides an aerosol supply device comprising: a heater comprising an elongate heater member and an extension member extending from the elongate heater member, the elongate heater member configured to generate heat to generate an aerosol from an aerosol-generating material; and a substrate supporting the heater, the substrate contacting the heater at the extension member such that the extension member forms a portion of a heat conduction path between the elongated heater member and the substrate. The present application also provides an aerosol supply system and a method of manufacturing an aerosol supply device.

Description

Technical Field

[0001] The present invention relates to a device for providing an aerosol, an aerosol supply system and a method of manufacturing the device. Background Art

[0002] Smoking articles (e.g., cigarettes, cigars, etc.) burn tobacco to produce tobacco smoke during use. Attempts have been made to provide substitutes for these tobacco-burning articles by producing products that release compounds without burning. The example of such a product is a heating device that releases compounds by heating but not burning the material. The material can be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the invention

[0003] According to a first aspect, an aerosol supply device is provided, which includes a heater and a substrate supporting the heater, the heater including a slender heater member and an extension part, the extension part extending from the slender heater member, the slender heater member being configured to generate heat to generate an aerosol from an aerosol generating material; and the substrate contacts the heater at the extension part, so that the extension part forms a part of a heat conduction path between the slender heater member and the substrate.

[0004] The extension part may extend from the elongate heater member in a lateral direction.

[0005] The extension member may include a flange.

[0006] The extension member may be formed from a metal or metal alloy, optionally wherein the extension member is formed from steel.

[0007] The extension member may be secured to the elongate heater member by welding.

[0008] The elongate heater member may comprise a housing, wherein the extension member is secured to the housing.

[0009] The housing may be formed from a metal or a metal alloy, optionally wherein the housing is formed from steel.

[0010] The elongate heater member may comprise a heater element, wherein the extension part is displaced from the heater element in a longitudinal direction.

[0011] The substrate may be formed from plastic, optionally wherein the substrate is formed from PEEK.

[0012] The extension member may be secured to the base by insert molding.

[0013] The end surface of the extension member may include a recess, wherein the base extends into the recess to secure the extension member to the base.

[0014] According to a second aspect, there is provided an aerosol supply system comprising the aerosol supply device of the first aspect and an article comprising an aerosol generating material.

[0015] According to a third aspect, a method for manufacturing an aerosol supply device is provided, the method comprising: receiving a heater comprising an elongated heater member and an extension part, the extension part extending from the elongated heater member; receiving a substrate; and arranging the substrate and the heater so that the substrate supports the heater, the substrate contacts the heater at the extension part, and the extension part forms a part of a heat conduction path between the elongated heater member and the substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0017] Figure 1 shows a perspective view of an aerosol supply system including an aerosol supply device located within a charging unit;

[0018] Figure 2 shows a perspective view of a heater forming part of an aerosol supply device;

[0019] Figure 3 shows a schematic cross-sectional view of a portion of a heater;

[0020] Figure 4 shows a perspective view of a heater secured to a substrate;

[0021] Figure 5 a schematic cross-sectional view showing a portion of the heater and substrate shown; and

[0022] Figure 6 A schematic cross-sectional view of a heater and substrate shown with an outer cover is shown. DETAILED DESCRIPTION

[0023] As used herein, the term "aerosol generating material" is a material that can generate an aerosol, for example, when heated, radiated, or stimulated in any other way. The aerosol generating material can be, for example, in the form of a solid, a liquid, or a gel, which may or may not contain an active substance and / or a flavoring agent. The aerosol generating material can include any plant-based material, such as a tobacco-containing material, and can, for example, include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or a tobacco substitute. The aerosol generating material can also include other non-tobacco products, which may or may not contain nicotine depending on the product. The aerosol generating material can, for example, be in the form of a solid, a liquid, a gel, a wax, etc. The aerosol generating material can, for example, also be a combination or blend of materials. The aerosol generating material can also be referred to as a "smokable material".

[0024] The aerosol generating material may include a binder and an aerosol forming agent. Optionally, an activating agent and / or a filler may also be present. Optionally, a solvent may also be present, such as water, and one or more other components of the aerosol generating material may or may not be dissolved in the solvent. In some embodiments, the aerosol generating material is substantially free of plant material. In some embodiments, the aerosol generating material is substantially free of tobacco.

[0025] The aerosol generating material may include or may be an "amorphous solid". The amorphous solid may be a "monolithic solid". In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that may retain some fluid (e.g., liquid) inside it. In some embodiments, the aerosol generating material may, for example, include from about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0026] The aerosol-generating material may comprise an aerosol-generating film. The aerosol-generating film may comprise or may be a sheet material, which may optionally be shredded to form shredded material. The sheet material may be a rolled sheet material. The aerosol-generating sheet material or shredded material may be substantially free of tobacco.

[0027] According to the present disclosure, a "non-flammable" aerosol supply system is an aerosol supply system in which constituent aerosol generating materials of the aerosol supply system (or components thereof) do not burn or ignite in order to deliver at least one substance to a user.

[0028] In some embodiments, the delivery system is a non-flammable aerosol supply system, for example, a powered non-flammable aerosol supply system.

[0029] In some embodiments, the non-flammable aerosol delivery system is an electronic cigarette, also known as a vapor device or an electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not required.

[0030] In some embodiments, the non-flammable aerosol supply system is an aerosol generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0031] In some embodiments, the non-flammable aerosol supply system is a hybrid system that uses a combination of aerosol generating materials to generate an aerosol, wherein one or more of the aerosol generating materials can be heated. Each aerosol generating material can be, for example, in the form of a solid, liquid or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material can include, for example, tobacco or non-tobacco products.

[0032] Generally, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and an article, which is generally a consumable for use with the non-flammable aerosol supply device.

[0033] In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-flammable aerosol supply device. These consumables are sometimes referred to as articles in the present disclosure.

[0034] In some embodiments, a non-flammable aerosol supply system, such as a non-flammable aerosol supply device thereof, may include a power source and a controller. The power source may be, for example, an electrical power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon matrix that can be powered to distribute power in the form of heat to an aerosol generating material or a heat transfer material proximate to the exothermic power source.

[0035] In some embodiments, a non-flammable aerosol supply system may include an area for receiving a consumable product, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0036] In some embodiments, consumables for use with a non-flammable aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material conveying component, an aerosol generator, an aerosol generating area, a shell, a wrapping paper, a filter, a mouthpiece and / or an aerosol modifier.

[0037] The aerosol generating device may receive an article comprising an aerosol generating material for heating. In the present context, an "article" is a component that comprises or contains an aerosol generating material that is heated in use to volatilize the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before heating the article to generate an aerosol, which the user then inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed in a heating chamber of the device that is sized to receive the article.

[0038] An aerosol generator is a device configured to cause an aerosol to be generated from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating material to thermal energy so as to release one or more volatiles from the aerosol generating material to form an aerosol.

[0039] A consumable is an article comprising or consisting of an aerosol generating material, some or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol generating material storage region, an aerosol generating material delivery component, an aerosol generating region, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol modifier.

[0040] The consumable may also include an aerosol generator, such as a heater, which, in use, emits heat to cause the aerosol-generating material to generate an aerosol. The heater may, for example, include a combustible material, a material that can be heated by electrical conduction, or a susceptor.

[0041] Figure 1 There is shown an aerosol supply system 10 comprising an aerosol supply device 100 and a charging unit 20. The device 100 is shown located within a cavity 21 of the charging unit 20. The cavity 21 has an open end 22 (also referred to as an opening). Figure 1 The charging unit embodiment also includes a longitudinal opening 23 .

[0042] The aerosol supply device 100 is arranged to generate an aerosol from an aerosol generating article (not shown) which, in use, may be inserted into the aerosol supply device 100. In an embodiment, the article forms part of the aerosol supply system 10.

[0043] The aerosol supply device 100 is an elongated structure extending along a longitudinal axis. The aerosol supply device 100 has: a proximal end 100a, which will be closest to the user (e.g., the user's mouth) when used by the user to inhale the aerosol generated by the aerosol supply device 100; and a distal end 100b, which will be farthest from the user when in use. The proximal end may also be referred to as a "mouth end". The aerosol supply device 100 also defines a proximal direction accordingly, which points to the user when in use. In addition, the aerosol supply device 100 also defines a distal direction, which points away from the user when in use. The terms proximal and distal applied to the features of the device 100 will be described with reference to the relative positioning of such features relative to each other in the proximal-distal direction along the longitudinal axis. The aerosol supply device 100 includes an opening at the proximal end 100a, which leads to a container. The container may be a heating chamber.

[0044] The aerosol supply device 100 can be removably inserted into the charging unit 20 for charging. Figure 1In the embodiment of the present invention, the distal end 100 b of the aerosol supply device 100 is inserted into the cavity 21 through the opening 22 .

[0045] A portion of the aerosol supply device 100 may include a first side 101. One or more user-operable control elements 106 (eg buttons) that may be used to operate the aerosol supply device 100 may be provided on the first side 101 of the aerosol supply device 100.

[0046] In an embodiment, the cavity of the charging unit 20 may have a cross-sectional profile that only allows the aerosol supply device 100 to be inserted into the charging unit 20 in a single orientation.

[0047] The charging unit 20 includes a slidable cover 25. When the aerosol supply device 100 is inserted into the charging unit 20 for recharging, the slidable cover 25 may be closed so as to cover an opening to the aerosol supply device 100.

[0048] In other embodiments, the charging unit 20 may have an alternative cover configuration, such as a hinged cover or a pivoting cover, or no cover may be provided.

[0049] The length of the cavity 21 of the charging unit is substantially equal to or slightly greater than the length of the aerosol supply device 100, so that substantially the entire aerosol supply device 100 is received in the cavity of the charging unit. This means that the device 100 is completely enclosed in the cavity 21 and protected.

[0050] The charging unit 20 may include a user interface, such as a display 28, which may be located in any convenient location, such as Figure 1 Position shown.

[0051] refer to Figure 2 and Figure 3 , the aerosol supply device 100 includes a heater 200. The heater 200 includes an elongated heater member 201 and an extension part 202.

[0052] The elongated heater member 201 is an elongated structure extending along a longitudinal axis. In the present embodiment, the elongated heater member 201 has a substantially cylindrical shape with a pointed tip at the proximal end closest to the user to form a generally pin-shaped. In alternative embodiments, the elongated heater member 201 may take the form of a different elongated structure having a different cross-sectional shape, such as a blade.

[0053] The elongated heater member 201 comprises a heating element 203, a connecting wire 207 and a housing 204. The housing 204 is hollow and forms the outer surface of the elongated heater member 201. The housing 204 surrounds the heating element 203. The heating element 203 and the connecting wire 207 are aligned with each other and both extend along the longitudinal axis at the center of the elongated heater member 201. The heating element 203 and the connecting wire 207 are electrically connected, wherein the connecting wire 207 provides power to the heating element 203 during use.

[0054] The distal end of the heating element 203 and the proximal end of the connecting wire 207 are displaced a short distance in the longitudinal direction from the position of the extension part 202 along the elongate heater member 201 .

[0055] In some embodiments, the distal end of the heating element 203 and the proximal end of the connecting wire 207 can be substantially aligned with the location of the extension member 202 along the elongated heater member 201 .

[0056] The elongate heater member 201 is configured to generate heat to generate an aerosol from an aerosol-generating material.The aerosol-generating material may be located in an aerosol-forming article.

[0057] In the present embodiment, the housing 204 is formed of steel. In other embodiments, the housing 204 may be formed of a different metal or metal alloy.

[0058] Forming the housing 204 from a metal or metal alloy allows heat from the heating element 203 to be efficiently conducted into an aerosol-forming article used in the device 100 .

[0059] The extension part 202 extends in a lateral direction from the elongated heater member 201. The extension part 202 extends around the periphery of the elongated heater member 201. The extension part 202 completely surrounds the elongated heater member 201. The top surface of the extension part 202 forms a circular ring shape.

[0060] The extension part is located at a position along the length of the elongate heater member 201 , preferably closer to the distal end of the aerosol supply device 100 than closer to the proximal end.

[0061] In this embodiment, the extension member 202 includes a flange 202 .

[0062] In this embodiment, the extension member 202 is formed of steel. In other embodiments, the extension member 202 can be formed of a different metal or metal alloy.

[0063] The extension part 202 is fixed to the elongated heater member 201 by welding so that the extension part 202 is fixed to the housing 204. The extension part 202 and the elongated heater member 201 are arranged so that the top surface of the extension part 202 is substantially perpendicular to the longitudinal axis. The extension part 202 is displaced from the heating element 203 in the longitudinal direction.

[0064] The extension member 202 comprises a recess 205. The recess 205 is located in an end face of the extension member 202. The recess 205 comprises an axially symmetrical opening in the end face of the extension member 202, wherein the opening faces in a lateral direction. The recess 205 extends around the periphery of the extension member 202 such that it completely surrounds the elongated heater member 201.

[0065] refer to Figure 4 and Figure 5 , the aerosol supply device 100 includes a heater 200 and a substrate 300 .

[0066] The substrate 300 is substantially cylindrical in shape, wherein the diameter of the substrate 300 is greater than the diameter of the elongated heater member 201. The substrate 300 is configured so that it can be connected to the aerosol supply device 100. For example, the substrate 300 may include a portion that allows it to be fixed to the housing 208 (see Figure 6 ) and other components of the aerosol supply device 100. The substrate 300 may include other cavities and protrusions on its outer surface, such as a groove configured to retain the sealant ring 206.

[0067] In this embodiment, the substrate 300 is formed of PEEK (polyetheretherketone). In other embodiments, the substrate 300 can be formed of different plastics or materials.

[0068] The substrate 300 contacts the heater 200 at the extension part 202 so that the substrate 300 supports the elongated heater member 201. Insert molding is used to fix the extension part 202 to the substrate 300. The substrate 300 extends into the recess 205 of the extension part 202 to support the heater 200. Insert molding can easily allow the substrate 300 to extend into the recess 205 in this way.

[0069] The substrate 300 and the heater 200 are connected so that the extension part 202 forms part of a heat conduction path between the elongated heater member 201 and the substrate 300. In other words, heat energy emitted from the elongated heater member 201 by conduction passes through the extension part 202 before being absorbed by the substrate 300. In this example 300, the substrate 300 does not contact the housing 204 of the heater 200. The substrate 300 contacts the heater 200 only at the extension part 202.

[0070] By having the extension member 202 form part of the heat conduction path, the amount of heat reaching the substrate 300 from the heating element 203 is reduced, thereby reducing the temperature reached by the substrate 300 during use. In some embodiments, the heating element 203 is configured to reach a temperature of 380° C. when the device 100 is in use, which may be above the melting point of the material of the substrate 300. When using an extension member 202 of a particular size, the temperature of the substrate 300 may be further reduced. This is beneficial because overheating of the substrate 300 may cause a number of problems, such as reducing the stability and overall safety of the device 100.

[0071] refer to Figure 6 , the base 300 and the heater 200 may be surrounded by a cylindrical housing 208. The housing may form part of a heating chamber of the device 100, wherein the heater 200 stands upright from a distal end of the heating chamber.

[0072] The outer cover 208 surrounds the perimeter of the base 300. The outer cover 208 is attached to the base 300 using, for example, snaps located on the perimeter of the base 300.

[0073] During use of the device 100, the elongate heater member 201 may be inserted into the distal end of an aerosol-forming article (not shown). The aerosol-forming article is received in the heating chamber such that the outer cover 208 surrounds the periphery of the article.

[0074] By using an elongate shape, such as a pin, for the heater member 201 , the aerosol-forming article may be heated internally along a majority of its length during use.

[0075] The various embodiments described herein are intended only to aid in understanding and teaching the claimed features. These embodiments are provided only as representative samples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not considered to be limitations on the scope of the invention as defined by the claims, or limitations on the equivalents of the claims, and other embodiments may be utilized and may be modified without departing from the scope of the claimed invention. In addition to those specifically described herein, various embodiments of the present invention may appropriately include, contain, or substantially contain appropriate combinations of disclosed elements, components, features, parts, steps, devices, etc. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An aerosol supply device, comprising: a heater comprising an elongated heater member and an extension member extending from the elongated heater member, the elongated heater member being configured to generate heat to generate an aerosol from an aerosol generating material; as well as A substrate supports the heater, the substrate contacting the heater at the extension member such that the extension member forms a portion of a heat conduction path between the elongate heater member and the substrate.

2. The aerosol supply device according to claim 1, wherein: The extension member extends from the elongated heater member in a lateral direction.

3. The aerosol supply device according to claim 2, wherein: The extension member includes a flange.

4. The aerosol supply device according to any one of claims 1 to 3, wherein: The extension member is formed from a metal or a metal alloy, optionally wherein the extension member is formed from steel.

5. The aerosol supply device according to any one of claims 1 to 4, wherein: The extension member is secured to the elongate heater member by welding.

6. The aerosol supply device according to any one of claims 1 to 5, wherein: The elongate heater member comprises a housing, wherein the extension member is secured to the housing.

7. The aerosol supply device according to claim 6, wherein: The housing is formed from metal or a metal alloy, optionally wherein the housing is formed from steel.

8. The aerosol supply device according to any one of claims 1 to 6, wherein: The elongate heater member comprises a heater element, wherein the extension part is displaced from the heater element in a longitudinal direction.

9. The aerosol supply device according to any one of claims 1 to 8, wherein: The substrate is formed from plastic, optionally wherein the substrate is formed from PEEK.

10. The aerosol supply device according to any one of claims 1 to 9, wherein: The extension member is fixed to the base by insert molding.

11. The aerosol supply device according to any one of claims 1 to 10, wherein: An end surface of the extension member includes a recess, wherein the base extends into the recess to secure the extension member to the base.

12. An aerosol supply system comprising the aerosol supply device according to any one of claims 1 to 11 and an article comprising the aerosol generating material.

13. A method of manufacturing an aerosol supply device, the method comprising: receiving a heater comprising an elongated heater member and an extension member extending from the elongated heater member; receiving substrate; as well as The substrate and heater are arranged such that the substrate supports the heater, the substrate contacts the heater at the extension member, such that the extension member forms part of a heat conduction path between the elongate heater member and the substrate.

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