Aerosol device and method for moving consumables

Abstract

A device for converting consumables into aerosols using a moving aerosol-generating substrate with high heat without burning the consumables to gradually heat portions of the substrate to release the consumables from different portions of the substrate. An aerosol-generating substrate is placed in an aerosol-generating device, wherein a portion of the aerosol-generating substrate is surrounded by an induction heating element. When the induction heating element is activated, the portion of the aerosol-generating substrate surrounded by the induction heating element may release the consumable. The actuator advances the aerosol-generating substrate through the induction heating element, causing another portion of the aerosol-generating substrate to enter the induction heating element, heating the portion causing more release of the consumable.

Description

Technical Field

[0001] The present invention relates to a device for aerosolizing drugs via a high temperature, non-combustion induction heating method and its use. The present invention further relates to a method and device for generating aerosols from tobacco and / or other non-drug substances using similar methods and devices. Background Art

[0002] When faced with a condition that causes physical discomfort (such as a disease state, illness, ailment, normal bodily disturbance, etc.), most people turn to medications, such as pharmaceuticals, supplements, herbs, etc., to immediately relieve the symptoms caused by the underlying condition. Certain legal and widely available over-the-counter (OTC) medications and supplements have beneficial effects when used for a variety of common conditions. Doctors also prescribe certain controlled narcotics and drugs for a variety of more serious conditions.

[0003] One of the most common routes of administration for these OTC and prescription drugs is oral administration. However, like any oral medication, it must pass through the digestive tract. There are many disadvantages to oral administration. For example, since the drug must pass through the digestive system, the activation of the drug begins slowly. In addition, in the digestive tract, the drug may be inactivated or destroyed and therefore lose its potency or efficacy. The drug itself may also cause digestive tract problems or side effects, such as loss of appetite, diarrhea, hyperacidity, etc. In addition, patients may be unwilling or unable to swallow oral medications in pill form.

[0004] Certain drugs are intended to affect the brain or the actions or activities of the brain, but considering the accepted method of ingestion, i.e., gastrointestinal, intravenous, or intramuscular, these drugs may also produce various unpleasant side effects due to the nature of ingestion or injection. These include, but are not limited to, gastrointestinal complications, digestive disturbances, high blood pressure and / or headaches, as well as the user's reluctance to self-administer via injection.

[0005] There are other delivery routes, such as intradermal injection, patch application, inhalation, etc. Each of these has its own advantages and disadvantages. Therefore, there is still room for improvement in the route of drug administration.

[0006] For example, there are a variety of drugs that are safer, more potent, and more efficient in terms of safety and efficacy if their intake is via inhalation of an aerosol (e.g., gas, vapor, mist, and any other inhalant) containing the drug or its active ingredient rather than through gastrointestinal, intravenous, or intramuscular delivery.

[0007] Additionally, some methods of aerosolizing and delivering these drugs also have disadvantages, particularly those methods that aerosolize the drug itself, which alters the drug's molecular or chemical structure, or those methods that may perform aerosolization at elevated temperatures, which prolongs the duration of heating and increases the risk of altering the molecular or chemical structure of the active ingredient. Other disadvantages of current aerosolization technology include that some drugs are shipped, stored, and sold in cartridges that are prone to leakage, and in many cases, the design and construction materials of the cartridges are not environmentally friendly, containing plastics and other non-biodegradable materials.

[0008] To ensure intact drug delivery via a high temperature, non-combustion induction method, it is preferred that the aerosolization process does not change the chemical or basic molecular structure of the drug or other materials that make up the drug, or if such changes occur, they do not affect and / or improve the efficacy of the drug.

[0009] Therefore, there is still a need to improve the route of administration of medicine. In particular, there is still a need to improve the method for aerosolizing medicine so that it can be inhaled, which will also provide the additional benefit of metering, monitoring and measuring the precise dose of the inhaler without destroying the active ingredient or adding other chemicals to the aerosol due to low energy efficiency or extended heating time. There is also a need for consumable embodiments that are biodegradable and do not contain materials that do not meet environmentally friendly disposal.

[0010] In addition to drug delivery systems, heat-not-burn (HNB) devices are devices of the following type: generally used to heat tobacco at a temperature lower than that causing combustion to produce an aerosol containing nicotine and other tobacco components, which is then used by the user of the device. In some embodiments, a heated element or susceptor is placed inside a solid tobacco product, wherein a coil is wrapped around the tobacco product and the susceptor to heat the susceptor by an induction mechanism. Unlike traditional cigarettes, the goal is not to burn tobacco, but to fully heat tobacco to release nicotine and other components by producing an aerosol. Ignition and burning of cigarettes can produce undesirable toxins, which can be avoided by using HNB devices. However, it is difficult to balance between providing enough heat to effectively release tobacco components in the form of aerosol and not burning or igniting tobacco. HNB devices on the current market have not yet found this balance, either heating tobacco at a temperature that produces an inappropriate amount of aerosol, or overheating tobacco and producing an unpleasant or "burned" flavor distribution. In addition, current methods make the internal components of traditional HNB devices dirty by burning tobacco byproducts and byproducts of accidental combustion.

[0011] Furthermore, to ensure that the change of state from solid or liquid to aerosol state occurs in a rapid and energy efficient manner via high temperature, non-combustion induction heating, the formulation must be configured in a manner that eliminates air flow between the formulation and the induction system susceptor.

[0012] For the foregoing reasons, there is a need for a device that will affect the temperature at which tobacco is heated via an inductive method, thereby reducing the risk of burning even at temperatures that would otherwise be sufficient for ignition, while increasing the efficiency and flavor profile of the aerosol produced. There is also a need for a device that uses a unique consumable that is inexpensive to produce and that provides a satisfying user experience when used in an associated device by moving the consumable through an induction coil for continuous inhalation. Summary of the invention

[0013] The present invention relates to devices and methods for delivering consumables in an aerosolized state for inhalation administration and ingestion using a high temperature, non-combustion induction method to aerosolize embodiments of the design and configuration of the formulation.

[0014] In particular, the present invention relates to further improvements in heat-not-burn devices, such as those described in U.S. Patent Nos. 10,750,787, PCT / US2019 / 012204, and PCT / US2020 / 040779. In general, a heat-not-burn device is a device for converting a consumable into an aerosol that contains some of its components but limits the byproducts most commonly associated with combustion, such as smoke, ash, tar, and certain other potentially harmful chemicals. This is achieved by using high heat without burning the consumable, by packaging the consumable containing an internal susceptor in a shell. The present invention may involve heating the susceptor by using an induction heating element wrapped around a consumable containing package to utilize the induction heating element to heat the susceptor by a magnetic field generated by moving one or both of the heating element or the consumable, so that the heat is positioned along the tobacco component of the consumable and gradually advanced.

[0015] Another object of the present invention is a consumable tobacco component, which is composed of at least one shell and an induction heating source that have accommodated consumable tobacco products. The shell can be paper, fabric, plastic or woven sheet or any other material, and the material is porous enough to convey the aerosol produced during the heating consumable. The consumable can be assembled with two sheets (top and bottom) of this material, so that a susceptor is clamped in the consumable product, and then the two sheets can be folded together to encapsulate the consumable product. Several of these "packs" can be used in a single consumable or only one pack can be used.

[0016] In an alternative embodiment, the shell can be an aluminum shell with a preset opening. The shell can be coated with a gel to seal the opening until the induction heating process melts the gel to unseal the opening. In some embodiments, the gel can include a flavoring agent that can add flavor to the tobacco aerosol or enhance its flavor.

[0017] In some embodiments, multiple shells can be stacked within a paper tube with spacing between the shells formed by excess wrapping at the bottom end of each shell, and channels on either side to allow passage of the generated aerosol. When the induction heating source is activated, the preset opening is unsealed, and the flavor and aerosol combination travels through the tube and is available to the user of the device.

[0018] By using these methods and apparatus, the device requires less mass to heat, can heat up instantly, cool down quickly and conserve power, thereby allowing more use between recharging periods. This is in contrast to the well known current commercially available heat-not-burn devices.

[0019] Another object of the present invention is to provide a consumable product containing package that is easy to replace and minimizes dirt inside the housing during use to reduce the cleaning work of the housing.

[0020] Another object of the present invention is to move the susceptor or consumable relative to the heating element to heat sections of the consumable independently of other sections. In this context, "section" refers to physically segmented consumable materials, or continuous consumable materials that are heated sequentially as they move past the induction coil, or vice versa.

[0021] Another object of the present invention is to aerosolize a consumable that can be compressed around a susceptor in a manner that eliminates any air flow between the consumable and the susceptor. For example, an aerosol-generating substrate can include inert, non-reactive compounds that are mixed with a form of consumable and then tightly compressed around the susceptor. A handheld high-temperature induction heating device configured for consumable embodiments can be used to aerosolize the formulation.

[0022] Therefore, the device, method and preparation of the present invention can be used to aerosolize a variety of consumables, preferably drugs. For example, these drugs include but are not limited to those that are configured to improve bronchial efficiency, support smoking cessation, help relaxation, relieve anxiety, prevent destructive thoughts, control pain, increase attention, help restful sleep, help sexual activity, increase energy and wakefulness, and offset the harmful effects of overdose of certain other drugs. In addition, these consumables may include tobacco, marijuana or other substances that can be inhaled and ingested by consumers. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A side view showing the interior of an embodiment of the present invention assembled in an HNB device.

[0024] Figure 2A A perspective view of an embodiment of the present invention assembled into a consumable product containment package is shown.

[0025] Figure 2B Shows Figure 2A A perspective view of the embodiment shown with a portion of the consumable product containment package cut away and / or removed to expose the susceptor.

[0026] Figure 2C Shows Figure 2A The illustrated embodiment is a cross-sectional view taken along line 2C-2C.

[0027] Figure 2D Shows Figure 2A An exploded view of a consumable product containment package is shown.

[0028] Figure 2E A perspective view of another embodiment of a consumable product containing package having a susceptor is shown, wherein portions of the consumable product containing package are cut away and / or removed to expose the susceptor.

[0029] Figure 3A A perspective view of an embodiment of a consumable product containing package is shown.

[0030] Figure 3B Shows Figure 3A A perspective view of the illustrated embodiment with portions of the consumable product containing package and consumable products removed to illustrate the internal configuration.

[0031] Figure 3C Shows Figure 3A Exploded view of the illustrated embodiment.

[0032] Figure 4A A perspective view of another embodiment of the present invention is shown.

[0033] Figure 4B Shown in open configuration Figure 4A The embodiments in .

[0034] FIG. 5A to FIG. 5D A series of perspective views of another embodiment of the invention is shown in which a consumable product moves through a housing.

[0035] FIG. 6A to FIG. 6C A series of perspective views of another embodiment of the invention is shown in which a consumable product moves through a housing.

[0036] 7A to 7E A series of perspective views of another embodiment of the present invention are shown in which a consumable is inserted into the HNB device and the consumable moves through the housing.

[0037] FIG. 8A to FIG. 8B A series of perspective views of another embodiment of the invention is shown in which a consumable product moves through a housing. DETAILED DESCRIPTION

[0038] The detailed description set forth below in conjunction with the accompanying drawings is intended as a description of the present preferred embodiment of the present invention and is not intended to represent the only form in which the present invention can be constructed or utilized. This description sets forth functions and step sequences for constructing and operating the present invention in conjunction with the embodiments shown. However, it should be understood that the same or equivalent functions and sequences can be realized by different embodiments, and these different embodiments are equally intended to be included in the spirit and scope of the present invention.

[0039] Heating without burning device

[0040] The invention content of the present application is a device for producing an aerosol for inhalation with a consumable containing product in a manner that utilizes relatively high heat and causes the consumable containing product to be burned to a minimum. For the purpose of the present application, the term "consumable" is broadly interpreted as covering any type of pharmaceutical agent, medicine, chemical compound, active agent, ingredient, any other medicine, etc., regardless of whether the consumable is used to treat a disease or disease, for nutrition, tonic, or for recreation. By way of example only, consumables may include drugs, nutritional supplements, and over-the-counter drugs, such as but not limited to tobacco, tobacco raw materials (cannabis), cigarettes, lavender, kava, coffee, caffeine, lobelia, cactus, melatonin, wolfberry, guarana, ginseng, etc.

[0041] Figures 1 to 2E An example of an HNB device 100 is shown in FIG. 1 and is fully described in U.S. Patent Nos. 10,750,787, PCT / US2019 / 012204, and PCT / US2020 / 040779, the entire contents of which are incorporated herein by reference. The device 100 includes a consumable product containing package 102 and an aerosol generating device 200. The consumable product containing package 102 includes an aerosol generating substrate 104 that releases an active agent (consumable) when heated, and a susceptor 106 embedded therein to heat the aerosol generating substrate 104. The device 100 generates an aerosol by a heating-not-burning process, in which the aerosol-generating substrate 104 is exposed to an aerosolizing heat state (such as a high aerosolizing temperature and the absence of oxygen), which does not burn the aerosol-generating substrate 104 in the consumables containing package 102, but does release the active ingredient (consumables) from the aerosol-generating substrate 104 in the form of an aerosol product that can be inhaled. Therefore, the aerosol-generating substrate 104 is any product that contains an active ingredient that can be released in the form of an aerosol when heated to an appropriate temperature and condition. Any description of the present invention to a specific application (such as a tobacco product) is provided only as a specific example and is not intended to be limiting. In this way, the present invention is not limited to use only with tobacco products.

[0042] refer to Figure 1 , the aerosol generating device 200 comprises a receiving member 151 for receiving the consumable product containing package 102, an inductive heating element 160 for heating the susceptor 106, a system controller 166 for controlling the inductive heating element 160, and a power supply 220 for powering the device 100. A user interface 230 operatively connected to the controller 166 may be provided to facilitate ease of operation. A trigger 232 may be provided to actuate the device 100, or the device 100 may be activated through the user interface 230.

[0043] refer to FIG. 2A to FIG. 2E , the consumable containing package 102 is a component that is heated to release the consumable (i.e., active agent) in the form of an aerosol. The consumable containing package 102 includes an aerosol generating substrate 104 and a susceptor 106 surrounded by the aerosol generating substrate 104 to heat the aerosol generating substrate 104 from the inside out by an induction heating system. In some embodiments, the consumable containing package 102 may have a shell 108 to at least partially contain the aerosol generating substrate 104 and the susceptor 106. For example, the aerosol generating substrate 104 may be completely covered by the shell 108. In some embodiments, the aerosol generating substrate 104 may be partially covered by the shell 108 so that part of the aerosol generating substrate 104 is exposed (such as all or part of the end, top, bottom, or any other part of the aerosol generating substrate 104). In some embodiments, the consumable containment package 102 may further include a housing 150 for containing one or more aerosol-generating substrates 104 with embedded susceptors 106 , with or without an enclosure 108 .

[0044] Receptors

[0045] The susceptor 106 is a component that is heated by an induction method and is used to heat the aerosol-generating substrate 104 from the inside out. As such, the susceptor 106 is made of a metal that can be heated by an induction method, such as a ferrous metal. Other metals or materials that have the ability to inductively heat the aerosol-generating substrate 104 may also be used. In order to maximize the effective heating of the aerosol-generating substrate 104, the susceptor 106 generally matches the shape of the largest cross-sectional area of ​​the aerosol-generating substrate 104 to maximize the surface area of ​​the aerosol-generating substrate 104 in contact with the susceptor 106, although other configurations may also be used.

[0046] The susceptor 106 can be produced by machine extrusion, made of sintered or otherwise molten metal particles, and can also be made of metal wool, stamping, pressing, or any other method that can produce a satisfactory susceptor. Some of these methods are described in U.S. Patent No. 10,750,787, PCT / US 2019 / 012204, PCT / US2020 / 040779, and U.S. Application No. 17 / 687,470, the entire contents of which are incorporated herein by reference. In some embodiments, the aerosol generating substrate 104 can be combined with or incorporated into the susceptor 106 by co-extruding it with the susceptor 106 to produce a layer of the aerosol generating substrate 104 on the top or bottom of the layer of the susceptor 106. In some embodiments, two layers of aerosol-generating substrates 104a, 104b may be coextruded with a susceptor 106 therebetween to form a sandwich around the susceptor 106, which may be compressed between the two layers of aerosol-generating substrates 104a, 104b. The coextruded material may then be cut to appropriate size.

[0047] In some embodiments where the susceptor 106 is steel wool or metal particles, the consumable may be incorporated directly into the susceptor 106, for example in the form of a fluid (e.g., liquid, semi-liquid, viscous substance, etc.) or loose solid (e.g., powder, granules, pellets, etc.), in which case the susceptor 106 has a dual function as a heating element and an aerosol-generating substrate 104. Thus, the aerosol-generating substrate 104 may be a combination of the susceptor 106 and the consumable incorporated therein.

[0048] Aerosol Generating Matrix

[0049] The design of the aerosol-generating substrate 104 is to minimize the amount of air to which the aerosol-generating substrate 104 is exposed. This eliminates or reduces the risk of oxidation or combustion during storage or during the heating process. Thus, in certain settings, the aerosol-generating substrate 104 may be heated to a temperature that would cause combustion when used with prior art devices that allow more air exposure.

[0050] Thus, in some embodiments, the aerosol-generating substrate 104 is made of a powdered form consumable that is compressed into a hard compressed pellet, rod, or cuboid. The compressed consumable reduces the oxygen trapped within the aerosol-generating substrate 104 and limits the entry of oxygen into the aerosol-generating substrate 104 during storage and heating.

[0051] In some embodiments, the aerosol-generating substrate 104 may be an elongated unit defining a longitudinal axis A. FIG. 2A to FIG. 2EThe aerosol-generating substrate 104 may be an elongated cylinder or tube having a circular cross-section, an elliptical cross-section, a rectangular cross-section, a polygonal cross-section, etc. In some embodiments, the aerosol-generating substrate 104 may be a plurality of cylindrical tablets or pellets stacked one on top of the other.

[0052] In a preferred embodiment, the aerosol-generating substrate 104 may be in the shape of a slightly elongated rectangular parallelepiped defining a longitudinal axis A, such as FIG. 3A to FIG. 3C and FIG. 4A to FIG. 4B Other cuboid shapes and combinations of substantially flat faces and / or rounded faces based on a substantially cuboid shape may also be used.

[0053] The susceptor 106 may similarly be elongated and embedded in the aerosol-generating substrate 104, preferably extending substantially the length L of the aerosol-generating substrate 104 along the longitudinal axis A. The susceptor 106 may also extend substantially the width W of the aerosol-generating substrate 104. In other embodiments, the susceptor 106 may extend beyond both the width (or diameter) and the length of the aerosol-generating substrate 104, or be substantially shorter than either dimension.

[0054] In some embodiments, the aerosol-generating substrate 104 can take any other shape, including spherical, oval, elliptical, and even amorphous. Typically, the susceptor 106 can be patterned in the shape of the aerosol-generating substrate 104 to maximize the surface area contact between the susceptor 106 and the aerosol-generating substrate 104; however, the susceptor 106 can also be other shapes, including multiple susceptors 106 dispersed within the aerosol-generating substrate 104.

[0055] In yet another alternative embodiment, the aerosol-generating substrate 104 may be formed into micro-pellets, granules, powders, or other forms that may be packaged to further reduce the air available to the consumable.

[0056] In some embodiments, the aerosol generating substrate 104 may include a consumable source ground into a powder form and then combined with the susceptor 106 by being tightly compressed around the susceptor 106. For example only, the consumable source may be a plant, seed, flower, root, leaf, plant component, or any other source from which consumables may be extracted. These components may be dried, ground, and mixed with other components known to produce pellets and tablets to compress around the susceptor 106 to form a pellet, tablet, or rod around the susceptor 106. The compressed pellet, tablet, or rod may be encapsulated in a shell 108 to form a consumable containing package 102.

[0057] Encapsulation

[0058] The invention of the present application relates to the construction of the consumable product containing package 102 and the structure of moving the consumable product containing package 102 past the induction coil 160 to heat sections of the consumable product containing package 102 in a sequential manner.

[0059] In some embodiments, such as in FIG. 2A to FIG. 2E As best seen in FIG. 1 , the shell 108 comprises an aerosol generating substrate 104, wherein the receptor 106 is embedded in the aerosol generating substrate. In some embodiments, the shell 108 may be configured with holes 120 to allow aerosol to escape from the shell 108, or the shell 108 may be a permeable membrane, paper, fabric or other material to allow aerosol to escape. The aerosol generating substrate 104 may be placed inside a housing 150 that may simulate a cigarette. In some embodiments, a filter 140 may surround the shell 108. The housing 150 may be capped with an end cap 154 ​​at one end 152 and capped with a mouthpiece 158 at the opposite end 156. The end cap 154 ​​may be made of a filter material. The mouthpiece 158 allows the user to draw the heated consumable aerosol out of the aerosol generating substrate 104 along the housing 150, toward the mouthpiece 158 into the user's mouth. Thus, the mouthpiece 158 may also include a filter, similar to the end cap 154. There may be a plurality of apertures 446 adjacent the nozzle 158 through which air may be drawn when a user draws suction on the housing 150 by sucking on the nozzle 158 .

[0060] In a preferred embodiment, the enclosure 108 comprises a top sheet 108a and a bottom sheet 108b, which may be two separate sheets or one continuous sheet. The sheets 108a, 108b may comprise a permeable material that allows the aerosol to escape, which may be filter paper, porous paper, fabric, plastic, film, metal with holes, tea bag material, or cigarette filter media (cellulose), or any suitable material.

[0061] The permeable nature of the shell 108 can expose the aerosol-generating substrate 104 to air and cause potential oxidation / degradation. To prevent this, a coating can be used to temporarily seal the holes or openings in the shell 108. The coating is preferably made of a composition that melts and / or becomes permeable at a temperature at which a consumable aerosol is generated. Therefore, as the susceptor 106 is heated, since there is no air inside the shell 108, the aerosol-generating substrate 104 can be heated to a very high temperature without burning. When the susceptor 106 reaches a high temperature, the consumable aerosol that begins to form cannot escape. When the coating melts or becomes permeable, the consumable aerosol can escape the shell 108 for inhalation. In a preferred embodiment, the coating can be propylene glycol alginate ("PGA") gel or food-grade starch. The coating can also include flavorings. Therefore, as the coating melts and releases the consumable aerosol, the flavoring is also released together with the consumable aerosol. In some embodiments, the flavoring can be mixed with an additive.

[0062] In a preferred embodiment, the enclosure 108 may include a top portion 108a and a bottom portion 108b, which may be separate pieces or one continuous piece. Preferably, the top and bottom portions of the enclosures 108a, 108b have preformed cup-shaped recesses or cavities 109 to surround the aerosol generating substrate 104, such as Figure 3C Alternatively, one or both of the top and bottom portions of the envelope 108a, 108b may be flat and subsequently squeezed or stretched around the aerosol-generating substrate 104 during production.

[0063] In a preferred embodiment, in order to securely seal the envelope 108 around the aerosol generating substrate 104, the ends 124, 126 of the envelope 108 may have folded portions 130, 132, such as Figure 4A and Figure 4B Before folding, the two parts of the enclosure 108a, 108b can be joined or sealed using conventional methods (such as adhesives, mechanical fasteners, crimping, RF welding) or any suitable method to close the enclosure 108. Similarly, after folding, the sealing / joining ends 124, 126 can be adhered to the outer surface of the enclosure 108, such as Figure 4A As shown. Alternatively, the ends 124, 126 of the enclosure 108 need not be sealed prior to folding, but rather maintained in a folded fashion by adhesive, mechanical fasteners, crimping, RF welding, or any suitable method. In yet another alternative, the enclosure 108 may simply be held in place by the fold itself, without any sealing or bonding.

[0064] Therefore, a method for manufacturing a consumable product containing package 102 for use in an aerosol generating device 200 includes: combining a receptor 106 with an aerosol generating substrate 104 containing the consumable product; covering the aerosol generating substrate 104 with an enclosure 108; folding the ends 124, 126 of the enclosure 108 to encapsulate the aerosol generating substrate 104; and placing the assembly into a shell 150.

[0065] In some embodiments, the enclosure 108 may be eliminated entirely, and the aerosol-generating substrate 104 is simply surrounded by the shell 150. In such embodiments, the aerosol is released from the aerosol-generating substrate 104 directly into the passage between the aerosol-generating substrate 104 and the shell 150. Similar to the enclosure embodiment, the exterior of the aerosol-generating substrate 104 does not reach combustion temperatures due to rapid inside-out inductive heating.

[0066] In embodiments where the enclosure 108 is porous or absent, the freshness of the consumables can be maintained by using an airtight package that can be filled with nitrogen or other inert gas to prevent oxidation. Such packaging can be used for large packages of consumable containment packages 102, such as tobacco products where multiple consumable containment packages 102 may be used per day. Alternatively, individual packaging can be used for consumable containment packages 102 containing medications where the consumables are only used periodically.

[0067] case

[0068] In a preferred embodiment, the shell 108 is configured to be aerosol permeable to allow aerosol to escape from the shell 108. The aerosol generating substrate 104 can be placed inside the housing 150 with or without the shell 108 as described above. The housing 150 is preferably less permeable or impermeable to the aerosol. The housing 150 can imitate a cigarette. In this way, the housing 150 can be an elongated structure having a first end 152 and a second end 156 opposite to the first end 152. The housing 150 is inserted into the device 200 so that the inductive heating element 160 surrounds the housing 150. Then, the current passing through the inductive heating element 160 can heat the susceptor 104 embedded in the aerosol generating substrate 104, so that the aerosol generating substrate is heated from the inside out. When the aerosol generating substrate 104 is heated by the susceptor 106, an aerosol containing consumables is generated. When the user draws on the housing 150, for example by sucking on the second end 156, the aerosol escapes from the envelope 108, but does not escape from the housing 150. The negative pressure generated by sucking at the second end 156 causes the aerosol to be drawn through any space between the aerosol-generating substrate 104 and the housing 150 toward the second end 156. An opening in or around the first end 152 may be used to facilitate the flow of air around the outside of the aerosol-generating substrate 104 and toward the second end 156. Such an opening may be equipped with a valve for one-way flow or restricted flow.

[0069] In order to allow multiple doses to be achieved using a single consumables containing package 102, a variety of strategies can be adopted. For example, the induction heating element 160 can be wrapped around a portion of the consumables containing package 102. Only the portion of the consumables containing package 102 surrounded by the heating element 160 is heated and releases the consumables. Then, the position of the induction heating element 160 relative to the consumables containing package 102 can be modified so that the induction heating element 160 surrounds the new portion of the consumables containing package 102 that has not yet been fully heated to release the consumables. In order to achieve this new position, the induction heating element 160 can be moved and the aerosol generating substrate 104 can be kept stationary, or the aerosol generating substrate 104 can be moved and the induction heating element 160 can be kept stationary, or both the induction heating element 160 and the aerosol generating substrate 104 can be moved. In some embodiments, neither the induction heating element 160 nor the aerosol generating substrate 104 moves. Rather, the inductive heating element 160 may be wrapped around the full length of the aerosol-generating substrate 104, and specific sections of the inductive heating element 160 may be activated so as to heat only specific portions 104c, 104d, 104e of the aerosol-generating substrate 104 at a given time.

[0070] like FIG. 5A to FIG. 5D , FIG. 6A to FIG. 6C , 7A to 7E and FIG. 8A to FIG. 8BAs shown, in a preferred embodiment, the aerosol-generating substrate 104 moves along the length of the housing 150 while the inductive heating element 160 remains stationary. By way of example only, the aerosol-generating device 200 may include a driver 448 that may be operatively connected or otherwise engaged with the aerosol-generating substrate 104 when the aerosol-generating substrate 104 is inserted into the aerosol-generating device 200. The driver 448 may be configured to advance the aerosol-generating substrate 104 through the housing 150. Advancing the aerosol-generating substrate 104 through the housing 150 allows different portions of the aerosol-generating substrates 104c, 104d, 104e to be surrounded by the inductive heating element 160. Thus, in use, the aerosol generating substrate 104 can be inserted into the housing 150 in a manner that allows the aerosol generating substrate 104 to move through the housing 150 from the end cap 154 ​​to the nozzle 158, so that the portions 104c, 104d, 104e of the aerosol generating substrate 104 gradually pass through the induction heating element 160 in sequence.

[0071] In a preferred embodiment, the drive 448 includes a rod 550 and a rotatable collar 552 that is operatively connected to the rod 550 or otherwise engaged with the rod to advance the rod 550. The collar 552 can be operated by a small motor that is operatively connected to the controller 166. The rod 550 can be inserted into the housing 150 through the end cap 154 ​​until the rod 550 encounters the first end 105 of the aerosol-generating substrate 104. In this position, the second end 107 of the aerosol-generating substrate 104c can be surrounded by the inductive heating element 160 (see, e.g., Figure 5A , Figure 5B , Fig. 6A , and 7B). When the inductive heating element 160 is activated, the aerosol-generating substrate 104 is heated only at the portion surrounded by the inductive heating element 160. When the driver 448 is activated, the collar 552 advances the rod 550 toward the second end 156 of the housing 150. This movement causes a new portion of the aerosol-generating substrate 104d (closer to the first end 105 of the aerosol-generating substrate 104) to be surrounded by the inductive heating element 160 (see, for example, Figure 5C , Figure 6B and Fig.7D ). Activation of the inductive heating element 160 may now heat a new portion 104d of the previously unheated aerosol-generating substrate 104, thereby causing another dose of the consumable to be released as an aerosol for inhalation. The collar 552 may advance the aerosol-generating substrate through the housing 150 again, placing a further unheated portion 104e of the aerosol-generating substrate 104 (even closer to the first end 105 if not already at the first end 105) within the heating range of the inductive heating element 160 (see, e.g. Figure 5D , Figure 6C and Fig. 7E). This process can continue until the entire aerosol generating substrate 104 has been heated and the consumable aerosol is released.

[0072] In a preferred embodiment, the rod 550 may be a jackscrew having threads 554 on a first end 556, such as 7A to 7E As shown. The thread 554 on the first end 556 of the rod 550 can cooperate with the rotatable collar 552. The actuation of the driver 448 causes the collar 552 to rotate, which in turn causes the rod 550 to advance. Alternatively, the collar 552 can be fixed, and the rod 550 can be engaged with the rotating mechanism so that the rod 550 is advanced when rotating. Other forms of drivers 448 for gradually advancing the aerosol generating substrate 104 along a linear path can be used, such as drivers 448 with telescopic action, sliding action, rolling action, etc. or any combination of actions thereof. In addition, the advancement of the aerosol generating substrate can be by smooth, gradual movement, or stepped more sudden movement. In an alternative embodiment, the aerosol generating substrate 104 or a certain structure attached thereto can be threaded and engaged with the thread on the housing 150, so that rotating the housing 150 or the aerosol generating substrate 104 will advance the aerosol generating substrate 104.

[0073] In some embodiments, to prevent the aerosol-generating substrate 104 from moving when not in use and before being connected to the rod 550, the aerosol-generating substrate 104 can be bonded to the interior of the housing 150, wherein the first end 105 of the aerosol-generating substrate 104 is adjacent to the rod 550. The bond between the aerosol-generating substrate 104 can be tight enough so that general movement and shaking of the housing 150 will not cause the aerosol-generating substrate 104 to move within the housing 150. Therefore, the movement associated with the transportation and shipping of the housing will not be sufficient to cause the aerosol-generating substrate 104 to be released from the bond. In addition, the bond between the aerosol-generating substrate 104 and the housing 150 can be strong enough to allow the rod 550 to be operatively connected to the aerosol-generating substrate 104. However, the advancement of the rod 550 is sufficient to break the bond between the aerosol-generating substrate 104 and the housing 150, thereby allowing the aerosol-generating substrate 104 to be advanced through the housing 150. The new connection between the rod 550 and the aerosol-generating substrate 104 is strong enough to prevent the aerosol-generating substrate 104 from moving around in the housing 150 during movement after the bond between the aerosol-generating substrate 104 and the housing 150 has been broken. Alternatively, if the bond is a temperature-sensitive material, the bond may be broken or weakened when the aerosol-generating substrate 104 is heated for the first time before the rod 550 is advanced.

[0074] However, to prevent unwanted movement of the aerosol-generating substrate 104 after first use (such as when the device is dropped into a purse or on a counter), the aerosol-generating substrate 104 may have a friction fit within the housing 150 that prevents movement other than that caused by the stem 550, or the aerosol-generating substrate 104 may be attached to the stem 550 or otherwise engaged to the stem to prevent movement independent of the stem 550. Alternatively, the aerosol-generating substrate 104 may engage the housing or other structure by threads or other structures that prevent unwanted movement of the aerosol-generating substrate 104.

[0075] In some embodiments, advancement of the rod 550 may only cause the aerosol-generating substrate 104 to be advanced through the housing 150. In some embodiments, the end cap 154 ​​may also be advanced through the housing 150, such as FIG. 8A to FIG. 8B As shown. In this way, the aerosol-generating substrate 104 can be connected to the end cap 154, and the rod 500 can be connected to or otherwise engaged with the end cap 154. Therefore, advancement of the rod 500 causes the end cap 154 ​​to advance through the housing 150, and the end cap 154 ​​causes the aerosol-generating substrate 104 to advance through the housing 150.

[0076] Having established the general principles of the consumable containment package 102, variations that achieve the same purpose are also envisioned. For example, in some embodiments, the aerosol generating substrate 104 may include two elongated sections 104a, 104b. The two elongated sections 104a, 104b of the aerosol generating substrate 104 may be defined by a plane parallel to the longitudinal axis A and cutting through the longitudinal axis A. Thus, the two elongated sections 104a, 104b may be cuboid sections or semi-cylindrical sections that, when fitted together, form a larger cuboid or complete cylindrical aerosol generating substrate 104.

[0077] In some embodiments, the enclosure 108 can be made of a porous material. For example, the enclosure 108 can be a porous paper wrapper or other similar material. In this way, the holes act as openings 120 to allow the aerosol to escape when the aerosol generating substrate 104 is heated. In addition, since the aerosol generating substrate 104 can be compressed to eliminate oxygen, it is still unlikely to burn at operating temperatures and during the short duration that the aerosol generating substrate 104 is exposed to high heat. Even if the outside of the enclosure 108 is exposed to oxygen along the passage between the enclosure 108 and the housing 150, the induction heating will quickly heat the consumable from the inside out, so the outside of the enclosure 108 will never reach a combustion temperature.

[0078] In embodiments where the enclosure 108 is a porous material, the enclosure 108 allows the aerosol to pass through the pores of the enclosure 108 and exit the enclosure 108 laterally or radially outward. This allows the aerosol to enter the passageway formed between the housing 150 and the enclosure 108.

[0079] In a preferred embodiment, the aerosol-generating substrate 104 is cuboid-shaped and the housing 150 is cylindrical, which creates four channels between the aerosol-generating substrate 104 and the housing 108, between the generally planar faces of the cuboid and the walls of the cylinder (i.e., above, below, and on both sides of the aerosol-generating substrate 104). Although cuboid is the preferred shape for the aerosol-generating substrate 104 and cylindrical is the preferred shape for the housing 108, any shape may be used for either of them.

[0080] In some embodiments, the enclosure 108 may be thicker and have sufficient porosity to allow the aerosol to travel through the holes longitudinally along the axis A over the length of the enclosure 108. In such embodiments, no designated passageway may be required between the housing 150 and the enclosure 108, as the aerosol may travel through the enclosure 108. Such porous materials may include cigarette paper, cellulose or other filter media, or any suitable material for this purpose.

[0081] The shell 108 containing the aerosol generating substrate 104 can then be inserted into the housing 150 to form the consumable product containing package 102. When the susceptor 106 is heated, the consumable product is aerosolized and escapes into the porous shell 108. When the user draws on the mouthpiece 158, the negative pressure generated within the housing 150 causes the airflow to flow in the direction of the mouthpiece 158, and the aerosolized consumable product passes through the holes of the shell 108 toward the mouthpiece, where the consumable product can be inhaled by the user.

[0082] For the purpose of illustration and description, the above description of the preferred embodiments of the present invention has been presented. The above description is not intended to be exhaustive or to limit the present invention to the precise form disclosed. In view of the above teachings, many modifications and variations are possible. The scope of the present invention is not intended to be limited by this detailed description, but by the appended claims and their equivalents.

Claims

1. A device for generating an aerosol, the device comprising: (a) Aerosol generating substrate; (b) a susceptor, wherein the susceptor is embedded in the aerosol generating substrate; (c) a housing containing the aerosol-generating substrate; (d) an aerosol generating device for receiving the housing, the aerosol generating device comprising: (i) a driver operatively connected to the aerosol-generating substrate to drive the aerosol-generating substrate through the housing; and (ii) an inductive heating element surrounding at least a portion of the housing, wherein the driver is configured to advance the aerosol-generating substrate through the housing such that portions of the aerosol-generating substrate sequentially pass through the inductive heating element.

2. The device according to claim 1, wherein: The housing further includes an end cap and a mouthpiece opposite the end cap, and the actuator includes a stem operatively connected to the aerosol-generating substrate via the end cap.

3. The device as claimed in claim 2, wherein: The rod is threaded at a first end to gradually advance the aerosol-generating substrate.

4. The device according to claim 2, wherein: The driver advances the end cap.

5. The device according to claim 2, wherein: The actuator advances the aerosol-generating substrate while the end cap remains stationary.

6. The device according to claim 5, wherein: The aerosol generating substrate is in the shape of a cuboid.

7. The device according to claim 6, wherein: The aerosol-generating substrate is at least partially located within the enclosure.

8. A method for aerosolizing a consumable product contained throughout an aerosol generating matrix by an aerosol generating device, the method comprising: (a) surrounding a first portion of the aerosol-generating substrate with an inductive heating element, wherein a susceptor is embedded in the aerosol-generating substrate; (b) aerosolizing the consumable product located in the first portion of the aerosol-generating substrate by activating the inductive heating element to heat the susceptor; (c) advancing the aerosol-generating substrate such that a second portion of the aerosol-generating substrate is surrounded by the induction heating element; and (d) activating the inductive heating element to aerosolize the consumable product located in the second portion of the aerosol-generating substrate.

9. The method of claim 8, wherein: The aerosol-generating substrate is located within a housing, and the inductive heating element surrounds the housing.

10. The method of claim 9, wherein: Advancing the aerosol-generating substrate comprises operatively engaging an actuator with the aerosol-generating substrate.

11. The method of claim 10, wherein: The housing comprises an end cap at a first end and a mouthpiece at a second end opposite the first end, and wherein the actuator comprises a stem operatively connected to the aerosol-generating device via the end cap.

12. The method of claim 11, wherein: The driver advances the end cap.

13. The method of claim 11, wherein: The actuator advances the aerosol-generating substrate without advancing the end cap.

14. The method of claim 11, wherein: The aerosol generating substrate is in the shape of a cuboid.

15. A method of manufacturing a device for generating an aerosol, the method comprising: (a) providing an aerosol generating substrate containing a consumable product; (b) embedding a susceptor into the aerosol generating matrix; (c) placing the aerosol generating substrate in a housing; (d) providing an aerosol generating device, the aerosol generating device comprising: (i) an induction heating element configured to surround at least a portion of the housing; as well as (ii) a driver operatively connected to the consumable generating substrate to propel the aerosol generating substrate through the inductive heating element.

16. The method of claim 15, further comprising: An end cap positioned at a first end of the housing is provided, as is a suction nozzle positioned at a second end of the housing.

17. The method of claim 16, further comprising: A rod from the driver is engaged with the aerosol-generating substrate via the end cap.

18. The method of claim 17, further comprising: The aerosol-generating substrate is advanced through the induction heating element by advancing the end cap.

19. The method of claim 17, further comprising advancing the aerosol-generating substrate without advancing the end cap.

20. The method of claim 17, wherein: The aerosol generating substrate is in the shape of a cuboid.

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