Aerosol provision system

Abstract

The present invention relates to an aerosol provision system, wherein a consumable component for the aerosol provision system comprises: an outer housing comprising an outer wall extending between a first end wall and a second end wall to define an inner chamber; a plurality of constituents of solid aerosol-forming material for generating an aerosol for inhalation by a user, wherein the plurality of constituents of solid aerosol-forming material are held within the inner chamber by the housing, and wherein the first end wall and the second end wall comprise openings to allow air to flow through the first end wall into the inner chamber and out of the inner chamber through the second end wall during use; and a heater located within the inner chamber and configured to heat the constituents of solid aerosol-forming material to generate a vapour for inhalation by a user during use.

Description

[0001] This application is a divisional application of Chinese patent application No. 201880066270.9 entitled "Aerosol Supply System" (based on international patent application No. PCT / GB2018 / 052910 filed on October 11, 2018, which entered the Chinese national phase on January 10, 2020). Technical Field

[0002] This disclosure relates to aerosol delivery systems, such as nicotine delivery systems (e.g., electronic cigarettes). Background Technology

[0003] Electronic aerosol delivery systems, such as those for electronic cigarettes (e-cigarettes), generally include aerosol precursor materials, such as a reservoir containing a liquid formulation (typically including nicotine) or a solid material (such as tobacco-based products), from which an aerosol is generated, for example by thermal evaporation, for inhalation by a user. Therefore, an aerosol delivery system typically includes a heater arranged to evaporate a portion of the aerosol precursor material to generate vapor / aerosol in a flow path extending from an air inlet through the electronic aerosol delivery system to an aerosol outlet. When a user inhales at the aerosol outlet and electricity is supplied to the vaporizer, air is drawn in through the air inlet along the flow path, where it mixes with the evaporated precursor material and forms a condensed aerosol. The air carrying the condensed aerosol continues along the flow path to the aerosol outlet, where it can be inhaled by the user. Summary of the Invention

[0004] According to a first aspect of certain embodiments, a consumable component for an aerosol delivery system is provided, the consumable component comprising: an outer housing including an outer wall extending between a first end wall and a second end wall to define an inner chamber; a plurality of components of a solid aerosol forming material for generating an aerosol for inhalation by a user upon heating, wherein the plurality of components of the solid aerosol forming material are held within the inner chamber by the housing, and wherein the first end wall and the second end wall include openings to allow air to flow through the first end wall into the inner chamber and through the second end wall out of the inner chamber during use; and a heater located within the inner chamber and configured to heat the components of the solid aerosol forming material during use to generate vapor for inhalation by a user.

[0005] According to another aspect of certain embodiments, an aerosol supply system using a consumable component to generate vapor is provided, wherein the consumable component includes: an outer housing including an outer wall extending between a first end wall and a second end wall to define an inner chamber; a plurality of components of a solid aerosol forming material for generating an aerosol for inhalation by a user upon heating, wherein the plurality of components of the solid aerosol forming material are held within the inner chamber by the housing, and wherein the first end wall and the second end wall include openings to allow air to flow through the first end wall into the inner chamber and through the second end wall out of the inner chamber during use; and a heater located within the inner chamber and configured to heat the components of the solid aerosol forming material during use to generate vapor for inhalation by a user, and wherein the aerosol supply system includes: the consumable component; a consumable component receiving section for removably receiving the consumable component for use; and a power source for selectively supplying power to the heater located in the consumable component to generate vapor from the solid aerosol forming material for inhalation by a user.

[0006] According to another aspect of certain embodiments, a consumable component device for an aerosol supply system is provided, the consumable component device comprising: an outer housing device including an outer wall device extending between a first end wall device and a second end wall device to define an inner chamber; a plurality of components of a solid aerosol forming device for generating an aerosol for inhalation by a user upon heating, wherein the plurality of components of the solid aerosol forming device are held within the inner chamber by the housing device, and wherein the first end wall device and the second end wall device include openings to allow air to flow through the first end wall device into the inner chamber and through the second end wall device out of the inner chamber during use; and a heater device located within the inner chamber and configured to heat the components of the solid aerosol forming device during use to generate vapor for inhalation by a user.

[0007] It should be understood that the features and aspects of the present invention described above in relation to the first and other aspects of the present invention can be applied equivalently to embodiments of the present invention according to other aspects of the present invention, and can be combined with embodiments of the present invention according to other aspects of the present invention as appropriate, and not limited to the specific combinations described above. Attached Figure Description

[0008] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 An aerosol supply system according to certain embodiments of the present disclosure is schematically illustrated, comprising a device portion and consumable components; Figure 2 An aerosol supply system according to certain other embodiments of the present disclosure is schematically illustrated, which includes device portions and consumable components; Figure 3 Consumable components according to certain embodiments of this disclosure are illustrated schematically; Figures 4 and 5 schematically illustrate end walls for consumable components according to certain embodiments of the present disclosure; Figure 6 and Figure 7 Consumable components according to certain embodiments of this disclosure are illustrated schematically; Figure 8 schematically illustrates a heater for a consumable component according to certain embodiments of the present disclosure; Figure 9 The schematic illustration shows a receiving section / region portion of a consumable component and device portion according to certain embodiments of the present disclosure; and Figure 10 and Figure 11 Consumable components according to certain embodiments of this disclosure are illustrated schematically. Detailed Implementation

[0009] This document discusses / describes aspects and features of certain examples and embodiments. Some aspects and features of these examples and embodiments are commonly implemented, and for the sake of brevity, these aspects and features are not discussed / described in detail. Therefore, it should be understood that aspects and features of the devices and methods discussed herein that are not described in detail can be implemented according to any conventional techniques.

[0010] This disclosure relates to vapor supply systems, which may also be referred to as aerosol supply systems, such as electronic cigarettes. Throughout the description below, the terms "electronic cigarette" or "electronic cigarette" are sometimes used; however, it should be understood that these terms are used interchangeably with vapor (aerosol) supply systems and electronic vapor (aerosol) supply systems. Furthermore, it is common in the art that the terms "vapor" and "aerosol," as well as related terms such as "evaporation" and "aerosolization," are also used interchangeably.

[0011] An aerosol delivery system according to one embodiment of this disclosure may include a modular assembly comprising a reusable portion and a replaceable cartridge portion, the replaceable cartridge portion also being referred to as a consumable component of the system. For a modular system using liquid aerosol precursor materials, the reusable device portion typically includes a power supply and control circuitry. The consumable component (i.e., the replaceable / disposable portion) typically includes vapor precursor material and an evaporator (e.g., a heating coil typically wound around a core). For a modular system using solid aerosol precursor materials, the reusable device portion typically includes a power supply, control circuitry, and an evaporator (e.g., a heater), while the consumable component typically contains vapor precursor material.

[0012] Figure 1 This is a cross-sectional view of an exemplary electronic cigarette 1 according to certain embodiments of the present disclosure. The electronic cigarette 1 includes two main components: a reusable (device) portion 2 and a consumable portion 4. The consumable portion may also be referred to as a replaceable / disposable cartridge portion. Figure 1 The reusable portion 2 and the consumable component 4 are shown separately, but in normal use, the consumable component 4 is placed in the consumable component receiving area 52 of the reusable portion 2. The consumable component receiving area 52 is essentially an opening / slot sized to receive the consumable component being used. The consumable component can be held in the consumable component receiving area by friction engagement or other means (such as a releasable latch or clamp), so that when the consumable component is depleted or the user wants to change it to a different consumable component (e.g., to change the flavor), the consumable component can be removed from the reusable portion and replaced with another consumable component. The specific manner in which the consumable component is held in the reusable portion during use is not important to the principles described herein.

[0013] In this example, the reusable part 2 includes: a battery 26 for providing operating power to the electronic cigarette; a control circuit 18 for controlling and monitoring the operation of the electronic cigarette; a user input button 14; and a visual display 24.

[0014] The outer casing 12 may be made of, for example, plastic or metal, and in this example, the outer casing has a generally circular cross-section with a diameter of about 1.5 cm and a length of about 12 cm. However, it should be understood that the overall shape and proportions of the electronic cigarette according to different embodiments of this disclosure are not important to the principles described herein. For example, in some embodiments, the electronic cigarette may have a significantly larger size, for example, to accommodate a larger battery to provide longer usage time between charges.

[0015] The outer housing 12 defines an opening 50 of a consumable component receiving area 52 at one end of the electronic cigarette 1, through which a consumable component 4 can be inserted for use. In this example, the receiving area 52 has a diameter of approximately 1 cm and a length of approximately 4 cm (i.e., the wall surrounding the consumable component receiving area defined by the outer housing has a thickness of approximately 2.5 mm). The opening 50 at the end of the electronic cigarette 1 may be referred to as a mouthpiece opening, and aerosols generated by the electronic cigarette 1 and inhaled by the user during use pass through this mouthpiece opening 50. In some examples, the electronic cigarette 1 may also include an additional mouthpiece cap that fits to the mouthpiece opening end of the electronic cigarette and tapers to a contour for comfortable placement between the user's lips.

[0016] The outer housing 12 has an air inlet 28 that passes through the reusable portion 2 and connects to an air path 30. The air path 30 leads to the consumable component receiving area at the consumable component receiving area air inlet 29. Therefore, when a user inhales through the mouthpiece opening 50 (or the mouthpiece attached thereto), air is drawn in such a way that it passes through the air inlet 28, along the air path 30 of the reusable portion, through the consumable component receiving area inlet 29, and into the consumable component receiving area 52. This air continues through the consumable component receiving area 52 (more specifically, through the consumable components located in the consumable component receiving area 52 during use) and exits through the mouthpiece opening 50 for the user to inhale. The surface of the consumable component receiving area around the consumable component receiving area air inlet 29 includes spacers 31 (e.g., in the form of molded protrusions) to ensure that the consumable components remain offset from the receiving area air inlet 29 when located in the consumable component receiving area 52, to prevent the consumable components from blocking the receiving area air inlet 29. Other configurations may not include such a spacing 31, but may include other means to avoid blocking the consumable component receiving area air inlet 29. An exemplary air inlet for the consumable component may be arranged to be aligned with the consumable component receiving area air inlet when the consumable component is located in the consumable component receiving area.

[0017] In this example, battery 26 is a rechargeable battery and can be a conventional type of battery, such as those commonly used in electronic cigarettes and other applications that require a relatively high current supply for a relatively short period of time. Battery 26 can be recharged via a charging connector (e.g., a USB connector) located in the reusable portion housing 12.

[0018] In this example, the user input button 14 is a conventional mechanical button, such as one including a spring-loaded component, which establishes electrical contact upon user pressure. However, the specific manner in which the button is implemented is not critical. For example, in other embodiments, one or more other forms of mechanical buttons or one or more touch-sensitive buttons (e.g., based on capacitive or optical sensing technologies) could be used.

[0019] A display 24 is provided to provide a user with visual indications of various features associated with the electronic cigarette, such as current power settings, remaining battery power, etc. The display can be implemented in various ways. In this example, the display 24 includes a conventional pixelated LCD screen, which can be driven according to conventional techniques to display the desired information. In other embodiments, the display may include one or more discrete indicators, such as multiple LEDs, arranged to display the desired information, for example, through a specific color and / or flashing sequence. More generally, the manner in which the display is set up and the manner in which it is used to display information to the user are not essential to the principles described herein. For example, some embodiments may not include a visual display and may include other means for providing the user with information related to the operating characteristics of the electronic cigarette, such as using audio signals, or may not include any means for providing the user with information related to the operating characteristics of the electronic cigarette.

[0020] Control circuitry 18 is suitably configured / programmed to control the operation of the electronic cigarette to provide the functionality of embodiments of the present disclosure as further described herein, and to provide conventional operational functions of the electronic cigarette according to established techniques for controlling such a device. Control circuitry (processor circuitry) 18 can be considered to logically include multiple sub-units / circuit elements associated with different aspects of the operation of the electronic cigarette. In this example, control circuitry 18 includes: power control circuitry 22 for controlling the power supply to consumable components to generate vapor in response to user input (e.g., using input button 14 or other means, such as a vaping detector), as will be further discussed herein; user program setting circuitry 20 for establishing configuration settings (e.g., user-defined power settings) in response to user input (e.g., using input button 14 or other means, such as connecting to a computer); and other functional units / circuits functionally associated with the principles described herein and conventional operational aspects of the electronic cigarette, such as display driver circuitry and user input detection circuitry. It should be understood that the functionality of control circuit 18 can be provided in a variety of different ways, for example, by using one or more appropriately programmed programmable computers configured to provide the required functionality and / or one or more appropriately constructed dedicated integrated circuits / chips / chipsets.

[0021] for Figure 1 In the exemplary embodiment shown, electricity is supplied to the consumable component to generate steam using electromagnetic induction. Therefore, the power control circuit 22 is configured to drive the induction heating coil 23 surrounding the consumable component receiving region 52.

[0022] Turn now Figure 1The consumable component 4 shown includes an outer housing 60 comprising an outer wall 62 extending between a first end wall and a second end wall 64 to define an inner chamber 66. The consumable component 4 is sized such that it can be received in a receiving area 52 of the reusable portion 1 using a frictional engagement. Thus, in this example, the consumable component 4 is generally cylindrical, having a diameter of approximately 1 cm (corresponding to a receiving area of ​​1 cm diameter) and a length of approximately 4 cm. In some examples, the consumable component may be slightly longer than the receiving area, allowing the end of the consumable component to protrude from the receiving area to facilitate its removal. In other examples, the consumable component may have a sufficiently loose frictional engagement in the receiving area, allowing it to be freely swung for removal. In yet another example, different arrangements may be provided to facilitate removal of the consumable component from the receiving area. For example, in some cases, a plunger- or slider-based ejection mechanism may be provided, which engages with the consumable component when located in the receiving area 52, thereby mechanically ejecting the consumable component. More generally, the specific manner in which consumable components are inserted into and removed from the receiving area is not important to the principles described herein.

[0023] The outer wall 62 and / or end wall 64 of the outer casing 60 may be at least partially made of any one of the following: paper material, card material, tobacco material (e.g., byproducts of the compressed tobacco industry, such as compressed tobacco fiber, stems, or tobacco pellets), ceramic material, metallic material, carbon material, and plastic material, or combinations thereof. Figure 1 In this example, it is assumed that the outer wall 62 is made of packaging paper, while the end wall 64 is made of ceramic material. The outer wall 62 defines a cylindrical body, and the end wall 64 includes a friction-fit plug that is inserted into a corresponding end of the cylindrical body defined by the outer wall 62. The end wall may, for example, have a diameter corresponding to the diameter of the outer wall 62, and its thickness is approximately 3 mm to 5 mm. The end wall 64 also includes an opening 68 through which air can enter and exit the inner chamber 66.

[0024] The inner chamber 66 of the consumable component 4 contains multiple fragments 63 (e.g., particles) of solid aerosol forming material for generating an aerosol for inhalation by a user upon heating. In this example, the fragments / components of the solid aerosol forming material include an absorbent solid matrix material, such as calcium carbonate or carbon, to hold liquid aerosol precursor material, such as liquid types commonly used in electronic cigarettes to generate vapor, for example, liquid-based glycerol (propylene glycol (PG), triacetin, and / or other humectants), and contain additives such as nicotine and / or flavorings. In some examples, the fragments of the solid aerosol forming material may include tobacco, such as shredded / cut tobacco, with or without the absorption of liquid aerosol precursor material. The fragments of the solid aerosol forming material may, for example, have an average characteristic size of at least 1 mm and less than 5 mm, 4 mm, or 3 mm. The average characteristic size may, for example, be the minimum or average size of each fragment. Fragments of solid aerosol forming material can be loosely enclosed within the inner chamber of a consumable component, with gaps between the fragments to allow air to be drawn through the consumable component during use. The fragments of aerosol forming material can have various shapes; for example, they can be irregular (e.g., formed by crushing / grinding large blocks of material or cutting tobacco leaves) or regular (e.g., formed by compressing suitable material). The fragments of solid aerosol forming material are held within the inner chamber by an outer wall 62 and an end wall 64. In this respect, the size of the opening 68 in the end wall 64, through which air enters and exits the inner chamber 66, can be selected to reduce the likelihood of fragments of solid aerosol forming material leaving the inner chamber 66. For example, the characteristic width of the opening 68 located in the end wall 64 can be equivalent to or less than the minimum average characteristic size of the fragments of solid aerosol forming material. In some examples, an adhesive may be used to help prevent fragments from settling within the consumable component.

[0025] Heater 70 is also located within the inner chamber 66 of the consumable component 4. This heater is arranged to heat the solid aerosol forming material when powered by the reusable component 2, thereby generating vapor for the user to inhale during use. As described above, in Figure 1 In this example, electricity is supplied to the consumable component via electromagnetic induction. Therefore, the heater 70 in the consumable component 4 comprises a material susceptible to electromagnetic induction, such as ferritic or martensitic steel. In this example, the heater 70 is in the form of a solid rod with a diameter of approximately 2 mm. In this example, the heater 70 is supported within the chamber 66 by having its ends located in recesses in the corresponding end walls, as... Figure 1The diagram is schematically shown. In other examples, the heater 70 can be mounted in different ways. For example, the heater can be provided with one or more mounting collars that extend from the heater to the inner surface of the outer wall 62. In yet another example, the heater may not be mounted to the outer housing, but can be simply held in place by fragments of solid vapor precursor material wrapped around it.

[0026] To use the electronic cigarette 1, the user inserts the consumable component 4 through the mouthpiece opening 50 into the consumable component receiving area 52. If a mouthpiece cover is provided, it can be added to the mouthpiece opening of the electronic cigarette 1. When the electronic cigarette is turned on and the user presses the input button 14, the control circuit 18, particularly the power control circuit 22, is configured to supply power to the induction heating coil 23, which surrounds the consumable component 4 located in the consumable component receiving area 52. Therefore, according to conventional electromagnetic heating technology, electromagnetic energy is transferred from the heating coil 23 to the heater 70. In this example, the induction heating coil 23 includes a helical coil that extends along a portion of the receiving area surrounding the heater 70 (in... Figure 1 In the example, it extends wound around the receiving region 52 (which is the majority of the length of the receiving region 52). Therefore, when the consumable component 4 is received in the receiving region 52 and the induction heating coil 23 is driven to generate current in the heater 70, the heater is heated. The operating characteristics of the induction heating coil 23 (e.g., in terms of the number of turns, current, and operating frequency) can be selected based on well-known induction heating principles and taking into account the geometry of the specific heater used in the given embodiment. In this regard, for example, the induction heating coil can be designed to heat the heater located in the consumable component to a temperature of approximately 200°C within a period of approximately a few seconds.

[0027] Heat from the heater is transferred to the solid aerosol forming material within chamber 66 to evaporate a portion of the absorbed liquid aerosol precursor material, thereby generating vapor for the user to inhale. When vapor is generated in the consumable component, the user inhales it through mouthpiece opening 50 (or a mouthpiece piece attached to the mouthpiece opening). Air is thus drawn through air inlet 28, along air path 30, and through the receiving area air inlet into the receiving area. The air then enters the consumable component 4 through opening 68, located in the end wall 64 adjacent to the base of the receiving area 52. The air then passes through the inner chamber 66 of the consumable component 4 through gaps between fragments of the solid aerosol precursor material. As the air passes through the inner chamber 66, it collects the vapor generated by heating the solid aerosol precursor material, as described above. The combination of vapor and air forms a condensed aerosol, which is drawn through the opening 68 in the end wall 64 at the mouthpiece opening end in the receiving area for subsequent inhalation by the user.

[0028] therefore, Figure 1 The electronic cigarette 1 shown can be used to generate vapor for a user to inhale via a consumable component that is easier to manufacture and less prone to leakage than liquid-based cartridges used in electronic cigarettes. However, the consumable component is also self-contained, easy to operate and replace, and clean, and can generate vapor faster than conventional electronic cigarettes with solid aerosol precursor materials.

[0029] although Figure 1 The exemplary electronic cigarette shown uses electromagnetic induction to heat the heater 70 located in the consumable component 4, but it should be understood that other embodiments may employ other methods for heating.

[0030] Figure 2 This is a cross-sectional view of an exemplary electronic cigarette 201 according to certain embodiments of the present disclosure. Figure 1 The electronic cigarette shown is the same as 1. Figure 2 The electronic cigarette 201 shown includes two main components: a reusable part 202 and a consumable part 204. Figure 2 The electronic cigarette 201 shown is Figure 1 A variation of the electronic cigarette 1 shown. In Figure 2 The components of the electronic cigarette 201 shown are... Figure 1 The corresponding components of the electronic cigarette 1 shown are functionally similar and will be understood with reference to these corresponding components, which will be indicated by corresponding reference numerals, and will not be described in detail for the sake of brevity. However, Figure 2 The electronic cigarette 201 shown Figure 1 The difference with respect to the electronic cigarette 1 shown is that it does not use electromagnetic induction to transfer power from the reusable part to the consumable part, but instead uses current supplied to the consumable part through direct electrical contact.

[0031] Therefore, consumable component 204 includes resistance heater 71, instead of Figure 1 An induction heater 70 of the type shown. The heater 71 may, for example, have a total resistance of approximately 1 ohm or 2 ohms and may be made of conventional heating resistance materials. Specific types of heaters can be selected to provide the desired resistance. For example, depending on the resistivity of the material used, the heater 71 may include materials similar to... Figure 1The solid rod of the induction reheat heater 70 in the consumable component 4 shown may include wires wound around an electrically insulating substrate. The respective ends of the heater 71 are connected via electrical leads 77, 79 to a corresponding one of a pair of electrodes 76, 78, which are mounted on one of the end walls 64. When the consumable component 204 is located in the receiving area 52 of the reusable portion 202 in the electronic cigarette 201, the electrodes 76, 78 on the consumable component are aligned and in contact with the corresponding electrodes 72 and 74 in the receiving area.

[0032] To use the electronic cigarette 201, the user inserts the consumable component 204 through the mouthpiece opening 50 into the consumable component receiving area 52. If a mouthpiece cap is provided, it can be added to the mouthpiece opening of the electronic cigarette 201. When the electronic cigarette is turned on and ready for use, the user presses the input button 14, and the control circuit 18, particularly the power control circuit 22, is configured to supply power to the heater 71 via electrodes 72, 74 located in the receiving area and electrodes 76, 78 located on the consumable component 204. Therefore, when the consumable component 4 is received in the receiving area 52 and power is supplied to the heater via the power control circuit through the corresponding electrodes and connecting leads, the heater is heated. The operating characteristics of the supplied power (e.g., in terms of the applied voltage and any pulse width / frequency modulation scheme) can be selected based on the known principles of resistance heating in electronic cigarettes. In this regard, for example, the power control circuit can be designed to supply power (current) to the heater to heat it to a temperature of approximately 200°C within a period of approximately a few seconds.

[0033] Heat from heater 71 is transferred to the solid aerosol forming material inside chamber 66, causing a portion of the liquid aerosol precursor material absorbed therein to evaporate, thereby reacting with the aforementioned... Figure 1 The electronic cigarette 1 shown produces vapor for the user to inhale in the same way.

[0034] Figure 3 It is used for Figure 1 The diagram shows a schematic perspective view of the consumable component 4 of the electronic cigarette 1, in a partially disassembled state. It can be seen that, in this embodiment, the fragments 63 of the solid aerosol precursor material are fairly regularly shaped and each has a generally columnar form, having a length of about 2 mm and a diameter of about 1 mm. They can be formed, for example, by extrusion, i.e., by cutting multiple segments from an extruded column. As mentioned above, other forms of solid aerosol precursor materials can be used, such as irregular or regular fragments of other shapes, such as spheres, and in other examples may also include cut / shredded tobacco or other sheet-like materials, such as paper.

[0035] Figures 4A to 4C yes Figure 1 and Figure 2 The diagram shows corresponding cross-sectional, front, and perspective views of the type of end wall 64 used in the consumable components 4 and 204 of the illustrated electronic cigarettes 1 and 201. As described above, the end wall comprises a ceramic material and can be formed according to conventional techniques. In this example, the end wall includes six openings 68 arranged in a circle approximately halfway between the center and the edge of the end wall 64. However, in some exemplary embodiments, the openings in the end wall may be more tightly clustered around the location where the heater is mounted in the end wall, i.e., in this example, the central portion of the end wall. This can help reduce heat conduction between the heater and the outer portion of the end wall / outer housing of the consumable component. Figure 4A It is also evident that the size of the recess 67 is set to receive the ends of the heaters 70 and 71, as discussed above.

[0036] Figures 4D to 4G This illustrates several embodiments according to the present disclosure. Figures 4A to 4C The cross-sectional view of the modified end wall 64 is shown. Figure 4D In the example, end wall 64 is provided with a chamfer 85 to facilitate insertion into outer housing 62 during assembly. Figure 4E In the example, the end wall 64 is provided with a chamfer 85 to facilitate insertion into the outer housing 62 during assembly, and is provided with a flange / lip 87 arranged to abut the end of the outer housing 62 when the end wall 64 is properly inserted. Figure 4F The example shows in more detail how the ends of heaters 70, 71 can be received in the recesses 67 of the end wall 64 to provide physical support to heaters 70, 71. Figure 4G In the example shown, the end wall 64 is provided with a protruding boss 67 instead of a recess 67 to support the heater 73. In this example, the heater includes a tubular portion into which the protruding boss 69 is inserted to support the heater 73. Of course, it should be understood that Figures 4A to 4G Different aspects of the different examples shown can be combined with other aspects of these examples, for example, Figure 4G The type of end wall shown can be provided with Figure 4E Chamfers 85 and / or flanges 87, etc., of the type shown.

[0037] Figures 5A to 5C Other examples of this disclosure are illustrated schematically. Figure 1 and Figure 2 Corresponding cross-sectional views, front views, and perspective views of alternative forms of the end wall 94 of the type of consumable component shown. Although the above references... Figure 1 The end wall 64 discussed in Figure 4 is formed of ceramic material, but Figures 5A to 5CThe end wall 94 shown is formed of a card and includes a circular surface 67 with an opening 98 to allow air to enter the consumable component. The circular surface also includes sidewall portions 96 arranged to couple the end wall 98 to the outer housing 62 of the consumable component, for example, via a friction fit. The end wall 98 can be coupled to the tubular outer wall 62 of the consumable component by first inserting it into the surface, such as by using a plug-like manner. Figure 5D As schematically shown in the cross-sectional view; or it can be placed as a cover over the tubular outer wall 62 of the consumable component, such as Figure 5E The cross-sectional view shown is schematic. In either case, the end wall can be held in place by friction fit or other means, such as the use of adhesives. Figures 5A to 5C The heater in the consumable component of the end wall of the type shown can be mounted to the end wall, for example, through an opening located in the end wall, or it can be left unmounted. For Figures 5A to 5E The example shown assumes that the heater is not mounted to the end wall, but rather that the end wall has an additional opening 98 facing the center of the end face 97.

[0038] Figure 6 A cross-sectional view of consumable component 304 is schematically shown. Figure 1 Variations of the consumable components shown. Figure 6 The components of the consumable part 304 shown are... Figure 1 The corresponding components of the consumable part 4 shown are functionally similar and can be understood from these corresponding components, which are indicated by corresponding reference numerals and will not be described further for the sake of brevity. However, Figure 6 The consumable component 304 shown is Figure 1 The consumable component 4 shown differs in that it has a second wall 600 disposed within the outer housing 62 to define an air gap 602 between the outer housing 62 and the second wall 600. The second wall 600 may be formed of the same or a different material as the outer housing 62. Fragments 63 of the solid aerosol precursor material are held by the second wall 600 and the end wall 64. In cases where heat generation is considered a potential problem, the presence of the air gap 602 can help prevent the outer wall 62 from undesirably heating up during use.

[0039] Figure 7 A cross-sectional view of consumable component 404 is schematically shown. Figure 1 Another variation of the consumable component shown. Figure 7 The components of the consumable part 404 shown are... Figure 1 The corresponding elements of the consumable component 4 shown are functionally similar and can be understood from these corresponding elements, which are indicated by the corresponding reference numerals and will not be described in detail for the sake of brevity. Figure 7The consumable component 404 shown is... Figure 1 The difference in consumable component 4 shown is that it does not include a heater in the form of a central rod, but... Figure 7 In the example, the heater includes dispersed metal bodies / particles 702 that are readily heated by electromagnetic induction. During use, these metal bodies / particles are in accordance with the above reference. Figure 1 The method discussed corresponds to heating by induced electromagnetic current. Dispersed particles can provide more dispersed heating throughout the chamber containing fragments of solid aerosol-forming material.

[0040] Other types of heaters may be used in other implementations.

[0041] For example, Figure 8A A perspective view of heater 801 is schematically shown, which has a generally planar form but has columnar ends for mounting. In some respects, it can be considered to correspond to the reference above. Figure 1 and Figure 2 The type of rod discussed is in a flattened form.

[0042] Figure 8B A perspective view of heater 811 is schematically shown, which has a similar shape to the one described in the reference above. Figure 1 and Figure 2 The heaters 70 and 71 discussed are in rod form, but also include blades 812 that are attached to heater 811 and extend out to the inner wall of the outer housing of the consumable component, such that they support heater 811 without being mounted to an end wall.

[0043] Figure 8C A perspective view of heater 821, which has a generally tubular form, is schematically shown. Such a heater can, for example, be... Figure 4G Installed onto the end wall as shown.

[0044] What should be understood is Figures 8A to 8C The heater shown can be made by means of the one discussed above. Figure 1 and Figure 2 The heaters 70 and 71 shown are made of similar materials, i.e., they are made of materials that are easily heated by magnetic induction / resistance, depending on the mode of energy transfer.

[0045] Figure 9 This is a cross-sectional view through a portion of an exemplary electronic cigarette 501 according to certain embodiments of this disclosure. Figure 1 The electronic cigarette shown is the same as 1. Figure 2 The electronic cigarette 502 shown includes two main components: a reusable part 502 and a consumable part 504. Figure 9The image shows only a portion of the reusable portion 502 located near its receiving area, wherein the consumable component 504 is in place (i.e., in the receiving area) for use. Figure 9 The electronic cigarette 501 shown is Figure 1 The electronic cigarette 1 shown is a variant. Figure 9 The components of the electronic cigarette 501 shown are... Figure 1 The corresponding components of the electronic cigarette 1 shown are functionally similar and can be understood from these corresponding components, which are indicated by corresponding reference numerals and will not be described further for the sake of simplicity. However, Figure 9 The electronic cigarette 501 shown is Figure 1 The difference in the electronic cigarette 1 shown is that the inner chamber of the consumable component 504 is divided into two sections (regions) by a central wall 564. Each section of the inner chamber contains fragments / components of solid aerosol precursor material and corresponding heaters 507, 508, as shown in the reference above. Figure 1 The heater under discussion. The central wall 564 can be made, for example, in the same manner as the end wall 64. The central wall 564 includes an opening 568 to allow air to flow through the central wall during intake. The reusable portion 502 includes a first induction heating coil 523 and a second induction heating coil 524, which can be independently driven to generate current and thereby heat a corresponding one of the heaters 507, 508. Therefore, Figure 9 The electronic cigarette 501 shown is Figure 1 The difference shown is that it has two separate chambers, which may, for example, contain different aerosol precursor materials and can be heated independently to produce vapors with different characteristics (e.g., different flavors and / or relative nicotine levels). It should be understood that in other exemplary embodiments, there may be more than two separate chambers in the consumable component. Furthermore, in some embodiments, the different chambers may contain the same aerosol precursor material and are arranged such that for each segment of use, different uses of the device can begin from the “fresh” portion of the consumable material. It should be understood that in some embodiments, instead of walls separating different areas of the aerosol-forming material, a single heater may extend the length of the consumable component through multiple abstract regions, with localized heating provided by appropriately arranged induction coils that can be selectively activated at different locations along the length of the heater (e.g., as shown in the image). Figure 9 (Illustrative illustration).

[0046] Figure 10 A cross-sectional view schematically illustrating a consumable component 604 for use in an electronic cigarette according to certain other embodiments of the present disclosure is shown. This consumable component can, for example, be used with... Figure 1 The reusable components of the electronic cigarette shown are used in combination. Figure 10 The consumable component 604 shown is similar to other consumable components discussed above in several respects and will be understood by referring to the other consumable components discussed above. Figure 10 The elements of the consumable component 604 shown are functionally similar to the corresponding elements of the other consumable components discussed above, and will be understood by referring to the elements of the other consumable components, which are indicated by the corresponding reference numerals and will not be described again for the sake of brevity. Figure 10 Consumable component 604 and Figure 1 The difference in consumable component 4 is that it has a shorter heater 670, which is not directly mounted to the end wall 64, but is mounted via an inserted insulating element (such as ceramic tubes 671, 672). In this exemplary configuration, the insulating element is mounted on a post 677 protruding from the respective end wall. In embodiments addressing this issue, this arrangement can help reduce heat transfer to the end wall 64.

[0047] Figure 11 A cross-sectional view schematically illustrating a consumable component 704 for use in an electronic cigarette according to certain other embodiments of the present disclosure is shown. This consumable component can, for example, be used with... Figure 1 The reusable components of the electronic cigarette shown are used in combination. Figure 11 The consumable component 704 shown is similar to other consumable components discussed above in several respects and will be understood by referring to the other consumable components discussed above. Figure 11 The elements of the consumable component 704 shown are functionally similar to the corresponding elements of the other consumable components discussed above and will be understood by these corresponding elements, which are indicated by the corresponding reference numerals and will not be described again for the sake of brevity. Figure 11 Consumable component 704 and Figure 1 The difference in consumable component 4 is that it has a shorter heater 770, which is mounted to one of the end walls 64 only at one end. In embodiments addressing this issue, this arrangement can help reduce heat transfer to the other end wall of the heater, which, for example, is expected to become particularly hot if the end wall protruding from the electronic cigarette comes into contact with the heater during normal use.

[0048] Therefore, a range of different arrangements of electronic cigarettes have been described. However, it should be understood that various modifications and variations of the above examples can be made in other embodiments. For example, in the above examples, the electronic cigarette includes a button for manually activating the power supply to a heater located in a consumable component, while other exemplary embodiments may include a puff detector, such as a puff detector in the form of a pressure sensor, coupled to the air path through the electronic cigarette and configured to automatically trigger the power supply to the heater in response to a user's inhalation.

[0049] In other examples, electronic cigarettes based on the principles described herein may additionally include a temperature sensor for monitoring the heater temperature. For example, this could be used to allow adjustment of the heater temperature during use. The temperature sensor may be, for example, mounted on the consumable component itself, such as a thermistor, which is appropriately connected to the reusable component, or the sensor may be located away from the consumable component. For example, the temperature sensor may be an infrared radiation sensor arranged to detect heat from the consumable component.

[0050] In some examples, a single component can provide some of the functions of the aforementioned components. For example, in one construction, the consumable component may be provided with a metal outer housing that both holds fragments of the solid aerosol forming material and serves as a heater (induction or resistance heater).

[0051] In some exemplary embodiments, the consumable component may simply include a source of vapor precursors / forming materials for the aerosol supply system / electronic cigarette. That is to say, in some cases, the consumable component does not actually correspond to an additional insert, such as a flavor modifier used in an electronic cigarette that also includes a vaporizer for heating the liquid formulation, but it is the primary source of vapor for the electronic cigarette.

[0052] Therefore, a consumable component for an aerosol delivery system has been described, comprising: an outer housing including an outer wall extending between a first end wall and a second end wall to define an inner chamber; and a plurality of components of a solid aerosol forming material for generating an aerosol for inhalation by a user upon heating, wherein the plurality of components of the solid aerosol forming material are held within the inner chamber by the housing, and wherein the first end wall and the second end wall include openings to allow air to flow through the first end wall into the inner chamber and through the second end wall out of the inner chamber during use; and a heater located within the inner chamber and configured to heat the components of the solid aerosol forming material during use to generate vapor for inhalation by a user.

[0053] To address various problems and improve the art, this disclosure illustrates, by way of illustration, several embodiments of the claimed invention that can be practiced. The advantages and features of this disclosure are merely representative examples of the embodiments and are not exhaustive and / or exclusive. These examples are presented only to aid in understanding and teaching the claimed invention. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of this disclosure should not be considered as limitations on this disclosure as defined by the claims or their equivalents, and other embodiments may be utilized and modified thereto without departing from the scope of the claims. In addition to those specifically described herein, various embodiments may suitably include, constitute, or substantially consist of the disclosed elements, components, features, parts, steps, devices, etc., and thus, in addition to the combinations expressly stated in the claims, it should be understood that dependent claims may be combined with the features of the independent claims. This disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. A consumable component for insertion into an aerosol supply system, the consumable component comprising: An outer housing includes an outer wall, a first end wall, and a second end wall, the outer wall extending between the first end wall and the second end wall to define an inner chamber, and wherein the first end wall and the second end wall include openings to allow air to flow through the first end wall into the inner chamber and through the second end wall out of the inner chamber during use. Multiple fragments or particles of a solid aerosol forming material for generating an aerosol for inhalation by a user, wherein the multiple fragments or particles of the solid aerosol forming material have an average characteristic size greater than 1 mm and are held within the inner chamber by the outer shell; and A heater, located within the inner chamber, is configured to heat fragments or particles of the solid aerosol forming material during use to generate steam for inhalation by the user.

2. The consumable component according to claim 1, wherein, The solid aerosol forming material comprises multiple fragments or particles, including fragments or particles of a solid matrix material that holds the liquid aerosol precursor material.

3. The consumable component according to claim 1, wherein, The solid aerosol forming material comprises multiple fragments or particles, including tobacco.

4. The consumable component according to claim 1, wherein, The solid aerosol forming material comprises multiple fragments or particles including calcium carbonate.

5. The consumable component according to claim 1, wherein, The average characteristic size of multiple fragments or particles of the solid aerosol forming material is less than 5 mm, 4 mm or 3 mm.

6. The consumable component according to claim 1, wherein, The heater comprises materials susceptible to electromagnetic induction.

7. The consumable component according to claim 1, wherein, The heater includes a resistance heater, and the consumable component further includes electrodes on the outer housing for electrically connecting a power source to the resistance heater.

8. The consumable component according to claim 1, wherein, At least a portion of the heater has a planar, tubular, or rod-shaped form, and / or includes a plurality of electromagnetically induction-heatable particles distributed through a plurality of fragments or particles of the solid aerosol forming material.

9. The consumable component according to claim 1, wherein, The heater is installed on at least one of the first end wall and the second end wall.

10. The consumable component according to claim 1, wherein, At least one of the first end wall and the second end wall includes a cap fitted onto the end of the outer wall or a plug fitted into the end of the outer wall.

11. The consumable component according to claim 1, wherein, At least a portion of the outer casing includes at least one of paper material, card material, tobacco material, ceramic material, metal material, carbon material, and plastic material.

12. The consumable component according to claim 1, wherein, Multiple fragments or particles of the solid aerosol forming material are arranged in different regions within the consumable component, and wherein the heater is configured to selectively and independently heat the fragments or particles of the solid aerosol forming material located in the different regions.

13. An aerosol supply system for generating vapor using a consumable component according to any one of claims 1 to 12, the aerosol supply system comprising: The consumable component; A consumable component receiving section is provided for removably receiving the consumable component for use. as well as A power source is provided to selectively supply electricity to the heater located in the consumable component to generate steam from the solid aerosol forming material for inhalation by the user.

14. The aerosol supply system according to claim 13, wherein, The aerosol supply system also includes electrodes for supplying power to the heater located in the consumable component via corresponding electrodes located on the outer housing of the consumable component.

15. The aerosol supply system according to claim 13, wherein, The aerosol supply system also includes an induction heating coil for inductively supplying power to the heater.

16. The aerosol supply system according to claim 13, wherein, The aerosol supply system also includes a sensor for measuring the temperature associated with the consumable component during use.

17. The aerosol supply system according to claim 13, wherein, The consumable components include only the vapor precursor material source for the aerosol supply system.

18. A consumable component device for insertion into an aerosol supply system, the consumable component device comprising: An external housing assembly includes an outer wall assembly, a first end wall assembly, and a second end wall assembly, the outer wall assembly extending between the first end wall assembly and the second end wall assembly to define an inner chamber, wherein the first end wall assembly and the second end wall assembly include openings to allow air to flow through the first end wall assembly into the inner chamber and through the second end wall assembly out of the inner chamber during use. A plurality of fragments or particles of a solid aerosol forming device for generating an aerosol for inhalation by a user, wherein the plurality of fragments or particles of the solid aerosol forming device have an average characteristic size greater than 1 mm and are held within the inner chamber by the outer housing device; and A heater device, located within the inner chamber, is configured to heat fragments or particles of the solid aerosol forming device during use to generate steam for inhalation by the user.

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