Modular device with mechanical, electrical and airtight connections for air management control

Abstract

The present invention relates to a three-piece modular aerosol generation device. The three-piece modular aerosol generation device comprises a mouthpiece and a functional module. The functional module comprises an air inlet. The three-piece modular aerosol generation device further comprises a body. The functional module is disposed between the mouthpiece and the body. The functional module comprises a cavity configured to receive a consumable. The present invention further relates to a modular aerosol generation system comprising the modular aerosol generation device described herein, the functional module comprises a cavity configured to receive a consumable. The modular aerosol generation system further comprises a consumable.

Description

[Technical field]

[0001] The present disclosure relates to an aerosol generating device.The present disclosure further relates to an aerosol generating system.The present disclosure further relates to a functional module. [Background technology]

[0002] It is known to provide an aerosol-generating device for generating an inhalable vapor. Such a device may heat an aerosol-forming substrate to a temperature at which one or more components of the aerosol-forming substrate volatilize without burning the aerosol-forming substrate. The aerosol-forming substrate may be present in a solid form or in a liquid state. The aerosol-forming substrate may be provided as part of an aerosol-generating article. The aerosol-generating article may have a rod shape for insertion of the aerosol-generating article into a cavity (such as a heating chamber) of the aerosol-generating device. A heating element may be disposed in or around the heating chamber to heat the aerosol-forming substrate when the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device. Additionally or alternatively, a cartridge with a liquid aerosol-forming substrate may be attached to or inserted into the aerosol-generating device to supply the liquid aerosol-forming substrate to the device for aerosol generation.

[0003] It would be desirable to have an aerosol generating device that provides high functionality. It would be desirable to have an aerosol generating device that is customizable. It would be desirable to have an aerosol generating device that allows for control of air management. It would be desirable to have an aerosol generating device that allows for control of withdrawal resistance. It would be desirable to have an aerosol generating device that allows for flavoring of the generated aerosol. It would be desirable to have an aerosol generating device that provides easy assembly. It would be desirable to have an aerosol generating device that has a compact design. It would be desirable to have an aerosol generating device that is intuitive to the user. It would be desirable to have modules for an aerosol generating device that provides high functionality. It would be desirable to provide modules that provide customization of the aerosol generating device. It would be desirable to have modules that provide control of air management. It would be desirable to have modules that allow for control of withdrawal resistance. It would be desirable to have a versatile aerosol generating system. It would be desirable to have an aerosol generating system that is intuitive to the user. It would be desirable to have an aerosol generating system that allows for control of air management. It would be desirable to have an aerosol generating system that allows for control of withdrawal resistance. It would be desirable to have an aerosol generating system that allows for flavoring of the generated aerosol. Summary of the Invention

[0004] According to an embodiment of the present invention, there is provided a three-piece modular aerosol generator. The three-piece modular aerosol generator may comprise a mouthpiece and a functional module. The functional module may comprise an air inlet. The three-piece modular aerosol generator may further comprise a body. The functional module may be disposed between the mouthpiece and the body. The functional module may comprise a cavity configured to receive a consumable.

[0005] According to an embodiment of the present invention, there is provided a three-piece modular aerosol generator. The three-piece modular aerosol generator comprises a mouthpiece and a functional module. The functional module comprises an air inlet. The three-piece modular aerosol generator further comprises a body. The functional module is disposed between the mouthpiece and the body. The functional module comprises a cavity configured to receive a consumable.

[0006] Providing a three-piece modular aerosol generator may provide high functionality. Providing a three-piece modular aerosol generator may provide customization. Providing a three-piece modular aerosol generator may allow control of air management. Providing a three-piece modular aerosol generator may allow control of withdrawal resistance. Providing a three-piece modular aerosol generator may allow flavoring of the generated aerosol. Providing a three-piece modular aerosol generator may provide easy assembly. Providing a three-piece modular aerosol generator may provide a compact design.

[0007] Consumers are keen to have versatility and modification of the generated aerosol. There are different types of aerosol generating systems (e.g., systems with liquid or solid aerosol-forming substrates) on the market. Thus, modification of the aerosol often requires a different aerosol generating system. Providing a modular aerosol generating device according to the present invention may provide high variability and modification of the aerosol with different aerosol generating systems (e.g., solid or liquid aerosol-forming substrates).

[0008] The functional module may be sandwiched between the mouthpiece and the body. The mouthpiece may be disposed downstream of the functional module. The body may be disposed upstream of the functional module. The mouthpiece may be configured to be connectable to a proximal end of the functional module. The distal end of the mouthpiece may be configured to be connectable to a proximal end of the functional module. The body may be configured to be connectable to a distal end of the functional module. The proximal side of the body may be configured to be connectable to a distal end of the functional module.

[0009] The air inlet of the functional module may be a lateral air inlet. The lateral air inlet may be located on an outer surface of the functional module. Providing a lateral air inlet on the functional module may enable airflow when the functional module is disposed between the mouthpiece and the body. The lateral air inlet may be a lateral groove.

[0010] The lateral air inlet may have a diameter measured perpendicular to the longitudinal axis of the modular aerosol generating device, which may be between 0.15 and 1.7 millimeters, preferably between 0.35 and 1.15 millimeters.

[0011] The mouthpiece may be configured to be connectable to the functional module and the body. The mouthpiece may be configured to be connectable to a functional module of a functional module. The mouthpiece may be configured to be connectable to the body. The mouthpiece may be configured to be connectable to a body without a functional module. The mouthpiece may be configured to be reversibly connectable to the functional module and the body.

[0012] The mouthpiece may include a first connection element disposed at a distal end of the mouthpiece. The functional module may include a second connection element disposed at a proximal end and a first connection element disposed at a distal end of the functional module. The body may include a second connection element disposed at a proximal end of the body. The first connection element may be configured to be connectable to the second connection element. The first and second connection elements may provide a form-fit connection.

[0013] The first and second connecting elements may have a cylindrical shape. The first and second connecting elements may be annular. The first and second connecting elements may be configured to provide a 360 degree circumferential connection along a longitudinal axis of the modular aerosol generation device. The first and second connecting elements may be configured to be interconnectable independent of their rotation about the longitudinal axis of the modular aerosol generation device, thereby providing a simple and intuitive assembly.

[0014] The first and second connecting elements may be disposed coaxially with the mouthpiece, the functional module, and the body.

[0015] The first and second connection elements may be configured to provide mechanical, electrical and airtight coupling. The first and second connection elements may provide airtight coupling of the mouthpiece, the functional module and the body. The first and second connection elements may provide airtight sealing of the mouthpiece, the functional module and the body. Mechanical coupling means that the three pieces of the modular system, i.e. the mouthpiece, the functional module and the body, can be connected to each other without being easily disassembled. Electrical coupling means that the flow of electric current between the three pieces of the modular aerosol generating device may be ensured.

[0016] The first connecting element may include an annular recess and the second connecting element may include a tubular protrusion, or vice versa. The annular recess may be configured to receive the tubular protrusion. The annular recess and the tubular protrusion may have matching shapes. The annular recess and the tubular protrusion may provide a mechanical connection of three pieces of the modular aerosol generating device, i.e., the mouthpiece, the functional module, and the body.

[0017] The tubular projection and the annular recess may extend in a direction along a longitudinal axis of the modular aerosol generation device.

[0018] The tubular projection and the annular recess may have outer and inner diameters measured perpendicular to the longitudinal axis of the modular aerosol generation device. The tubular projection and the annular recess may have the same outer and inner diameters. The outer diameters of the tubular projection and the annular recess may be smaller than the outer diameters of the mouthpiece, the functional module, and the body measured in the same direction.

[0019] The outer diameter of the tubular projection and the annular recess may be 6 to 19 mm, preferably 9 to 16 mm, more preferably 12 mm. The inner diameter of the tubular projection and the annular recess may be 5 to 14 mm, preferably 8 to 12 mm, more preferably 9 mm.

[0020] The annular recess may include two sides. The two sides may be an inner side and an outer side. The inner side may be closer to the longitudinal axis of the annular recess than the outer side. The annular recess may include a bottom portion. The bottom portion may include a bottom surface on a bottom of the recess. The bottom surface may be transverse to the longitudinal axis of the recess.

[0021] The annular recess may have a depth, measured in a direction along the longitudinal axis of the modular aerosol generation device, of between 3 and 7 millimeters, preferably between 4 and 6 millimeters, and more preferably 6 millimeters.

[0022] The tubular projection may be a hollow cylinder. The tubular projection may have two sides. The two sides may be an inner side and an outer side. The inner side may be closer to the longitudinal axis of the tubular projection than the outer side. The tubular projection may have a distal end. The distal end may be the end pointing away from the center of the functional module. The tubular projection may have a top surface at the distal end. The top surface may be transverse to the longitudinal axis of the modular aerosol generation device.

[0023] The tubular protrusion may have a height, measured in a direction along the longitudinal axis of the modular aerosol generating device, of between 4 and 11 millimeters, preferably between 5 and 9 millimeters, and more preferably 7 millimeters.

[0024] The first and second connection elements may comprise a magnetic connection. The annular recess may comprise a first magnetic connection element and the tubular protrusion may comprise a second magnetic connection element. The first and second magnetic connection elements may be annular. The first and second magnetic connection elements may provide a magnetic connection of three pieces of the modular aerosol generation device, namely, the mouthpiece, the functional module, and the body. The mechanical coupling of the two pieces of the modular aerosol generation system, the tubular protrusion and the annular recess, may provide a proximity of the first and second magnetic connection elements. Thereby, even a weaker magnetic connection element may provide a strong connection.

[0025] The annular recess may include a first magnetic connection element at a bottom portion of the annular recess. The tubular projection may include a second magnetic connection element at a distal end of the tubular projection. The annular recess may include a first magnetic connection element at a rearward bottom surface. The tubular projection may include a second magnetic connection element at a rearward top surface.

[0026] The first magnetic connection element may include an annular magnet and the second magnetic connection element may include a metal ring, or vice versa. Alternatively, both the first and second magnetic connection elements comprise an annular magnet. The annular magnet may be a permanent magnet or an electromagnet. The metal ring may include a ferromagnetic material.

[0027] The annular magnet may have an outer diameter and an inner diameter measured in a direction perpendicular to the longitudinal axis of the modular aerosol generation device. The outer diameter may be 9 to 20 millimeters, preferably 11 to 18 millimeters, more preferably 15 millimeters. The inner diameter may be 4 to 18 millimeters, preferably 6 to 16 millimeters, more preferably 12 millimeters. The annular magnet may have a height measured in a direction along the longitudinal axis of the modular aerosol generation device. The height may be 1 to 5 millimeters, preferably 2 to 4 millimeters, more preferably 3 millimeters. The metal ring may have the same dimensions as the annular magnet. The metal ring may have a smaller height than the annular magnet.

[0028] The permanent magnets or electromagnets may provide a holding force of 40 to 400 grams, preferably 80 to 120 grams. The permanent magnets may include ferrite or neodymium, or both.

[0029] The first connecting element may comprise first and second electrical contacts. The second connecting element may comprise first and second electrical contacts. The first and second electrical contacts may provide electrical coupling of three pieces of the modular aerosol generating device, i.e., the mouthpiece, the functional module, and the body.

[0030] The first and second electrical contacts may be annular contacts on the side of the annular recess and the side of the tubular protrusion. Preferably, the first and second electrical contacts may be located on the inner surface of the annular recess and the tubular protrusion. Alternatively, the first and second electrical contacts may be located on the outer surface of the annular recess and the tubular protrusion. By locating both the first and second electrical contacts on either the inner or outer surface of the annular recess and the tubular protrusion, direct contact of the two first electrical contacts with each other and direct contact of the two second electrical contacts with each other may be provided. The first electrical contact may be disposed downstream of the second electrical contact. The first and second electrical contacts may not be in direct contact with each other.

[0031] The mouthpiece, the functional module, and the body may have an elongated shape, preferably a cylindrical elongated shape. The mouthpiece, the functional module, and the body have the same outer diameter. The mouthpiece, the functional module, and the body may each include a housing. The housing may include a hard plastic. The hard plastic may include polycarbonate, polycarbonate ABS covered with a thermoplastic elastomer, fluorinated ethylene propylene, or other suitable material.

[0032] The mouthpiece may comprise a cavity configured to receive the aerosol-generating article or cartridge. The cavity may be a heating chamber. The cavity may have an elongated shape. The aerosol-generating article or cartridge may comprise an aerosol-forming substrate. The aerosol-generating article or cartridge may comprise a susceptor material.

[0033] The mouthpiece may comprise a heating element disposed at least partially around the cavity. Only the mouthpiece may comprise a heating element. The functional module may not comprise a heating element. Preferably, the heating element may be an induction heating element comprising at least one inductor coil for inductively heating the aerosol generating article or cartridge.

[0034] The mouthpiece may comprise a distal opening configured to be fluidly connected to a functional module or body. The distal opening may have a diameter measured in a direction perpendicular to a longitudinal axis of the modular aerosol generating device. The diameter of the distal opening of the mouthpiece may be smaller than the diameter of the cavity measured in the same direction. The mouthpiece may comprise a proximal opening. The mouthpiece may receive an aerosol-generating article or cartridge through the proximal opening.

[0035] The mouthpiece may comprise an airflow channel. Preferably, the airflow channel is a central airflow channel. The mouthpiece may be hollow.

[0036] The mouthpiece may have a length measured along the longitudinal axis of the modular aerosol generation device. The length may be between 31 and 47 millimeters, preferably between 33 and 40 millimeters, more preferably 36.5 millimeters. The mouthpiece may have an outer diameter measured perpendicular to the longitudinal axis of the modular aerosol generation device. The outer diameter may be between 6 and 22 millimeters, preferably between 9 and 19 millimeters, more preferably 18.4 millimeters.

[0037] The functional module may be hollow. The functional module may comprise a distal opening. The functional module may comprise a lateral air inlet between the second connection element and the first connection element and proximal to the second connection element. When the mouthpiece and the functional module are assembled, the lateral air inlet of the functional module may provide a fluid connection to the mouthpiece. The functional module may not comprise a heating element.

[0038] The functional module may include wiring interconnecting first and second electrical contacts of a first connection element of the functional module with first and second electrical contacts of a second connection element of the functional module.

[0039] The functional module may have a length measured along the longitudinal axis of the modular aerosol generation device. The length may be between 17 and 32 mm, preferably between 20 and 30 mm, more preferably between 24 and 26 mm, more preferably 25.3 mm. The functional module may have an outer diameter measured perpendicular to the longitudinal axis of the modular aerosol generation device. The outer diameter may be between 6 and 22 mm, preferably between 9 and 19 mm, more preferably 18.4 mm.

[0040] The functional module may comprise a cavity configured to receive the consumable, the cavity being preferably a cylindrical cavity. The cavity may have a diameter measured perpendicular to the longitudinal axis of the modular aerosol generating device. The diameter may be smaller than the inner diameter of the tubular protrusion and the annular recess. The diameter of the cavity may be larger than the diameter of the distal opening measured in the same direction. The cavity of the functional module may have a diameter approximately the same as the diameter of the consumable measured in the same direction. The cavity of the functional module may be fluidly connected to the distal opening. Thereby, the consumable may be easily removed by a thin object when inserted into the cavity. Such a thin object may be, for example, a pen.

[0041] The cavity of the functional module may be fluidly connected to a lateral air inlet of the functional module.The cavity of the functional module may be fluidly connected to the lateral air inlet via an inclined airflow channel.

[0042] The body may include an air inlet. When the mouthpiece and body are assembled without the functional module, the lateral air inlet of the body may provide a fluid connection to the mouthpiece. The air inlet of the body may be a lateral air inlet. The air inlet of the body may be a lateral groove. The air inlet of the body may have a diameter measured perpendicular to the longitudinal axis of the modular aerosol generation device. The diameter may be 0.15 to 1.7 millimeters, preferably 0.35 to 1.15 millimeters.

[0043] The body may have a length measured along a longitudinal axis of the modular aerosol generation device. The body may have a length measured along a longitudinal axis of the modular aerosol generation device. The length may be 55 to 127 millimeters, preferably 60 to 90 millimeters, more preferably 65 to 70 millimeters, more preferably 67.3 millimeters. The body may have an outer diameter measured perpendicular to the longitudinal axis of the modular aerosol generation device. The outer diameter may be 6 to 22 millimeters, preferably 9 to 19 millimeters, more preferably 18.4 millimeters.

[0044] The body may include a power source and a controller. The body may include a power plug connector at a distal end of the body.

[0045] The present invention further relates to a modular aerosol generation system comprising the modular aerosol generation device described herein, wherein the functional module may comprise a cavity configured to receive a consumable. The modular aerosol generation system may further comprise a consumable.

[0046] The present invention further relates to a modular aerosol generation system comprising the modular aerosol generation device described herein, wherein the functional module comprises a cavity configured to receive a consumable. The modular aerosol generation system further comprises a consumable.

[0047] The consumable may include a filtration material. The consumable may consist of the filtration material. The consumable may include a ceramic material. The ceramic material may include silicon carbide, silicon-based compounds, cordierite, silica, and zirconium-based ceramic compounds. The consumable may be porous. The porosity of the consumable may be 30 to 80 percent, preferably 40 to 70 percent, and more preferably 50 to 60 percent.

[0048] As used herein, "porosity" is defined as the percentage of a unit volume that is completely free of material. Porosity may be derived using standard methods and equations, which may give a decimal value for porosity. By knowing the pore volume (Vp) of a defined volume of material and its total volume (Vt), the porosity (Pt) is given by the ratio Vp / Vt. To express porosity as a percentage, simply multiply the decimal by 100%. For example, Pt=0.51 is therefore 0.51×100%=51%.

[0049] The consumable may include a porous basalt-based material.The consumable may include a basalt-based material and a silica-based compound.

[0050] The consumable may include at least one of a sensory medium, an aerosol-forming substrate, or a flavoring agent, which may include licorice, wintergreen, cherry and berry type flavorings, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cinnamon, cardamom, celery, clove, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, mint, cinnamon, caraway, cognac, jasmine, chamomile, menthol, ylang, sage, fennel, pimenta, ginger, anise, chai, coriander, coffee, peppermint oil from Mint species, cocoa, and combinations thereof.

[0051] The ceramic material may be impregnated with a liquid flavouring.

[0052] The consumable may comprise a top portion and a bottom portion. The bottom portion may be upstream of the top portion. The top portion and the bottom portion may have different porosities. The top portion may have a higher porosity than the bottom portion. The airflow may thereby be slowed down, resulting in a higher resistance to draw (RTD). The porosity of the top portion may be 25-80 percent, preferably 55-75 percent, more preferably 65-75 percent.

[0053] The top and bottom sections may be flavored and filtered sections. Preferably, the top section may be the flavored section and the bottom section may be the filtered section, whereby the air is first filtered and then flavored.

[0054] The consumable may have a cylindrical shape. The consumable may have a diameter measured perpendicular to the longitudinal axis of the modular aerosol generation device. The consumable may have a length measured along the longitudinal axis of the modular aerosol generation device. The diameter of the consumable may be at least equal to the length of the consumable. The diameter of the consumable may be greater than the length of the consumable. The diameter of the consumable may be between 4.5 and 11 millimeters, preferably between 6 and 9 millimeters. The length of the consumable may be between 4.5 and 11 millimeters.

[0055] The consumable may comprise a distal sealing layer configured to hermetically seal the distal opening of the functional module when the consumable is received within the cavity. The distal sealing base may preferably be a laminated foil. The laminated foil may be adjacent to a bottom portion of the consumable. The laminated foil may be branded, whereby a consumer may directly identify the connections and functions of the consumable.

[0056] When a consumable is received within a functional module, the lateral air inlet of the functional module may be the only air inlet of the modular aerosol generation system, thereby ensuring a particular RTD.

[0057] When the consumable is received in the cavity of the functional module and the mouthpiece, functional module and body are assembled, the resistance to draw (RTD) of the system may be 10-65 mmH20, preferably 30-60 mmH20, measured according to ISO standard 6565:2002. Such RTD refers to the static pressure difference between the lateral air inlet of the functional module and the mouth end outlet of the aerosol-generating article received in the cavity of the mouthpiece from which the consumer inhales the generated aerosol, when air flows across the mouth end as the outlet of the aerosol-generating article under steady conditions with a volumetric flow rate of 17.5 milliliters per second.

[0058] The aerosol-forming substrate may be part of the aerosol-generating article. The aerosol-forming substrate may be part of a liquid held in a liquid storage portion of the cartridge. The aerosol-forming substrate may be part of a liquid sensory medium held in a liquid storage portion of the cartridge. The liquid storage portion may contain a liquid aerosol-forming substrate. Alternatively, or additionally, the liquid storage portion may contain a solid aerosol-forming substrate. For example, the liquid storage portion may contain a suspension of a solid aerosol-forming substrate and a liquid. Preferably, the liquid storage portion contains a liquid aerosol-forming substrate.

[0059] Preferably, a liquid nicotine or flavour / flavour-containing aerosol-forming substrate may be employed within the liquid storage portion of the cartridge.

[0060] The aerosol-forming substrate may comprise nicotine. The nicotine-containing aerosol-forming substrate may be a nicotine salt matrix.

[0061] The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material comprising volatile tobacco flavour compounds which are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise a homogenised plant-derived material. The aerosol-forming substrate may comprise a homogenised tobacco material. The homogenised tobacco material may be formed by agglomerating particulate tobacco.

[0062] The aerosol-forming substrate may include at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol in use and is substantially resistant to thermal decomposition at the operating temperature of the device. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate, etc.), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). A preferred aerosol former is a polyhydric alcohol or mixtures thereof (such as triethylene glycol, 1,3-butanediol, etc.). Preferably, the aerosol former is glycerin. When present, the homogenized tobacco material may have an aerosol former content of 5 weight percent or more on a dry weight basis, and preferably has an aerosol former content of 5 weight percent to 30 weight percent on a dry weight basis. The aerosol-forming substrate may contain other additives and ingredients, such as flavourants.

[0063] As used herein, the term "aerosol-generating article" refers to an article that includes an aerosol-forming substrate capable of releasing a volatile compound capable of forming an aerosol. For example, the aerosol-generating article may be an article that generates an aerosol that can be directly inhaled by a user sucking or puffing on a mouthpiece at the proximal or user end of the device. The aerosol-generating article may be disposable. The aerosol-generating article may be insertable into a heating chamber of a modular aerosol-generating device.

[0064] As used herein, the term "liquid reservoir" refers to a reservoir that includes a liquid sensory medium and, additionally or alternatively, an aerosol-forming substrate capable of releasing a volatile compound capable of forming an aerosol. The liquid reservoir may be configured as a container or reservoir for storing the liquid aerosol-forming substrate.

[0065] The liquid reservoir may be configured as a replaceable tank or container. The liquid reservoir may be of any suitable shape and size. For example, the liquid reservoir may be substantially cylindrical. The cross section of the liquid reservoir may be, for example, substantially circular, elliptical, square, or rectangular.

[0066] As used herein, the term "aerosol-generating device" refers to a device that interacts with an aerosol-generating article and / or a cartridge to generate an aerosol.

[0067] As used herein, the term "aerosol generating system" refers to a combination of an aerosol generating device with a cartridge and / or an aerosol-generating article, in which the aerosol generating device and the aerosol-generating article and / or cartridge cooperate to generate a respirable aerosol.

[0068] The modular aerosol generating device is preferably portable. The modular aerosol generating device may have a size comparable to a conventional cigar or cigarette. The device may be an electrically operated smoking device. The device may be a handheld aerosol generating device. The modular aerosol generating device may have an overall length of between 30 mm and 150 mm. The aerosol generating device may have an outer diameter of between 5 mm and 30 mm.

[0069] The modular aerosol generating device may include a housing. The housing may be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. The material is preferably lightweight and not brittle.

[0070] The housing may include at least one air inlet. The housing may include two or more air inlets.

[0071] The modular aerosol generator may include a heating element. The heating element may be an induction heater. The heating element may include at least one inductor coil for inductively heating one or more susceptors. Alternatively, the heating element may be a resistive heater.

[0072] Operation of the heating element may be triggered by a puff detection system. Alternatively, the heating element may be triggered by pressing an on-off button and held for the duration of the user's puff. The puff detection system may be provided as a sensor, which may be configured as an airflow sensor for measuring airflow velocity. Airflow velocity is a parameter that characterizes the amount of air per time drawn by the user through the airflow path of the aerosol generating device. The start of a puff may be detected by the airflow sensor when the airflow exceeds a predefined threshold. The start may also be detected upon the user activating a button. The sensor may also be configured as a pressure sensor.

[0073] The modular aerosol generating device may include a user interface for starting the aerosol generating device, such as a button to initiate heating of the modular aerosol generating device, or a display that indicates the status of the modular aerosol generating device or the aerosol-forming substrate.

[0074] The modular aerosol generating device may include additional components, such as, for example, an electrically operated or charging unit for recharging an on-board power supply within the electric aerosol generating device.

[0075] As used herein, the term "proximal" refers to the user or mouth end of a modular aerosol generation device or system or portion thereof, and the term "distal" refers to the end opposite the proximal end. When referring to the heating chamber, the term "proximal" refers to the area closest to the open end of the cavity, and the term "distal" refers to the area closest to the closed end.

[0076] As used herein, the term "lateral" refers to a direction perpendicular to the longitudinal axis of the modular aerosol generation device.

[0077] As used herein, the terms "upstream" and "downstream" are used to describe the relative positions of components or portions of components of a modular aerosol generation device with respect to the direction in which a user draws on the modular aerosol generation device during use of the modular aerosol generation device.

[0078] As used herein, the term "airflow path" means a channel suitable for transporting a gaseous medium. The airflow path may be used to transport ambient air. The airflow path may be used to transport an aerosol. The airflow path may be used to transport a mixture of air and an aerosol.

[0079] As used herein, "susceptor" or "susceptor element" means an element that heats up when subjected to an alternating magnetic field. This may be the result of eddy currents induced in the susceptor element, hysteresis losses, or both eddy currents and hysteresis losses. In use, the susceptor element is positioned in thermal contact or in thermal proximity with an aerosol-forming substrate received in an aerosol-generating article or cartridge. In this manner, the aerosol-forming substrate is heated by the susceptor, thereby forming an aerosol.

[0080] The susceptor material may be any material that can be inductively heated to a temperature sufficient to aerosolize the aerosol-forming substrate. The following examples and features of the susceptor may apply to one or both of the susceptor element of the cartridge, the susceptor of the aerosol-generating device, and the susceptor of the aerosol-generating article. Suitable materials for the susceptor material include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptor materials include metals or carbon. Advantageously, the susceptor material may include or consist of ferromagnetic or ferrimagnetic materials, such as ferromagnetic alloys, e.g., ferritic iron, ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrites. A suitable susceptor material may be or include aluminum. The susceptor material may contain more than 5 percent, preferably more than 20 percent, more preferably more than 50 percent or more than 90 percent ferromagnetic, ferrimagnetic, or paramagnetic material. Preferred susceptor materials may be heated to temperatures in excess of 250 degrees Celsius without degradation.

[0081] The susceptor material may be formed from a single layer of material, which may be a layer of steel.

[0082] The susceptor material may comprise a non-metallic core having a metallic layer disposed thereon. For example, the susceptor material may comprise a ceramic core or a metallic track formed on the outer surface of the substrate.

[0083] The susceptor material may be formed from a layer of austenitic steel. One or more layers of stainless steel may be disposed on the layer of austenitic steel. For example, the susceptor material may be formed from a layer of austenitic steel having a layer of stainless steel on each of its upper and lower surfaces. The susceptor element may include a single susceptor material. The susceptor element may include a first susceptor material and a second susceptor material. The first susceptor material may be disposed in intimate physical contact with the second susceptor material. The first susceptor material and the second susceptor material may be in intimate contact to form a single susceptor that cannot be disassembled. In one particular embodiment, the first susceptor material is stainless steel and the second susceptor material is nickel. The susceptor element may have a two-layer structure. The susceptor element may be formed from a stainless steel layer and a nickel layer.

[0084] The intimate contact between the first and second susceptor materials may be achieved by any suitable means. For example, the second susceptor material may be plated, deposited, coated, clad, or welded onto the first susceptor material. Preferred methods include electroplating, galvanizing, and cladding.

[0085] The modular aerosol generating device may include a power source to power the heating element. The power source may include a battery. The power source may be a lithium-ion battery. Alternatively, the power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery (e.g., a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery). The power source may require recharging and may have a capacity that allows for storage of sufficient energy for one or more use experiences, for example, the power source may have a capacity sufficient to continuously generate aerosol for a period of approximately six minutes, or a multiple of six minutes. In another embodiment, the power source may have a capacity sufficient to provide a predetermined number of puffs, or discontinuous activation of the heating element.

[0086] The power source may be a direct current (DC) power source. In one embodiment, the power source is a DC power source having a DC supply voltage in the range of 2.5 volts to 4.5 volts and a DC supply current in the range of 1 amp to 10 amps (corresponding to a DC power source in the range of 2.5 watts to 45 watts). Advantageously, the modular aerosol generating device may comprise a direct current to alternating current (DC / AC) inverter for converting the DC current provided by the DC power source to an alternating current. The DC / AC converter may comprise a class D, class C, or class E power amplifier. The AC power output of the DC / AC converter is provided to the induction coil.

[0087] The power source may be adapted to supply power to the inductor coil and may be configured to operate at high frequencies. For operation at high frequencies, a class E power amplifier is preferred. As used herein, the term "high frequency oscillating current" means an oscillating current having a frequency between 500 kilohertz and 30 megahertz. The high frequency oscillating current may have a frequency between 1 megahertz and 30 megahertz, preferably between 1 megahertz and 10 megahertz, and more preferably between 5 megahertz and 8 megahertz.

[0088] In alternative embodiments, the switching frequency of the power amplifier may be in the lower kHz range, for example 100 kHz to 400 KHz. In embodiments where class D or class C power amplifiers are used, switching frequencies in the lower kHz range are particularly advantageous.

[0089] The modular aerosol generating device may include a controller. The controller may be electrically connected to the inductor coil. The controller may be electrically connected to the first induction coil and to the second induction coil. The controller may be configured to control the current supplied to the induction coil and thus the magnetic field strength generated by the induction coil(s).

[0090] A power source and a controller may be connected to the inductor coil.

[0091] The controller may be configured to chop the current supply on the input side of the DC / AC converter, thus controlling the power supplied to the inductor coil by conventional methods of duty cycle management.

[0092] Below is provided a non-exhaustive list of non-limiting examples, any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0093] Example 1: A three-piece modular aerosol generation device comprising: A mouthpiece, a functional module, the functional module comprising an air intake; A main body; A modular aerosol generating device, wherein a functional module is disposed between the mouthpiece and the body.

[0094] Example 2: A modular aerosol generating device according to example 1, wherein the air inlet of the functional module is a lateral air inlet.

[0095] Example 3: A modular aerosol generating device according to any of the preceding examples, wherein the mouthpiece is configured to be connectable to the functional module and the main body.

[0096] Example 4: A modular aerosol generation device according to any of the preceding examples, wherein the mouthpiece comprises a first connection element disposed at a distal end of the mouthpiece, the functional module comprises a second connection element disposed at a proximal end and a first connection element disposed at a distal end of the functional module, the body comprises a second connection element disposed at a proximal end of the body, and the first connection element is configured to be connectable to the second connection element.

[0097] Example 5: A modular aerosol generation device according to any of the preceding examples, wherein the first and second connecting elements are configured to provide a mechanical, electrical and airtight coupling.

[0098] Example 6: A modular aerosol generation device according to Example 4 or Example 5, wherein the first connecting element has an annular recess and the second connecting element has a tubular protrusion, or vice versa, and the annular recess is configured to receive the tubular protrusion.

[0099] Example 7: A modular aerosol generation device according to example 6, in which the annular recess and the tubular protrusion have matching shapes.

[0100] Example 8: A modular aerosol generation device according to example 6 or example 7, wherein the annular recess comprises a first magnetic connecting element and the tubular protrusion comprises a second magnetic connecting element.

[0101] Example 9: A modular aerosol generating device according to example 8, wherein the first and second magnetic connecting elements are annular.

[0102] Example 10: A modular aerosol generation device according to Example 8 or Example 9, wherein the annular recess comprises a first magnetic connecting element at a bottom portion of the annular recess, and the tubular protrusion comprises a second magnetic connecting element at a distal end of the tubular protrusion.

[0103] Example 11: A modular aerosol generating device according to any of Examples 8 to 10, wherein the first magnetic connection element comprises an annular magnet and the second magnetic connection element comprises a metal ring, or vice versa, or both the first and second magnetic connection elements comprise annular magnets.

[0104] Example 12: A modular aerosol generation device according to any of the preceding examples, wherein the first connecting element according to example 4 comprises first and second electrical contacts, and the second connecting element according to the example comprises first and second electrical contacts.

[0105] Example 13: A modular aerosol generation device according to Example 12, wherein the first and second electrical contacts are annular contacts on the sides of the annular recess and the sides of the tubular protrusion, preferably the first and second electrical contacts are positioned on the inner side of the annular recess and the inner surface of the tubular protrusion, or the first and second electrical contacts are positioned on the outer side of the annular recess and the outer surface of the tubular protrusion.

[0106] Example 14: A modular aerosol generating device according to any of the preceding examples, wherein the mouthpiece, the functional module and the body have an elongated shape, preferably a cylindrical elongated shape.

[0107] Example 15: A modular aerosol generation device according to any of the preceding examples, wherein the mouthpiece, the functional module, and the body have the same outer diameter.

[0108] Example 16: A modular aerosol generating device according to any of the preceding examples, wherein the mouthpiece comprises a cavity configured to receive an aerosol generating article or cartridge.

[0109] Example 17: A modular aerosol generating device according to Example 16, wherein the mouthpiece comprises a heating element arranged at least partially around the cavity, preferably an inductive heating element comprising at least one inductor coil for inductively heating the aerosol generating article or cartridge.

[0110] Example 18: A modular aerosol generation device according to any of the preceding examples, wherein the mouthpiece comprises a distal opening configured to be fluidly connected to the functional module and the body.

[0111] Example 19: A modular aerosol generation device according to any of the preceding examples, wherein the mouthpiece comprises an airflow channel, preferably a central airflow channel.

[0112] Example 20: A modular aerosol generating device according to any of the preceding examples, wherein the functional module is hollow.

[0113] Example 21: A modular aerosol generating device according to any of the preceding examples, wherein the functional module comprises a distal opening.

[0114] Example 22: A modular aerosol generation device according to any of the preceding claims, wherein the functional module comprises a lateral air intake according to example 2 between the second connecting element and the first connecting element and proximal to the second connecting element, and when the mouthpiece and the functional module are assembled, the lateral air intake of the functional module provides a fluid connection to the mouthpiece.

[0115] Example 23: A modular aerosol generation device according to any of the preceding examples, wherein the functional module comprises wiring connecting first and second electrical contacts of the first connection element of the functional module with first and second electrical contacts of the device connection element of the functional module.

[0116] Example 24: A modular aerosol generating device according to any of the preceding examples, wherein the functional module comprises a cavity configured to receive a consumable, preferably the cavity being a cylindrical cavity.

[0117] Example 25: A modular aerosol generating device according to Example 24, in which the cavity of the functional module is fluidly connected to the lateral air inlet of Example 2.

[0118] Example 26: A modular aerosol generating device according to any preceding claim, wherein the body is provided with an air inlet, and when the mouthpiece and body are assembled without the functional module, a lateral air inlet of the body provides a fluid connection to the mouthpiece.

[0119] Example 27: A modular aerosol generating device according to any preceding claim, wherein the main body comprises a power source and a controller.

[0120] Example 28: A modular aerosol generation system comprising: A modular aerosol generating device according to any one of the preceding claims, wherein the functional module comprises a cavity according to example 24 or example 25, A modular aerosol generating system comprising:

[0121] Example 29: A modular aerosol generation system according to Example 28, wherein the consumable comprises a filtration material.

[0122] Example 30: A modular aerosol generation system according to either Example 28 or Example 29, wherein the consumable comprises at least one of a sensory medium, an aerosol-forming substrate, or a flavoring agent.

[0123] Example 31: A modular aerosol generation system according to any of Examples 28 to 30, wherein the consumable comprises a distal sealing layer configured to hermetically seal the distal opening of Example 21 when the consumable is received within the cavity, preferably wherein the distal sealing base is a laminated foil.

[0124] Example 32: A modular aerosol generation system according to any of Examples 28 to 31, wherein the lateral air intake of claim 2 is the only air intake of the modular aerosol generation system when a consumable is received within the functional module.

[0125] Example 33: A modular aerosol generation system according to any of Examples 28 to 32, wherein when the consumable is received within the cavity of the functional module, and when the mouthpiece, functional module, and main body are assembled, the resistance to withdrawal (RTD) of the system is 10 to 65 mmH20, preferably 30 to 60 mmH20.

[0126] Features described with respect to one embodiment may be equally applied to other embodiments of the invention.

[0127] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0128] [Figure 1] 1A and 1B show a modular aerosol generation device. [Diagram 2] 2A and 2B show the mouthpiece of a modular aerosol generation device. [Diagram 3] 3A and 3B show the functional modules of a modular aerosol generation device. [Figure 4] 4A and 4B show functional modules together with consumables. [Diagram 5] 5A and 5B show the main body of the modular aerosol generation device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0129] Figure 1A shows a perspective view of a modular aerosol generation device 10 in an exploded state. The modular aerosol generation device 10 comprises a mouthpiece 12, a functional module 14, and a body 16. The functional module 14 can be connected to the mouthpiece 12. The body 16 can be connected to the functional module 14. Figure 1B shows the modular aerosol generation device 10 in an assembled state.

[0130] FIG. 2A shows the mouthpiece 12 with an aerosol-generating article or cartridge 18. FIG. 2B shows a cross-section of the mouthpiece 12. The aerosol-generating article or cartridge 18 can be received in a cavity 20. The cavity 20 can be fluidly connected to a distal opening 22. The mouthpiece includes a heating element 24 having an induction coil 26. The mouthpiece includes a first connecting element 28 at a distal end. The first connecting element 28 includes an annular recess 30. The annular recess includes a bottom surface 32. A first magnetic connecting element 34 is positioned behind the bottom surface 32. The first magnetic connecting element can be an annular magnet or a metal ring. The annular recess 30 includes first and second electrical contacts 36 and 38 on an inner surface of the annular recess 30. Alternatively, the first and second electrical contacts 36 and 38 can be positioned on an outer surface of the annular recess 30.

[0131] FIG. 3A shows a perspective view of the functional module 14. FIG. 3B shows a cross-section of the functional module 14. The functional module 14 includes a second connection element 40 disposed at a proximal end of the functional module 14 and a first connection element 28 disposed at a distal end of the functional module 14. The first connection element 28 of the functional module 14 includes the same components as the first connection element 28 of the mouthpiece 12. The second connection element 40 includes a tubular protrusion 42. The tubular protrusion 42 includes an upper surface 44. A second magnetic connection element 46 is located behind the upper surface 44. The second magnetic connection element 46 can be an annular magnet or a metal ring. Both the first magnetic connection element 34 and the second magnetic connection element 46 can be annular magnets. Alternatively, one of the first magnetic connection element 34 and the second magnetic connection element 46 can be an annular magnet and the other can be a metal ring. The second connection element 40 further comprises first and second electrical contacts 38 and 40. The first and second electrical contacts 38 and 40 are disposed on an inner surface of the tubular protrusion 42. Alternatively, the first and second electrical contacts 36 and 38 can be located on an outer surface of the tubular protrusion 42. The functional module 14 further comprises a wiring 48. The wiring 48 connects the first electrical contact 38 of the second connection element 40 of the functional module 14 to the first electrical contact 38 of the first connection element 28. The wiring 48 connects the second electrical contact 38 of the second connection element 40 of the functional module 14 to the second electrical contact 38 of the first connection element 28.

[0132] The functional module 14 further comprises a lateral air inlet 50. The lateral air inlet 50 may be a lateral groove 52. The functional module 14 further comprises a cavity 54. The cavity 54 is fluidly connected to the lateral air inlet 50 via an angled airflow channel 56 and to a distal opening 58.

[0133] 4A and 4B show two embodiments 14a and 14b of the functional module 14 together with consumables 60a-60c. The functional modules 14a and 14b differ in terms of the length of the cavity 54 and the width of the distal opening 58. The cavity 54a of the functional module 14a has a longer length than the cavity 54b of the functional module 14b. The distal opening 58a of the functional module 14a is wider than the distal opening 58b of the functional module 14b. The functional module 14a may also include a distal opening 58b and the functional module 14b may also include a distal opening 58a.

[0134] The cavity 54a is configured to receive the consumable 60a or 60b. The consumables 60a-60c further comprise distal sealing layers 62a-62c, respectively. The distal sealing layers 62a-62c may be laminated foils. Such laminated foils may be marked with a brand to allow identification of the type of consumable 62. The distal sealing layers 62a and 62b further provide an airtight seal of the distal opening 58a when the consumable 60a or 60b is inserted into the functional module 14a. The consumable 60a comprises a filtering material. The filtering material may additionally comprise a flavoring agent. The consumable 60b comprises two different parts, a filtering part 66 and a flavoring part 64. The two parts 64 and 66 may also be arranged inversely.

[0135] Functional module 14b includes a smaller cavity 54b. Cavity 54b is configured to receive consumable 60c having a shorter length than consumables 60a and 60b. Consumable 60c includes a distal sealing layer 62c. Consumable 60c includes a filtration material. The filtration material may additionally include a flavoring agent. Distal sealing layer 62c hermetically seals distal opening 58b when consumable 60c is inserted into functional module 14b.

[0136] Distal openings 58a and 58b provide access to cavities 54a and 54b, such that consumables 60a-60c can be easily removed from functional modules 14a or 14b with a thin object, such as a pen, when consumables 60a-60b are depleted after use.

[0137] 5A shows the body 16 in a perspective view, and FIG. 5B shows the body 16 in a cross section. The body 16 comprises a second connection element 40, which is similar to the second connection element 40 of the functional module. The second connection element 40 comprises first and second electrical contacts 36 and 38, a tubular protrusion 42, and a second magnetic connection element 46. The body 16 further comprises an air inlet 68, which is a transverse groove 70. The body 16 further comprises a controller 72 for controlling a power source 74, and a power plug connector 76.

Claims

1. 1. A three-piece modular aerosol generating device comprising: A mouthpiece and a functional module having an air intake; a main body; the functional module is disposed between the mouthpiece and the body, the functional module comprising a cavity configured to receive a consumable product, the functional module does not comprise a heating element; the mouthpiece comprises a first connecting element disposed at a distal end of the mouthpiece, the functional module comprises a second connecting element disposed at a proximal end and a first connecting element disposed at a distal end of the functional module, the body comprises a second connecting element disposed at a proximal end of the body, and the first connecting element is configured to be connectable to the second connecting element; the first and second connection elements are configured to provide a mechanical, electrical, and gas-tight coupling; A modular aerosol generation device, wherein the first connecting element has an annular recess and the second connecting element has a tubular protrusion, or vice versa, the annular recess is configured to receive the tubular protrusion, and the annular recess and the tubular protrusion have matching shapes.

2. 2. The modular aerosol generation device of claim 1, wherein the air inlet of the functional module is a lateral air inlet.

3. The modular aerosol generating device of claim 1 , wherein the mouthpiece is configured to be connectable to the functional module and the main body.

4. 2. A modular aerosol generating device as described in claim 1, wherein the annular recess comprises a first magnetic connecting element and the tubular protrusion comprises a second magnetic connecting element, and preferably the first and second magnetic connecting elements are annular.

5. 5. The modular aerosol generating device of claim 4, wherein the annular recess has the first magnetic connection element at a bottom portion of the annular recess, and the tubular protrusion has the second magnetic connection element at a distal end of the tubular protrusion.

6. 5. The modular aerosol generating device of claim 4, wherein the first magnetic connection element comprises a ring magnet and the second magnetic connection element comprises a metal ring, or vice versa, or both the first and second magnetic connection elements comprise ring magnets.

7. 2. The modular aerosol generation device of claim 1, wherein the first connecting element comprises first and second electrical contacts, and the second connecting element comprises first and second electrical contacts.

8. A modular aerosol generation device as described in claim 7, wherein the first and second electrical contacts are annular contacts on the side surfaces of the annular recess and the tubular protrusion, and preferably the first and second electrical contacts are positioned on the inner surface of the annular recess and the inner surface of the tubular protrusion, or the first and second electrical contacts are positioned on the outer surface of the annular recess and the outer surface of the tubular protrusion.

9. 2. A modular aerosol generating device according to claim 1, wherein the mouthpiece, the functional module and the body have an elongated shape, preferably a cylindrical elongated shape.

10. 10. The modular aerosol generation device of claim 1, wherein the mouthpiece, the functional module, and the body have the same outer diameter.

11. 10. The modular aerosol generating device of claim 1, wherein the mouthpiece comprises a cavity configured to receive an aerosol generating article or cartridge.

12. A modular aerosol generating device as described in claim 11, wherein the mouthpiece comprises a heating element arranged at least partially around the cavity, preferably an induction heating element comprising at least one inductor coil for inductively heating the aerosol generating article or cartridge.

13. 10. The modular aerosol generation device of claim 1, wherein the mouthpiece comprises a distal opening configured to be fluidly connected to the functional module and the body.

14. 2. A modular aerosol generating device according to claim 1, wherein the mouthpiece comprises an airflow channel, preferably a central airflow channel.

15. 10. The modular aerosol generating device of claim 1, wherein the functional module is hollow.

16. The modular aerosol generation device of claim 1 , wherein the functional module comprises a distal opening.

17. 3. The modular aerosol generating device of claim 2, wherein the functional module has a lateral air intake between the second connecting element and the first connecting element and proximal to the second connecting element, and when the mouthpiece and functional module are assembled, the lateral air intake of the functional module provides a fluid connection to the mouthpiece.

18. 2. The modular aerosol generation device of claim 1, wherein the functional module comprises wiring connecting the first and second electrical contacts of the first connection element of the functional module with the first and second electrical contacts of the device connection element of the functional module.

19. 3. A modular aerosol generating device according to claim 2, wherein the cavity is a cylindrical cavity, and preferably the cavity of the functional module is fluidly connected to the lateral air inlet.

20. 2. The modular aerosol generating device of claim 1, wherein the main body has an air intake port, and when the mouthpiece and the main body are assembled without the functional module, the lateral air intake port of the main body provides a fluid connection to the mouthpiece.

21. The modular aerosol generating device of claim 1 , wherein the main body comprises a power source and a controller.

22. 1. A modular aerosol generation system comprising: A modular aerosol generating device according to any one of claims 1 to 21; and a consumable.

23. 23. The modular aerosol generating system of claim 22, wherein the consumable comprises a filtration material, and preferably the consumable comprises at least one of a sensory medium, an aerosol-forming substrate, or a flavoring agent.

24. the functional module having a distal opening; 23. The modular aerosol generation system of claim 22, wherein the consumable comprises a distal sealing layer configured to hermetically seal the distal opening when the consumable is received within the cavity, and preferably the distal sealing base is a laminated foil.

25. the air inlet of the functional module is a lateral air inlet; 23. The modular aerosol generation system of claim 22, wherein the lateral air inlet is the only air inlet of the modular aerosol generation system when the consumable is received within the functional module.

26. 23. A modular aerosol generation system as described in claim 22, wherein when the consumable is received in the cavity of the functional module, and when the mouthpiece, the functional module, and the main body are assembled, the resistance to withdrawal (RTD) of the system is 10 to 65 mmH20, preferably 30 to 60 mmH20.

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