Aerosol provision device

Abstract

To provide an aerosol provision device.SOLUTION: The device comprises a receptacle configured to receive aerosol generating material, where the receptacle comprises a susceptor 132 heatable by penetration with a varying magnetic field. The device further comprises an insulating member 128 extending around the susceptor, where the insulating member is positioned away from the receptacle to provide an air gap around the susceptor. The device further comprises an inductor coil 224 extending around the insulating member such that the insulating member is positioned between the inductor coil and the susceptor, where the inductor coil is configured to generate the varying magnetic field.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device and an aerosol delivery system comprising an aerosol delivery device and an article comprising an aerosol-generating material. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide an alternative to these tobacco-burning articles by creating products that release compounds without combustion. Examples of such products include heating devices that release compounds by heating, rather than burning, a material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of the present disclosure, there is provided an aerosol delivery device comprising: a receptacle configured to receive an aerosol-generating material, the receptacle including a susceptor that is heatable by penetration of a varying magnetic field; an insulating member extending around the susceptor, the insulating member being spaced from the receptacle to provide a gap around the susceptor; an inductor coil extending around the insulating member such that the insulating member is disposed between the inductor coil and the susceptor, the inductor coil configured to generate a varying magnetic field; Equipped with.

[0004] According to a second aspect of the present disclosure, there is provided an aerosol delivery system comprising: An aerosol delivery device according to a first aspect; an article comprising an aerosol-generating material, the article being dimensioned to be at least partially received within the receptacle; Equipped with.

[0005] According to a third aspect of the present disclosure, there is provided an aerosol delivery device comprising: a susceptor configured to receive the aerosol-generating material and heatable by penetration of a varying magnetic field; an insulating member extending around the susceptor and spaced apart from the susceptor; an inductor coil extending around the insulating member such that the insulating member is disposed between the inductor coil and the susceptor, the inductor coil configured to generate a varying magnetic field; an outer cover forming at least a portion of an outer surface of the aerosol delivery device, the inner surface of the outer cover being spaced from the outer surface of the susceptor by a distance of about 4 mm to about 10 mm; Equipped with.

[0006] According to a fourth aspect of the present disclosure, there is provided an aerosol delivery device comprising: a receptacle configured to receive an aerosol-generating material, the receptacle including a susceptor that is heatable by penetration of a varying magnetic field; an insulating member extending around the susceptor and spaced apart from the receptacle; an inductor coil extending around the insulating member such that the insulating member is disposed between the inductor coil and the susceptor, the inductor coil configured to generate a varying magnetic field; an outer cover forming an outer surface of the aerosol delivery device, the inner surface of the outer cover being spaced from the outer surface of the inductor coil by a distance of about 0.2 mm to about 1 mm; Equipped with.

[0007] According to a fifth aspect of the present disclosure, there is provided an aerosol delivery system comprising: an aerosol delivery device according to the third or fourth aspect; an article comprising an aerosol-generating material, the article having dimensions such that, in use, it is at least partially received within a susceptor of an aerosol delivery device; Equipped with.

[0008] According to a sixth aspect of the present disclosure, there is provided an aerosol delivery system comprising: an aerosol delivery device according to the third or fourth aspect; an article comprising an aerosol-generating material, the article being dimensioned to contact, in use, a susceptor of an aerosol delivery device; Equipped with.

[0009] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments thereof, which description is given by way of example only and is made with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a front view of an example of an aerosol delivery device. [Diagram 2] FIG. 2 is a front view of the aerosol delivery device of FIG. 1 with the outer cover removed. [Diagram 3] 2 is a cross-sectional view of the aerosol delivery device of FIG. 1. [Figure 4] FIG. 3 is an exploded view of the aerosol delivery device of FIG. 2. [Diagram 5] FIG. 5A is a cross-sectional view of a heating assembly in an aerosol delivery device, and FIG. 5B is an enlarged view of a portion of the heating assembly of FIG. 5A. [Figure 6] FIG. 2 is a diagram of a configuration consisting of a susceptor, an inductor coil, and an insulating member. [Figure 7] FIG. 2 is a perspective view of a susceptor surrounded by an insulating member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] As used herein, the term "aerosol-forming material" includes materials that upon heating provide volatile components, typically in the form of an aerosol. Aerosol-forming materials include any tobacco-containing material, and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials may also include other non-tobacco products, which may or may not contain nicotine depending on the particular product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-forming materials may be, for example, a combination or mixture of materials. Aerosol-forming materials may also be referred to as "smoking materials."

[0012] Devices are known that heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, typically to form an inhalable aerosol, without burning or combusting the aerosol-generating material. Such devices are sometimes described as "aerosol generating devices", "aerosol delivery devices", "non-combustion heating devices", "tobacco heating product devices" or "tobacco heating devices". There are also so-called e-cigarette devices, which typically vaporize aerosol-generating material in liquid form, which may or may not contain nicotine. The aerosol-generating material may be in the form of, or provided as part of, a rod, cartridge, cassette, or the like that can be inserted into the device. A heater for heating and volatilizing the aerosol-generating material may be provided as a "permanent" part of the device.

[0013] The aerosol delivery device can receive an article comprising an aerosol-generating material for heating. An "article" in this context is a component that, in use, contains or houses the aerosol-generating material, and optionally other ingredients, where the aerosol-generating material is heated to volatilize it. A user may insert the article into the aerosol delivery device before the article is heated to generate an aerosol that is inhaled by the user. The article may be, for example, of a predetermined or specific size configured to be placed in a heating chamber of a device dimensioned to receive the article.

[0014] A first aspect of the present disclosure defines a particular configuration of a susceptor, an insulating member, and one or more inductor coils. As discussed in more detail herein, the susceptor is an electrically conductive object that can be heated by the penetration of a varying magnetic field. The inductor coil generates a varying magnetic field that causes the susceptor to heat. An article comprising an aerosol-generating material can be received in the receptacle. When heated, the susceptor transfers heat to the aerosol-generating material, which releases an aerosol. In one example, the susceptor defines a receptacle, and the susceptor receives the aerosol-generating material.

[0015] In this configuration, the susceptor is surrounded by an insulating member, which may be arranged, for example, coaxially with the susceptor. The insulating member is arranged away from the outer surface of the receptacle or susceptor to provide an air gap. An inductor coil extends around the insulating member. This means that the insulating member is arranged between the inductor coil and the susceptor, and an air gap is arranged between the insulating member and the susceptor. In certain configurations, the inductor coil may contact the insulating member. However, in other examples, a further air gap may be provided between the insulating member and the inductor coil.

[0016] The above configuration provides a device with improved insulation. The particular sequence of the air gap and insulating member provides improved insulation from the heated susceptor. The air gap helps to insulate the insulating member from heat, and the air gap and insulating member together help to insulate other components of the device from heat. For example, the air gap and insulating member reduce any heating of the inductor coil, electronics, and / or battery by the susceptor.

[0017] As mentioned above, the insulating member is spaced from the receptor / susceptor to provide a gap. For example, the inner surface of the insulating member is spaced from the outer surface of the susceptor. This means that the gap surrounds the outer surface of the susceptor and the susceptor is not in contact with the insulating member in this area. Any contact may result in a thermal bridge through which heat can flow. In some examples, the end of the susceptor may be directly or indirectly connected to the insulating member. This contact may be far enough away from the main heating area of ​​the susceptor so as not to excessively reduce the insulating properties provided by the gap and the insulating member. Alternatively or additionally, this contact may be over a relatively small area so that any heat transfer from the susceptor to the insulating member by conduction is small.

[0018] In certain configurations, the susceptor is elongated and defines an axis, such as a longitudinal axis. The insulating member extends around the susceptor and the axis in an azimuthal direction. Thus, the insulating member is disposed radially outward from the susceptor, e.g., the insulating member may be coaxial with the susceptor. This radial direction is defined as being perpendicular to the axis of the susceptor. Similarly, the inductor coil extends around the insulating member and is disposed radially outward from both the susceptor and the insulating member, and the inductor coil may be coaxial with the insulating member and the susceptor.

[0019] The susceptor may be hollow and / or substantially tubular such that the aerosol-generating material can be received within the susceptor such that the susceptor surrounds the aerosol-generating material. The insulating member may be hollow and / or substantially tubular such that the susceptor can be disposed within the insulating member.

[0020] The inductor coil may be substantially helical, for example, the inductor coil may be formed from a wire, such as a Litz wire, wound in a helical shape around an insulating member.

[0021] The inductor coil may be positioned from the outer surface of the susceptor by a distance of about 3 mm to about 4 mm. Thus, the inner surface of the inductor coil and the outer surface of the susceptor may be separated by this distance. This distance may be a radial distance. A distance within this range has been found to represent a good balance between the susceptor being radially close to the inductor coil to allow efficient heating of the susceptor, yet being radially far away for improved insulation of the inductor coil and insulating members.

[0022] In another example, the inductor coil may be positioned away from the outer surface of the susceptor by a distance greater than about 2.5 mm.

[0023] In another example, the inductor coil may be positioned from the outer surface of the susceptor by a distance of about 3 mm to about 3.5 mm. In a further example, the inductor coil may be positioned from the outer surface of the susceptor by a distance of about 3 mm to about 3.25 mm, such as preferably about 3.25 mm. In another example, the inductor coil may be positioned from the outer surface of the susceptor by a distance of more than about 3.2 mm. In a further example, the inductor coil may be positioned from the outer surface of the susceptor by a distance of less than about 3.5 mm, or less than about 3.3 mm. These distances have been found to provide a balance between the susceptor being radially close to the inductor coil to allow efficient heating, and being radially farther apart for improved insulation of the inductor coil and insulating members.

[0024] In an alternative example, the inductor coil may be positioned away from the outer surface of the susceptor by a distance between about 2 mm and about 10 mm.

[0025] Reference to an "outer surface" of an entity means the surface disposed furthest from the axis of the susceptor in a direction perpendicular to the axis. Similarly, reference to an "inner surface" of an entity means the surface disposed closest to the axis of the susceptor in a direction perpendicular to the axis.

[0026] The insulating member may have a thickness of about 0.25 mm to about 1 mm. For example, the insulating member can have a thickness of less than about 0.7 mm, or less than about 0.6 mm, or can have a thickness of about 0.25 mm to about 0.75 mm, or preferably has a thickness of about 0.4 mm to about 0.6 mm, such as about 0.5 mm. These thicknesses have been found to represent a good balance between reducing heating of the insulating member and inductor coil (by making the insulating member thinner to increase the air gap size) and increasing robustness of the insulating member (by making it thicker).

[0027] The susceptor may have a thickness of about 0.025 mm to about 0.5 mm, or about 0.025 mm to about 0.25 mm, or about 0.03 mm to about 0.1 mm, or about 0.04 mm to about 0.06 mm. For example, the susceptor may have a thickness of more than about 0.025 mm, or more than about 0.03 mm, or more than about 0.04 mm, or less than about 0.5 mm, or less than about 0.25 mm, or less than about 0.1 mm, or less than about 0.06 mm. These thicknesses have been found to provide a good balance between allowing the susceptor to heat up quickly (by being thinner) and ensuring robustness of the susceptor (by being thicker).

[0028] In one example, the susceptor has a thickness of about 0.05 mm. This provides a balance between fast and effective heating and robustness. Such a susceptor may be easier to manufacture and assemble as part of an aerosol delivery device than other susceptors with thinner dimensions.

[0029] Reference to the "thickness" of an entity means the average distance between the inner surface of the entity and the outer surface of the entity. The thickness may be measured in a direction perpendicular to the axis of the susceptor.

[0030] In a particular configuration of the aerosol delivery device, the inductor coil is positioned from an outer surface of the susceptor by a distance of about 3 mm to about 4 mm, the insulating member has a thickness of about 0.25 mm to about 1 mm, and the susceptor has a thickness of about 0.025 mm to about 0.5 mm. Such an aerosol delivery device allows for rapid heating and effective insulating properties of the susceptor.

[0031] In another particular configuration, the inductor coil can be positioned from an outer surface of the susceptor by a distance of about 3 mm to about 3.5 mm, the insulating member has a thickness of about 0.25 mm to about 0.75 mm, and the susceptor has a thickness of about 0.04 mm to about 0.06 mm. Such an aerosol delivery device allows for improved heating and improved insulating properties of the susceptor.

[0032] In a further specific configuration, the inductor coil is positioned from an outer surface of the susceptor by a distance of about 3.25 mm, the insulating member has a thickness of about 0.5 mm, and the susceptor has a thickness of about 0.05 mm. Such an aerosol delivery device allows for efficient heating and good insulating properties of the susceptor.

[0033] The inductor coil, susceptor, and insulating member may be coaxial. This configuration ensures that the susceptor is heated effectively, and that the air gap and insulating member provide effective insulation.

[0034] The inner surface of the inductor coil may contact the outer surface of the insulating member. In this way, the insulating member can support the inductor coil without the need for other components. However, in other examples, there may be an additional gap between the inner surface of the inductor coil and the outer surface of the insulating member. The distance between the inner surface of the inductor coil and the outer surface of the insulating member may be less than about 0.1 mm, for example about 0.05 mm.

[0035] As mentioned above, in a second aspect of the present disclosure, an aerosol delivery system is provided comprising an aerosol delivery device as described above and an article comprising an aerosol-generating material. The article may be dimensioned to be received within a susceptor of the aerosol delivery device such that an outer surface of the article contacts an inner surface of the susceptor. Thus, the article may be dimensioned to abut against an inner surface of the susceptor.

[0036] A third aspect of the present disclosure defines a particular configuration of a susceptor, an insulating member, one or more inductor coils, and an outer cover. In the third aspect, the device includes an outer cover forming at least a portion of an outer surface of the device. An inner surface of the outer cover is spaced from the outer surface of the susceptor by a distance of about 4 mm to about 10 mm.

[0037] This distance is the distance at the closest point between the outer surface of the susceptor and the inner surface of the outer cover. Thus, this distance may be the minimum distance between the outer surface of the susceptor and the inner surface of the outer cover. In one example, this distance may be measured between the susceptor and the side of the device.

[0038] It has been found that when the outer cover is positioned this distance away from the susceptor, the outer cover is sufficiently insulated from the heated susceptor to avoid discomfort or injury to the user while reducing the size and weight of the device, and thus a distance within this range represents a good balance between insulating properties and device dimensions.

[0039] The outer cover, which may also be known as the outer casing, may completely surround the device or may extend partially around the device.

[0040] In one example, the inner surface of the outer cover is spaced from the outer surface of the susceptor by a distance of about 4 mm to about 6 mm. In another example, the inner surface of the outer cover is spaced from the outer surface of the susceptor by a distance of about 5 mm to about 6 mm. Preferably, the inner surface of the outer cover is spaced from the outer surface of the susceptor by a distance of about 5 mm to about 5.5 mm, such as about 5.3 mm to about 5.4 mm. Spacing within this distance range provides better insulation while also ensuring that the device remains small and lightweight. In a particular example, the spacing is 5.3 mm.

[0041] In some examples, during use, the inductor coil is configured to heat the susceptor to a temperature of about 200° C. to about 300° C., or about 250° C. to about 280° C., such as about 240° C. to about 300° C. When the outer cover is spaced at least this distance from the susceptor, the temperature of the outer cover is maintained at a safe level, such as less than about 60° C., less than about 50° C., less than about 48° C., or less than about 43° C.

[0042] In an alternative configuration, the inner surface of the outer cover may be spaced from the outer surface of the susceptor by a distance between about 2 mm and about 10 mm.

[0043] In some examples, an air gap is formed between the inductor coil and the outer cover, the air gap providing insulation.

[0044] As explained above, the insulating member may have a thickness of about 0.25 mm to about 1 mm. The insulating member (and any gap between the susceptor and the insulating member) helps to insulate the outer cover from the heated susceptor.

[0045] The insulating member may be constructed from any insulating material, such as, for example, plastic. In a particular example, the insulating member is constructed from polyetheretherketone (PEEK), which has good insulating properties and is well suited for use in aerosol delivery devices.

[0046] In another example, the insulating member may include mica or mica glass ceramic, as these materials have good insulating properties.

[0047] The insulating member may have a thermal conductivity of less than about 0.5 W / mK, or less than about 0.4 W / mK. For example, the thermal conductivity may be about 0.3 W / mK. PEEK has a thermal conductivity of about 0.32 W / mK.

[0048] The insulating member may have a melting point above about 320° C., or above about 340° C., such as above about 300° C. PEEK has a melting point of 343° C. An insulating member with such a melting point ensures that the insulating member remains rigid / solid when the susceptor is heated.

[0049] The inner surface of the outer cover may be spaced from the outer surface of the insulating member by a distance of about 2 mm to about 3 mm. A separation distance of this size has been found to provide sufficient insulation to ensure that the outer cover does not become too hot. Air may be disposed between the outside of the insulating member and the outer cover.

[0050] More specifically, the inner surface of the outer cover may be spaced from the outer surface of the insulating member by a distance of about 2 mm to about 2.5 mm, such as about 2.3 mm. Such dimensions provide a good balance between providing insulation and reducing the size of the device.

[0051] The inner surface of the outer cover may be spaced from the outer surface of the inductor coil by a distance of about 0.2 mm to about 1 mm. In some examples, when the inductor coil is used to induce a magnetic field, the inductor coil itself may heat up, for example, from resistive heating due to current flowing through the inductor coil inducing a magnetic field. Providing a space between the inductor coil and the outer cover ensures that the heated inductor coil is insulated from the outer cover. In some examples, a ferrite shield is disposed between the inner surface of the outer cover and the inductor coil. The ferrite shield further helps insulate the inner surface of the outer cover. It has been found that when the ferrite shield is in contact with the one or more inductor coils and at least partially surrounds the one or more coils, the surface temperature of the outer cover can be reduced by about 3°C.

[0052] In one example, the inductor coil comprises a Litz wire having a circular cross-section, hi such examples, the inner surface of the outer cover is spaced from the outer surface of the inductor coil by a distance between about 0.2 mm and about 0.5 mm, or between about 0.2 mm and about 0.3 mm, such as about 0.25 mm.

[0053] In one example, the inductor coil comprises a Litz wire having a rectangular cross-section. In such an example, the inner surface of the outer cover is spaced from the outer surface of the inductor coil by a distance of about 0.5 mm to about 1 mm, or about 0.8 mm to about 1 mm, such as about 0.9 mm. A Litz wire having a circular cross-section can be positioned closer to the outer cover than a Litz wire having a rectangular cross-section because the circular cross-section wire has less surface area exposed toward the outer cover.

[0054] As mentioned above, the inner surface of the inductor coil may be spaced from the outer surface of the susceptor by a distance of about 3 mm to about 4 mm.

[0055] The outer cover may comprise aluminum, which has good heat dissipation properties.

[0056] The outer cover may have a thermal conductivity of about 200 W / mK to about 220 W / mK. For example, aluminum has a thermal conductivity of about 209 W / mK. In this manner, the outer cover may have a relatively high thermal conductivity to ensure that heat is dispersed throughout the outer cover and lost to the atmosphere, thereby cooling the device.

[0057] The outer cover may have a thickness of about 0.75 mm to about 2 mm. Thus, the outer cover can act as an insulating barrier. These thicknesses provide a good balance between providing good insulation and reducing the size and weight of the device. Preferably, the outer cover has a thickness of about 1 mm to about 1.75 mm, such as about 1.25 mm to about 1.75 mm. Even more preferably, the outer cover has a thickness of about 1.4 mm to about 1.6 mm, such as about 1.5 mm. This particular thickness has been found to reduce the outer surface temperature of the outer cover.

[0058] In alternative examples, the thickness is from about 0.75 mm to about 1.25 mm, such as about 1 mm.

[0059] In any of the above aspects, the aerosol delivery device may additionally or alternatively include at least one insulating layer disposed within the device, the insulating layer further insulating the outer cover from the susceptor, the device including at least the susceptor and at least one inductor coil.

[0060] The insulating layer may be disposed in any or all of the following locations: (i) between the susceptor and the insulating member, (ii) between the insulating member and the inductor coil, (iii) between the inductor coil and the outer cover. In (ii), the insulating member may have a smaller outer diameter to accommodate the insulating layer. Additionally or alternatively, the inductor coil may have a larger inner diameter to accommodate the insulating layer. The insulating layer may comprise multiple layers of material.

[0061] The insulating layer may be provided by any of the following materials: (i) air (having a thermal conductivity of about 0.02 W / mK); (ii) AeroZero® (having a thermal conductivity of about 0.03 W / mK to about 0.04 W / m); (iii) polyetheretherketone (PEEK) (which may in some instances have a thermal conductivity of about 0.25 W / mK); (iv) ceramic cloth (having a specific heat of about 1.13 kJ / kgK); and (v) thermally conductive putty.

[0062] Preferably, the device is a tobacco heating device, also known as a non-combustion heating device.

[0063] 1 shows an example of an aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. In general, device 100 can be used to heat a replaceable article 110 that contains an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0064] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it is heated by one or more components of the heater assembly.

[0065] The device 100 of this example includes a first end member 106 with a lid 108 movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. In Figure 1, the lid 108 is shown in an open configuration, but the cap 108 may be moved to a closed configuration. For example, a user may slide the lid 108 in the direction of arrow "A."

[0066] The device 100 may include a user-operable control element 112, such as a button or switch, that when pressed activates the device 100. For example, a user may turn on the device 100 by operating the switch 112.

[0067] Device 100 may include an electrical component, such as a socket / port 114, that can receive a cable for charging a battery of device 100. For example, socket 114 may be a charging port, such as a USB charging port. In some examples, socket 114 may additionally or alternatively be used to transfer data between device 100 and another device, such as a computing device.

[0068] 2 depicts the device 100 of FIG. 1 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134.

[0069] 2, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first end member 106 and the second end member 116 together at least partially define an end surface of the device 100. For example, a bottom surface of the second end member 116 at least partially defines a bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of a top surface of the device 100.

[0070] The end of the device closest to the opening 104 is sometimes referred to as the proximal end (or mouth end) of the device 100, as it is closest to the user's mouth during use. In use, a user inserts an article 110 into the opening 104, operates a user control 112 to initiate heating of the aerosol-generating material, and inhales the aerosol generated by the device, which causes the aerosol to flow through the device 100 along a flow path toward the proximal end of the device 100.

[0071] The other end of the device, furthest from opening 104, is sometimes referred to as the distal end of device 100, as it is the end furthest from a user's mouth in use. As a user inhales the aerosol generated by the device, the aerosol flows out of the distal end of device 100.

[0072] The device 100 further comprises a power source 118. The power source 118 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power to heat the aerosol-generating material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

[0073] The device further comprises at least one electronic module 122. The electronic module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may comprise one or more electrical traces for electrically connecting various electronic components of the device 100. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via electrical traces.

[0074] In the exemplary device 100, the heating assembly is an induction heating assembly, which includes various components for heating the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element, for example one or more induction coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. This varying magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore the susceptor is heated by Joule heating due to the eddy currents flowing against this resistance. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., the orientation of the magnetic dipoles of the magnetic material changes as a result of alignment with the varying magnetic field. Compared to heating by thermal conduction, for example, induction heating allows for rapid heating since heat is generated inside the susceptor, and furthermore, no physical contact is required between the induction heater and the susceptor, allowing greater flexibility in manufacturing and application.

[0075] The induction heating assembly of the exemplary device 100 includes a susceptor device 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are made from a conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made from a Litz wire / cable that is wound in a helical shape to form the helical inductor coils 124, 126. The Litz wire is composed of multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect losses of the conductor. In the exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are made from copper Litz wire with a rectangular cross-section. In other examples, the Litz wire may have other shaped cross-sections, such as circular.

[0076] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first portion of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second portion of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along a longitudinal axis 134 of the device 100 (i.e., the first inductor coil 124 and the second inductor coil 126 do not overlap). The susceptor device 132 may include a single susceptor or may include two or more separate susceptors. Each end 130 of the first inductor coil 124 and the second inductor coil 126 may be connected to the PCB 122.

[0077] It should be understood that the first inductor coil 124 and the second inductor coil 126 may have at least one different characteristic in some examples. For example, the first inductor coil 124 may have at least one different characteristic than the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different value of inductance than the second inductor coil 126. In FIG. 2, the first inductor coil 124 and the second inductor coil 126 are of different lengths such that the first inductor coil 124 is wound over a smaller portion of the susceptor 132 compared to the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0078] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when each inductor coil is energized at a different time. For example, the first inductor coil 124 may be operated to heat a first portion of the article 110 first, and the second inductor coil 126 may be operated to heat a second portion of the article 110 at a later time. Winding each coil in opposite directions helps reduce the current induced in the non-energized coil when used in combination with certain types of control circuits. In FIG. 2, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124, 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0079] The susceptor 132 in this example is hollow and thus defines a receptacle in which the aerosol-generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 132 is tubular with a circular cross-section.

[0080] 2 further includes an insulating member 128, which may be generally tubular and may at least partially surround the susceptor 132. The insulating member 128 may be made from any insulating material, such as, for example, plastic. In this particular example, the insulating member is made from polyetheretherketone (PEEK). The insulating member 128 may help insulate various components of the device 100 from heat generated by the susceptor 132.

[0081] The insulating member 128 may also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 2, the first inductor coil 124 and the second inductor coil 126 are disposed around the insulating member 128 and contact a radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, a small gap may exist between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

[0082] In a particular example, the susceptor 132 , the insulating member 128 , and the first and second inductor coils 124 and 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0083] 3 is a partial cross-sectional side view of device 100. In this example, outer cover 102 is present. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 can be seen more clearly.

[0084] The device 100 further comprises a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0085] The device may also include a second printed circuit board 138 that resides within the control element 112 .

[0086] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward a distal end of the device 100. The spring 142 allows the second lid 140 to be opened to access the susceptor 132. A user may open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0087] The device 100 further includes an expansion chamber 144 that extends away from the proximal end of the susceptor 132 toward the opening 104 of the device. A retaining clip 146 is positioned at least partially within the expansion chamber 144 to abut and retain the article 110 when the article 110 is received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0088] FIG. 4 is an exploded view of the device 100 of FIG. 1 without the outer cover 102.

[0089] FIG 5A illustrates a cross-section of a portion of the device 100 of FIG 1. FIG 5B illustrates a close-up of a region of FIG 5A. FIGs 5A and 5B show the article 110 received in a receptacle provided by the susceptor 132, with the article 110 sized so that an outer surface of the article 110 abuts an inner surface of the susceptor 132. This ensures that heating is most efficient. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also include other components, such as a filter, packaging material, and / or cooling structure.

[0090] FIG. 5B illustrates a longitudinal axis 158 of a hollow, tubular susceptor 132. The inner and outer surfaces of the susceptor 132 extend azimuthally about the axis 158. Surrounding the susceptor 132 may be a hollow, tubular insulating member 128. The inner surface of the insulating member 128 is spaced from the outer surface of the susceptor 132 to provide a gap between the insulating member 128 and the susceptor 132. This gap provides insulation from heat generated in the susceptor 132. Surrounding the insulating member 128 are inductor coils 124, 126. It will be appreciated that in some instances, only one inductor coil may surround the insulating member 128. The inductor coils 124, 126 are spirally wound around the insulating member and extend along the axis 158.

[0091] 5B shows that the outer surface of the susceptor 132 is separated from the inner surfaces of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In a specific example, the distance 150 is about 3.25 mm. The outer surface of the susceptor 132 is the surface furthest from the axis 158. The inner surface of the susceptor 132 is the surface closest to the axis 158. The inner surfaces of the inductor coils 124, 126 are the surfaces closest to the axis 158. The outer surface of the insulating member 128 is the surface furthest from the axis 158.

[0092] The insulating member 128 may be formed with specific dimensions to provide relative spacing between the susceptor 132 and the inductor coils 124, 126. The insulating member 128 and susceptor 132 may be held in place by one or more components of the device 100. In the example of Figure 5A, the insulating member 128 and susceptor 132 are held in place at one end by the support 136 and at the other end by the expansion chamber 144. In other examples, different components may hold the insulating member 128 and susceptor 132.

[0093] 5B further illustrates that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm such that the inductor coils 124, 126 abut and contact the insulating member 128.

[0094] In this example, the susceptor 132 has a thickness 154 of about 0.05 mm. The thickness of the susceptor 132 is the average distance between the inner surface of the susceptor 132 and the outer surface of the susceptor 132, measured in a direction perpendicular to the axis 158.

[0095] In one example, the susceptor 132 has a length of about 40 mm to about 50 mm, or about 40 mm to about 45 mm. In this particular example, the susceptor 132 has a length of about 44.5 mm and is capable of receiving an article 110 having an aerosol-generating material 110a having a length of about 42 mm. The lengths of the aerosol-generating material and the susceptor 132 are measured in a direction parallel to the axis 158.

[0096] In one example, the insulating member 128 has a thickness 156 of about 0.25 mm to about 2 mm, or about 0.25 mm to about 1 mm. In this particular example, the insulating member has a thickness 156 of about 0.5 mm. The thickness 156 of the insulating member 128 is the average distance between the inner surface of the insulating member 128 and the outer surface of the insulating member 128, measured in a direction perpendicular to the axis 158.

[0097] Figure 6 is a cross-sectional diagram of the susceptor 132 and insulating member 128 shown in Figures 5A and 5B. However, in this example, the two inductor coils have been replaced with a single inductor coil 224 for clarity. The inductor coil 224 may be replaced with two or more inductor coils.

[0098] The inductor coil 224 is wrapped around the insulating member 128 and is in contact with the outer surface 128b of the insulating member 128. In another example, they may not be in contact. Thus, the inner surface 224a of the inductor coil is spaced from the outer surface 132b of the susceptor 132 by a distance 150. In this example, the wire forming the inductor coil 224 has a circular cross-section, although other cross-section shapes may be used. The dimensions shown in FIG. 6 are not drawn to scale.

[0099] FIG. 6 more clearly illustrates the thickness 154 of the susceptor 132 as the distance between the inner and outer surfaces 132a, 132b of the susceptor 132, and the thickness 156 of the insulating member 128 as the distance between the inner and outer surfaces 128a, 128b of the insulating member 128.

[0100] 6 also shows the gap 202 having a width 204. The width 204 of the gap 202 is the distance between the outer surface 132b of the susceptor 132 and the inner surface 128a of the insulating member.

[0101] 6 also shows a cross section of a portion of the outer cover 102. The outer cover 102 may continue to extend further above and below the insulating member 128. The outer cover 102 provides protection to the internal components of the device and typically comes into contact with a user's hands during use of the device. The illustrated portion of the outer cover 102 is the portion that is positioned closest to the susceptor 132.

[0102] The outer cover 102 includes an inner surface 102a and an outer surface 102b. The inner surface 102a is disposed farther from the susceptor 132 than the outer surface 102b. To ensure that the device 100 is not too hot to touch, a gap 208 may be provided between the inner surface 102a of the outer cover 102 and the outer surface 128b of the insulating member 128. In this example, the inner surface 128a of the outer cover 102 is disposed away from the outer surface 132b of the susceptor 132 by a distance 160 of about 4 mm to about 10 mm. In this particular example, the distance 160 is about 5.3 mm.

[0103] The outer cover 102 has a thickness 162 of about 0.75 mm to about 2 mm. In this example, the outer cover 102 has a thickness 162 of about 1 mm and is made from 6063 aluminum. The thickness 162 is the distance between the outer surface 102b and the inner surface 102a measured in a direction perpendicular to the axis 158.

[0104] The inner surface 102a of the outer cover 102 is spaced from the outer surface 128b of the insulating member 128 by a distance 164 of about 2 mm to about 3 mm. In this example, the inner surface 102a of the outer cover 102 is spaced from the outer surface 128b of the insulating member 128 by a distance 164 of about 2.3 mm.

[0105] The inner surface 102a of the outer cover 102 may be spaced from the outer surface 224b of the inductor coil 224 by a distance 166 of about 0.2 mm to about 1 mm. In this example, the inductor coil comprises Litz wire having a circular cross-section. In such an example, the distance 166 is about 0.2 mm to about 0.5 mm, such as about 0.25 mm. In examples where the cross-section is rectangular (such as the examples of FIGS. 5A and 5B), the distance may be greater, and may be about 0.5 mm to about 1 mm, such as about 0.9 mm.

[0106] 7 is a perspective view of a tubular susceptor 132 disposed within and surrounded by an insulating member 128. Both the susceptor 132 and the insulating member 128 have circular cross-sections, although the cross-sections may have any other shape and may be different from one another in some instances. A user may introduce the item 110 into the susceptor 132 by inserting the item 110 in the direction of arrow 206.

[0107] The above embodiments should be understood as illustrative of the invention. Further embodiments of the invention are envisioned. It should be understood that any feature described with respect to any one embodiment may be used alone or together with other features described, and may also be used together with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Moreover, equivalents and modifications not described above may also be used without departing from the scope of the invention, which is defined in the appended claims.

Claims

1. a receptacle configured to receive an aerosol-generating material; a tubular member extending around the receptacle; an inductor coil configured to heat a susceptor that is heatable by penetration of a varying magnetic field; wherein the inductor coil extends around the tubular member such that a gap is provided between the inductor coil and a housing and such that the tubular member is positioned between the inductor coil and the receptacle, and the inductor coil is configured to generate the varying magnetic field.

2. An aerosol delivery device as described in claim 1, wherein the inner surface of the housing is positioned away from the outer surface of the inductor coil.

3. An aerosol delivery device as described in claim 1, wherein a gap is provided between the inductor coil and the housing.

4. An aerosol delivery device as described in claim 1, wherein a ferrite shield is disposed between the inner surface of the housing and the inductor coil.

5. An aerosol delivery device as described in claim 1, wherein a gap is provided between the inner surface of the housing and the outer surface of the tubular member.

6. An aerosol delivery device as described in claim 1, wherein the housing surrounds the tubular member, the receptacle, the inductor coil, and the susceptor.

7. 10. The aerosol delivery device of claim 1, wherein the susceptor is hollow, the tubular member is hollow, and the inductor coil is substantially helical.

8. The aerosol delivery device of claim 7 , wherein the susceptor is substantially tubular.

9. 10. The aerosol delivery device of claim 1, wherein the inductor coil is spaced from the exterior surface of the receptacle by a distance of about 3 mm to about 4 mm.

10. 10. The aerosol delivery device of claim 1, wherein the inductor coil is positioned from an outer surface of the receptacle by a distance greater than about 2.5 mm.

11. 10. The aerosol delivery device of claim 9, wherein the inductor coil is spaced from the exterior surface of the receptacle by a distance less than about 3.5 mm.

12. 10. The aerosol delivery device of claim 1, wherein the tubular member has a thickness of about 0.25 mm to about 1 mm.

13. 10. The aerosol delivery device of claim 1, wherein the tubular member has a thickness of less than about 0.7 mm.

14. 10. The aerosol delivery device of claim 1, wherein the receptacle has a thickness of about 0.025 mm to about 0.5 mm.

15. 10. The aerosol delivery device of claim 1, wherein the receptacle has a thickness of less than about 0.25 mm.

16. 10. The aerosol delivery device of claim 1, wherein the receptacle has a thickness greater than 0.025 mm.

17. the inductor coil is spaced from an outer surface of the receptacle by a distance of about 3 mm to about 4 mm; the tubular member has a thickness of about 0.25 mm to about 1 mm; 10. The aerosol delivery device of claim 1, wherein the receptacle has a thickness of about 0.025 mm to about 0.5 mm.

18. The aerosol delivery device of claim 1 , wherein the inductor coil, the receptacle, and the tubular member are coaxial.

19. The aerosol delivery device of claim 1 , wherein the inner surface of the inductor coil contacts the outer surface of the tubular member.

20. The aerosol delivery device of claim 1; an article comprising an aerosol-forming material, the article being sized to be at least partially received within the receptacle; and An aerosol delivery system comprising:

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