Aerosol generation system

Abstract

To provide a non-combustible aerosol provision device for heating aerosol-generating material to volatise at least one component of the aerosol-generating material.SOLUTION: There is provided a non-combustible aerosol provision device. The device comprises: a first heating element 210 for defining at least partially a heating zone for receiving at least one part of a consumable including an aerosol generating material. The device has a second heating element 212 extending from an end in an axial direction of the first heating element beyond the heating zone. The device also has a thermal insulator 202 including: an inner wall 204; an outer wall 206; and a heat insulation region 208 bound by the inner wall and the outer wall, the heat insulation region being evacuated to a lower pressure lower than an exterior of the heat insulation region. The thermal insulator is arranged to extend around at least part of the first heating element and at least part of the second heating element.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device, a method for generating an aerosol using the aerosol delivery device, and an aerosol generation system comprising the aerosol delivery device.

[0002] Smoking articles, such as cigarettes and cigars, 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 a material rather than burning it. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Overview

[0003] According to a first aspect of the present disclosure, there is provided a non-combustion aerosol delivery device for heating an aerosol generating material to volatilize at least one component of the aerosol generating material, the device comprising: a first heating element at least partially defining a heating zone for receiving at least a portion of a consumable including the aerosol generating material; a second heating element extending from an axial end of the first heating element beyond the heating zone; and an insulation comprising an inner wall, an outer wall, and an insulation region surrounded by the inner wall and the outer wall, the insulation region being vented to a pressure lower than that outside the insulation region, the insulation being arranged to extend around at least a portion of the first heating element and at least a portion of the second heating element.

[0004] According to a second aspect of the present disclosure, there is provided a non-combustion aerosol delivery device for heating an aerosol generating material to volatilize at least one component of the aerosol generating material, the device comprising: a first heating element at least partially defining a heating zone for receiving at least a portion of a consumable including the aerosol generating material; a second heating element extending from an axial end of the first heating element beyond the heating zone; and an insulation comprising an inner wall, an outer wall, and an insulation region surrounded by the inner wall and the outer wall, the insulation region being vented to a pressure lower than that outside the insulation region, the inner wall comprising at least a portion of each of the first heating element and the second heating element.

[0005] According to a third aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an apparatus according to the first or second aspect of the present disclosure and an aerosol-generating material that, in use, is at least partially disposed within the heating zone of the first and / or second heating elements. Further characteristics and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, with reference to the accompanying drawings, in which:

[0006] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0007] [Figure 1] 1 is a schematic cross-sectional view of an exemplary aerosol delivery device. [Diagram 2] 2 is a schematic diagram illustrating an exemplary thermal insulation construction for use in the device of FIG. 1 along with other components of the device of FIG. 1. [Diagram 3] 3 is a cross-sectional view of the exemplary thermal insulation construction taken along line AA in FIG. 2, shown with another component of the device in FIG. 1. [Figure 4] FIG. 4 is a more detailed schematic diagram of region B shown in FIG. 3. [Diagram 5]FIG. 2 is a schematic diagram illustrating another exemplary thermal insulation construction for use in the device of FIG. 1 along with other components of the device. [Figure 6] 6 is a cross-sectional view of the exemplary thermal insulation construction along line CC of FIG. 5 along with other components of the device. [Figure 7] FIG. 7 is a more detailed schematic diagram of area D displayed in FIG. 6. Detailed Description

[0008] As used herein, the term "aerosol-forming material" includes materials that, when heated, 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 product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, or wax. Aerosol-forming materials may also be, for example, a combination or mixture of materials. Aerosol-forming materials may also be referred to as "smoking materials."

[0009] Devices are known that use an aerosol generator to generate an aerosol from an aerosol-generating material. One particularly common way to generate an aerosol is by heating the aerosol-generating material. In such devices, the aerosol generator is a heater that heats the aerosol-generating material to volatilize at least one component of the aerosol-generating material, typically forming an inhalable aerosol without burning or combusting the aerosol-generating material. Such devices are sometimes described as "aerosol delivery devices," "non-combustion heated 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 that may or may not contain nicotine. The aerosol-generating material may be in the form of, or formed as part of, a rod, cartridge, or cassette that can be inserted into the device. The aerosol generator for volatilizing the aerosol-generating material may be provided as a "permanent" part of the device, or may be combined with the aerosol-generating substance in a replaceable or consumable component. While this disclosure focuses on aerosol generators that are heaters, it should be understood that alternative methods of generating aerosols from aerosol-generating materials may also be used.

[0010] The aerosol delivery device can receive and heat an article that includes an aerosol-generating material. An "article" in this context refers to a component that, when in use, includes or contains an aerosol-generating material that is heated to volatilize the aerosol-generating material, and optionally other components. A user can insert an article into the aerosol delivery device before the article is heated and heated to generate an aerosol, which is then inhaled by the user. The article can be, for example, of a predetermined or specific size that is configured to fit into the heating chamber of the device that is dimensioned to receive the article. Alternatively, the aerosol-generating material can simply be placed freely or without constraint into the heating chamber of the device; for example, unbound tobacco can be used in this manner.

[0011] Induction heating is a process in which an electrically conductive object is heated by penetrating a varying magnetic field through the object. This process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another so that the varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, they flow against the electrical resistance of the object, causing the object to heat up. This process is called Joule heating, Ohmic heating, or resistive heating. Objects that can be inductively heated are known as susceptors.

[0012] Magnetic hysteresis heating is a process whereby an object made of a magnetic material is heated by subjecting the object to a varying magnetic field. A magnetic material can be thought of as containing many atomic-scale magnets, i.e., magnetic dipoles. When a magnetic field is applied to such a material, the magnetic dipoles align with the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field produced by an electromagnet, is applied to a magnetic material, the orientation of the magnetic dipoles changes with the applied varying magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0013] If an object is both conductive and magnetic, then the penetration of a varying magnetic field into the object can result in both Joule heating and magnetic hysteresis heating in the object. Furthermore, the magnetic field can be strengthened using magnetic materials, which can enhance Joule heating and magnetic hysteresis heating.

[0014] In each of the above processes, because heat is generated within the object itself, rather than by thermal conduction from an external heat source, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selecting the appropriate object material and geometry, and the appropriate magnitude and orientation of the varying magnetic field relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical coupling between the source of the varying magnetic field and the object, which may allow greater design freedom and control over the heating profile, and may be less costly.

[0015] To facilitate the formation of aerosol during use, aerosol-generating materials for aerosol delivery devices (e.g. tobacco heating products) typically contain more water and / or aerosol-generating agents than aerosol-generating materials in combustion smoking articles. This high content of water and / or aerosol-generating agents may increase the risk of condensation collecting within the aerosol delivery device during use, particularly at locations away from the heating unit(s). It has been found that the formation of condensation can be exacerbated by relatively rapid heating, such as that achieved by induction heating systems.

[0016] This problem may be even greater in devices with a sealed heating chamber. In such devices, the heating chamber may be fluidly connected to the outside of the device by a conduit (e.g., an inlet or outlet conduit). Since the conduit tends to be at a significantly lower temperature than the heating chamber to which it is connected, there is a particular risk of condensation collecting in such conduits. Such collected condensation may possibly leak out of the device, resulting in a less pleasant user experience. Additionally or alternatively, such condensation may dry out over time and form gum on the inner surface of the conduit. This gum may be difficult to remove and may therefore become clumpy over time. Furthermore, in cases where aerosol-generating materials are contained in the consumable, the gum may adhere to the consumable, discoloring it or preventing its removal after use.

[0017] Thus, the aerosol delivery device may be configured such that the inner surface of a given conduit is heated during use, thereby limiting, and in some cases substantially preventing, the build-up of condensed water within the conduit in question. In particular, the build-up of condensed water on the inner surface of the conduit may be reduced.

[0018] In aerosol delivery devices, insulation is typically provided around the heating chamber to protect the user and the electronic components of the device from the heat generated. It should be appreciated that if the conduit of the aerosol delivery device is also heated, insulation of the conduit components is also beneficial. The present disclosure provides for providing such insulation effectively and efficiently in situations where the heating chamber is also insulated.

[0019] FIG. 1 shows a schematic cross-sectional view of an aerosol delivery device 100 according to one example of the present invention. FIG. 2 and FIG. 3 show schematic diagrams of an exemplary insulation 102 for use in the aerosol delivery device 100. The insulation 102 is shown in FIG. 1 in a simplified form for clarity. The insulation 102 of the aerosol delivery device 100 is configured to receive an aerosol-generating material (not shown) to be heated in that it comprises a heating chamber or zone 144. The aerosol-generating material, which may also be supplied in a consumable article or "consumable", is insertable into an opening of the heating chamber 144 of the aerosol delivery device 100. The aerosol delivery device 100 includes a magnetic field generator 106 for generating a varying magnetic field in use, and a housing 108 for housing each of the components of the aerosol delivery device 100.

[0020] In this example, the magnetic field generator 106 comprises a power source 114 and a device 118 for passing a varying current, such as an alternating current, through the coils. In the example shown in Figure 1, the coils are two-part coils 116a, 116b. In some examples, such as that shown in Figure 1, the magnetic field generator 106 is further connected to a controller 120 and a user interface 122 for a user to operate the controller 120.

[0021] The power source 114 may be a rechargeable battery (such as a lithium ion battery), a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power source.

[0022] The coils 116a, 116b may take any suitable form, including a single coil having two parts, with a single part coil being an alternative. In the example shown in FIG. 1, the two-part coils 116a, 116b are helical coils made of a conductive material such as copper. In some examples, the coils 116a, 116b may be flat coils; that is, the coils may be pseudo-two-dimensional helices. In some examples, the coils may comprise Litz wire.

[0023] Aerosol delivery device 100 includes an inlet conduit 130 that fluidly connects the interior of the apparatus with the exterior of housing 108 of aerosol delivery device 100 so that air can be drawn into device 100. In use, a user can inhale the volatile component(s) of the aerosol-generating material by sucking on a consumable containing the aerosol-generating material. Air is drawn into aerosol delivery device 100 via inlet conduit 130 as the volatile component(s) are removed from the aerosol-generating material.

[0024] The insulation 102 is shown in more detail in Figures 2-7. The exemplary insulation 102 shown in Figures 1-7 comprises an outer wall, an inner wall, and an insulation region wrapped with the inner and outer walls, which is vented to a pressure lower than that outside the insulation region. In fact, the pressure outside the insulation region is atmospheric pressure in almost all cases. By providing an insulation region with a pressure lower than atmospheric pressure, the heating chamber / zone 144 is insulated from the outer wall and the housing 108, limiting heat transfer from the heating chamber / zone 144 to the rest of the aerosol delivery device 100 (outside the heating chamber / zone 144). This heat transfer limitation is advantageous because other components of the aerosol delivery device 100, such as the power supply 114, may be susceptible to increased temperatures. For example, it is well known that batteries and other electronic circuits may be damaged or even dangerous if exposed to high temperatures. Furthermore, heat transfer to the housing 108 of the aerosol delivery device 100 may cause discomfort or even injury to the user during use.

[0025] 2 shows an exterior schematic view of insulation 202 and hollow chamber 216 according to a first embodiment of the present disclosure, which are component parts of aerosol delivery device 100. Hollow chamber 216 is discussed in further detail below.

[0026] FIG. 3 shows cross section AA of the insulation 202 shown in FIG. 2. FIGS. 2, 3 and 4 are not drawn to scale. The insulation 202 comprises an inner wall 204 and an outer wall 206. The inner wall 204 and the outer wall 206 surround an insulation region 208, which is evacuated to a lower pressure than the exterior of the insulation region 208. The inner wall 204 and the outer wall 206 may be joined together by any suitable means, for example, by welding, brazing, or may be bonded together with an adhesive. The pressure in the insulation region 208 is about 10 -1 ~10 -7 torr range, and -3 Pressures of less than 1000 torr are believed to be particularly advantageous. In some examples, the pressure in the insulating region 208 may be a vacuum. The inner and outer walls 204, 206 of the insulation 202 are strong enough to withstand any forces acting thereon due to the pressure differential between the insulating region 208 and regions outside the insulating region 208, preventing the insulation 202 from collapsing inward. Gas absorbing materials may be used in the insulating region 208 to maintain or help create a relatively low pressure in the insulating region 208.

[0027] Providing insulation region 208 at subatmospheric pressure is particularly advantageous because it allows for very effective insulation to be achieved in an area that is much smaller in size than might be possible with alternative insulation options. This allows the overall size of aerosol delivery device 100 to be kept to a minimum without compromising the insulation of heating chamber / zone 144.

[0028] The cross-section of the aerosol delivery device 100 shown in FIG. 3 further includes a first heating element 210 and a second heating element 212. The first heating element 210 and the second heating element 212 may be joined by any suitable means, such as by welding, brazing, adhesives, or by an interference fit. Alternatively, they may simply abut each other or be disposed next to each other. In the example shown in FIG. 3, the first heating element 210 defines a heating zone into which an aerosol-generating material (not shown) is inserted during use. The second heating element 212 may, for example, comprise at least a portion of an inlet conduit 130 that fluidly connects a heating chamber defined by the first heating element 210 with the exterior of the device 100. During use, air is drawn into the device 100 and flows along the inlet conduit 130 at least partially defined by the second heating element 212 before flowing into the heating chamber 144 defined by the first heating element 210. As previously discussed, the second heating element 212 warms the inlet conduit 130 to limit the buildup of condensation that may occur within the inlet conduit 130 during use. Although the example shown in Figure 3 illustrates the first heating element 210 as an elongated tubular member and the second heating element 212 as a short tubular member axially disposed at one end of the first heating element 210, it should be understood that the terms "first" and "second" should be considered merely arbitrary labels and do not exclude alternative configurations, relative locations, and relative sizes of such members.

[0029] In Fig. 3, the insulation 202 is shown as extending along the entire length of the first heating element 210. However, in the alternative, the insulation 202 may only extend partially along the length of the first heating element 210. That is, the insulation 202 may only extend along a portion of the first heating element 210 such that insulation may occur only around a portion of the first heating element 210. Providing insulation 202 that extends only partially along the length of the first heating element 210 may allow the overall size of the aerosol delivery device 100 to be further reduced. Although the insulation 202 and the first heating element 210 are shown as being coaxial with one another, this is not required. Each of the statements in this paragraph regarding the first heating element 210 emphasizes that the insulation 102 extends around at least a portion of the first heating element 210 and at least a portion of the second heating element 212 in all cases, but it should be understood that the same may apply to the second heating element 212 as well. By extending around at least a portion of the first heating element 210 and around at least a portion of the second heating element 212, the insulation 202 can reduce unwanted heat transfer to other components of the device 100. This is beneficial because, as discussed above, heat transfer to other areas of the device 100 can cause damage to other components and even injury to the user. The insulation 202 with low pressure areas will be ineffective if damage or fatigue allows outside air to leak into the insulated areas 208, allowing the pressure to rise to normal atmospheric levels. By having a single insulation piece 202 extend continuously between the first heating element 210 and the second heating element 212 around at least a portion of both heating elements, the reliability of the insulation of the aerosol delivery device is improved by reducing the number of components that can fail. Furthermore, it is known to be technically difficult to manufacture insulation 202 that includes exhaust insulation regions 208, and therefore providing a single insulation 202 that reduces heat transfer from both the first heating element 210 and the second heating element 212 reduces the complexity of the manufacturing process.

[0030] In some examples, the insulation 102 extends around at least a portion of the first heating element 210 and the second heating element 212 to surround at least a portion of the first heating element 210 and at least a portion of the second heating element 212. By surrounding at least a portion of the first heating element 210 and / or the second heating element 212, reduction of unwanted heat transfer to other components of the device 100 may be improved.

[0031] In some examples, the first heating element 210 can be heated by penetrating a fluctuating magnetic field. Heating by penetrating a fluctuating magnetic field is advantageous because heat is generated within the object itself, rather than by thermal conduction from an external heat source, and thus a rapid temperature rise and more uniform heat distribution within the object can be achieved. This heating may be further improved by selecting an appropriate object material and geometry, and an appropriate fluctuating magnetic field magnitude and orientation relative to the object. Furthermore, heating by penetrating a fluctuating magnetic field may provide greater design freedom and control over the heating profile of the first heating element 210, and may be less costly, since no physical coupling is required between the source of the fluctuating magnetic field and the object. In one example, the first heating element 210 may be formed of mild steel, which is inexpensive, easy to machine, and susceptor. Suitable mild steel grades are, for example, SPCE steel or 1010 grade steel. In another example, the first heating element 210 may be formed of ferritic stainless steel. Ferritic stainless steels are easy to machine, have good corrosion resistance, and are susceptors. Nickel-cobalt-iron alloys such as Kovar® may also be used as alternatives.

[0032] In some examples, the second heating element 212 is also heatable by the penetration of a fluctuating magnetic field. In examples in which the second heating element 212 is heatable by the penetration of a fluctuating magnetic field, the second heating element 212 may also be formed from mild steel, such as SPCE steel or 1010 grade steel, or ferritic stainless steel. As with the first heating element 210, Kovar® is a suitable alternative material for the second heating element 212.

[0033] In some examples, the first heating element 210 and / or the second heating element 212 are heatable by resistive heating. Resistive heating can be in addition to or an alternative to heating by penetrating a fluctuating magnetic field. In examples where only one of the first heating element 210 or the second heating element 212 is heatable by penetrating a fluctuating magnetic field, the other heating element can be heatable by thermal conduction from the element heatable by penetrating a fluctuating magnetic field or can be resistively heated separately. This example has the advantage that the fluctuating magnetic field applied during heating only needs to be configured to penetrating one of the heating elements, which can reduce the size and / or complexity of the aerosol delivery device. The material requirements of a resistively heated or conductively heated heating element are less restrictive than those of a heating element heatable by penetrating a fluctuating magnetic field. For example, a resistively heatable or conductively heatable heating element may include a metal such as austenitic stainless steel or aluminum. Austenitic stainless steel is cheap, easy to form, and has good corrosion resistance properties, whereas aluminum is light, corrosion resistant, and easy to machine. Austenitic stainless steel and aluminum are not heatable by the penetration of a fluctuating magnetic field. It should be noted that the expression "not heatable by the penetration of a fluctuating magnetic field" should be understood to mean that the heat generated in such a material by the penetration of a fluctuating magnetic field is negligible, if any, when compared to a material that can be easily heated by the penetration of a fluctuating magnetic field, such as mild steel. When considering heating by conduction, in particular when one heating element is heated by contact with or through a connecting thermally conductive component with another heating element (the other heating element is resistively or inductively heated), other materials are also suitable as heating element materials. For example, ceramic or glass materials have good heat conducting properties.

[0034] In instances where the first heating element 210 and / or the second heating element 212 comprise a metallic material, the metal may be coated with a corrosion resistant coating. For example, in instances where mild steel is used, nickel plating may be applied to the mild steel. Nickel plating is beneficial because surface oxidation (i.e., rust in the case of iron-based metals) can result in reduced thermal performance. For example, surface oxidation can act like an insulator, reducing the efficiency with which the heating element can transfer heat to the consumable as intended. The presence of an oxidation layer may also adversely affect the sensory experience of the user.

[0035] In some examples, the materials of first heating element 210 and second heating element 212 are selected to have similar coefficients of thermal expansion, which is beneficial in reducing mechanical stresses on the components during any high temperature manufacturing processes, such as brazing or welding, and during repeated heating and cooling cycles that the heating elements of aerosol delivery device 100 are subjected to during use.

[0036] In some examples, an air gap 214 may be present between the inner wall 204 of the insulation 202 and the first heating element 210. Alternatively, or additionally, an air gap 214 may be present between the inner wall 214 and the second heating element 212. The air gap 214 helps improve the thermal insulation provided by the insulation by reducing conductive heat transfer from the first heating element 210 and / or the second heating element 212 to the inner wall 204 of the insulation 202. Reducing conductive heat transfer by providing an air gap 214 may also be advantageous because the air gap may allow a material to be used for the inner wall 204 that has advantageous properties but that would be damaged or degraded by direct contact with the first heating element 210 and / or the second heating element 212.

[0037] In some examples, the inner wall 204 and the outer wall 206 of the insulation 202 include a thermally insulating material. In some examples, the inner wall 204 and the outer wall 206 are formed of a material that is insensitive and non-conductive so that they are not significantly heated by induction heating when exposed to a fluctuating magnetic field. Providing the inner wall 204 and the outer wall 206 of an insensitive material means that the insulation 202 is not heated by induction heating when a fluctuating current, such as an alternating current, is passed through the coils 116a, 116b. Thus, the efficiency of the system and the thermal management within the system can be improved since energy is not wasted heating the insulation 202 and excessive temperature rise of the inner wall 204 and the outer wall 206 does not have to be controlled and / or mitigated. Even though the inner wall 204 and the outer wall 206 are heated by the fluctuating applied magnetic field, the first heating element 210 and / or the second heating element 212 may actually experience minimal undesired heating. This structure also serves to maintain the temperature of the exterior of the housing 108, especially at its surfaces, at an acceptable level for user handling.

[0038] In some examples, the inner wall 204 and the outer wall 206 are formed from a material with low thermal conductivity so that heat is not easily conducted through the material of the insulation. In some examples, the inner wall 204 and the outer wall 206 include a non-porous material to reduce the rate at which outside air may leak into the insulated region 208 during use. In some examples, the inner wall 204 and the outer wall 206 include one or more of a metal, a non-porous plastic, a glass, or a ceramic material. Metals are cheap, easy to process, and have good mechanical properties, plastics are cheap, easy to mold, and are strong, and glass is cheap, easy to mold, and has good strength, while ceramic materials are cheap, strong, strong, and lightweight. A suitable plastic material may be a polymer that is thermally and mechanically stable up to at least 250° C., and in some cases at least 320° C. An example of such a polymer is polyetheretherketone (PEEK). A suitable glass material may be borosilicate glass, which has a low coefficient of thermal expansion making it particularly thermal shock resistant. A suitable ceramic material may be zirconia. Composite materials including two or more of the materials listed above, such as glass reinforced plastic, may allow for beneficial properties of the combined materials.

[0039] The inner wall 204 and the outer wall 206 may comprise the same or different materials. Using the same material allows the inner wall 204 and the outer wall 206 to be more easily bonded to one another, thus reducing manufacturing complexity. Alternatively, if different materials are used for the inner wall 204, the respective materials for the inner wall 204 and the outer wall 206 may be selected to more closely address the specific requirements of each component. For example, the inner wall 204 is located closer to the first heating element 210 and the second heating element 212 than the outer wall 206, and therefore the material of the inner wall 204 may require a higher resistance to temperature and / or thermal cycling than the material of the outer wall 206. The outer wall 206, in contrast, is less likely to be directly exposed to high temperatures as the inner wall 204, and therefore may be selected to have, for example, less thermal stability but improved mechanical properties.

[0040] 3 further illustrates a hollow chamber 216 extending axially from one end of the first heating element 210 and connected to the heating chamber 144. The hollow chamber 216 is positioned such that when a consumable containing an aerosol-generating material is inserted into the heating zone / chamber 144 defined by the first heating element 210, the hollow chamber 216 surrounds at least a portion of the consumable and an inner wall of the hollow chamber 216 and at least a portion of the consumable define an air channel (not shown in FIG. 3) therebetween. In some examples, the hollow chamber 216 comprises at least a portion of the first heating element 210 or the second heating element 212. Alternatively, or additionally, the hollow chamber 216 may be integrally formed with the first heating element 212 or the second heating element 212, or the hollow chamber 216 may simply abut or be disposed adjacent to the first heating element 212 or the second heating element 212. In instances where the hollow chamber 216 comprises or is joined to at least a portion of the first heating element 210 or the second heating element 212, the material requirements of the hollow chamber 216 are similar to the material requirements of the first heating element 210 and the second heating element 212. In such examples, the material chosen for the hollow chamber 216 may be selected to have a similar coefficient of thermal expansion as the first heating element 210 and / or the second heating element 212, or alternatively, the material chosen may be selected to be resistant to thermal and mechanical stresses that may be introduced into the hollow chamber 216 by the heating elements 210, 212. In examples where the hollow chamber 216 is joined to the first heating element 210 or the second heating element 212, the joining may be achieved by welding, brazing, by adhesive, or by an interference fit.

[0041] Figure 4 is an enlarged view of section B identified in Figure 3. The enlarged view shown in Figure 4 more clearly illustrates the arrangement of first heating element 210, insulation 202, and hollow chamber 216 as shown in Figure 3. Air gap 214, illustrated in Figure 3 and discussed in detail above, is also more clearly shown in Figure 4 and is disposed between first heating element 210 and inner wall 204 of insulation 206.

[0042] An air channel (not shown) defined by the inner wall of the hollow chamber 216 and the consumable may be in fluid communication with an area outside the housing 108 of the device 100. In such an example, the fluid communication path between the air channel defined by the inner wall of the hollow chamber 216 and the area outside the housing 108 of the device 100 does not extend into the heating zone defined by the first heating element 210. Such a fluid communication path may, for example, allow heated volatiles escaping from the consumable through its outer packaging to safely flow out of the device 100 without being inhaled by a user or re-entering the heating chamber 144. The fluid communication path may further allow cool air to enter the air channel. To improve the ventilation capacity of the air channel defined by the inner wall of the hollow chamber 216 and the consumable, the fluid communication path may be divided into multiple ventilation paths extending circumferentially around the inner wall of the hollow chamber 216 by including protrusions around the inner surface of the hollow chamber 216.

[0043] In examples where the hollow chamber 216 does not include the first heating element 210 or the second heating element 212, the material requirements of the hollow chamber 216 may be similar to the material requirements of the outer wall 206, as discussed above.

[0044] 5 shows an external schematic view of one example of an insulating material 302 according to the second embodiment of the present disclosure, which is also part of the aerosol delivery device 100, as an alternative to the insulating material 202. FIG. 5 also shows a hollow chamber 316.

[0045] FIG. 6 shows cross section CC of the insulation 302 shown in FIG. 2. FIGS. 5, 6 and 7 are not drawn to scale. Similar to the insulation 202 discussed above, the insulation 302 comprises an inner wall and an outer wall 306, but the inner wall comprises at least a portion of each of the first heating element 310 and the second heating element 312. Because the inner wall serves as the wall of the first heating element 310, the second heating element 312 and the insulation 302, the overall size and weight of the aerosol delivery device 100 can be reduced when there is no requirement to include separate heating elements and separate insulating members. Similar to the insulations 202, 302 described above, the inner and outer walls 306 surround an insulation region 308, which is evacuated to a lower pressure than the outside of the insulation region 308. Similar to the insulation 202, 302 discussed above, the first heating element 310 and the second heating element 312 may be joined by any suitable means. However, since the first heating element 310 and the second heating element 312 constitute at least a portion of the interior wall, the means by which the first heating element 310 and the second heating element 312 are joined must be suitable to prevent outside air from leaking into the insulated region. In some examples, the first heating element 310 and the second heating element 312 are integral with each other. The pressure in the insulated region 308 is about 10 -1 ~10 -7 Torr range, 10 -3 Pressures of less than 100 torr are believed to be particularly advantageous. In some examples, the pressure in the insulating region 308 is believed to be a vacuum. The components comprising the inner and outer walls 306 of the insulation 302 are strong enough to withstand any forces acting thereon due to the pressure differential between the insulating region 308 and regions outside the insulating region 308, preventing the insulation 302 from collapsing inward. Gas absorbing materials may be used in the insulating region 308 to maintain or help create a relatively low pressure within the insulating region 308.

[0046] In the example shown in FIG. 6, the second heating element 312 is joined to the exterior wall 306 to enclose the insulated region 308. In such an example, the second heating element 312 is joined to the exterior wall 306 by any suitable means, such as by welding, brazing, or using an adhesive. Similar to the joining of the first heating element 310 and the second heating element 312 discussed above, the means of joining the second heating element 312 and the exterior wall 306 should be suitable to prevent outside air from leaking into the insulated region 308. This particular configuration may not be present in all examples of the second aspect of the present disclosure. For example, the second heating element 312 may be joined to the hollow chamber 316 and the first heating element 310, each of which is joined to the exterior wall 306 to enclose the insulated region. In all instances, it should be understood that any joints formed between components surrounding the insulating region should be selected to be suitable for preventing outside air from leaking into the insulating region 308.

[0047] The example shown in FIG. 6 shows that the first heating element 310 and the outer wall 306 surround a portion of the hollow chamber 316, and that the hollow chamber 316 is one of the components captured within and enclosing the insulating region 308. Such a configuration is merely an example of one possible option according to the second aspect of the present disclosure. It should be understood that the hollow chamber 316 may not be included in this manner in some examples. Furthermore, in some examples where the hollow chamber 316 is included, the outer wall 306 may be bonded directly to the first heating element 310 such that the hollow chamber 316 does not protrude into the insulating region 308. Doing so may be advantageous as it reduces the number of components required to encompass the insulating region 308. Doing so may also simplify the manufacturing process and may help prevent outside air from leaking into the insulating region 308 during the life of the aerosol delivery device 100.

[0048] Figure 7 is an enlarged view of section D identified in Figure 6. The enlarged view shown in Figure 7 more clearly illustrates the arrangement of first heating element 310, outer wall 306, and hollow chamber 316 as shown in Figure 6. The insulating region 308 shown in Figure 6 and discussed in detail above is also more clearly shown in Figure 7, in this example disposed between first heating element 310 and a portion of outer wall 306 and hollow chamber 316.

[0049] Returning to FIG. 6 , the outer wall 306 is shown as extending along the entire length of the first heating element 310. However, in one alternative, the outer wall 306 may only extend partially along the length of the first heating element 310. That is, the outer wall 306 may extend along only a portion of the first heating element 310 such that insulation may occur only around a portion of the first heating element 310. Providing an outer wall 306 that extends only partially along the length of the first heating element 310 may allow the overall size of the aerosol delivery device 100 to be further reduced. Although the outer wall 306 and the first heating element 310 are shown as being coaxial with each other, this is not required. It should be understood that each of the statements in this paragraph regarding the first heating element 310 may apply to the second heating element 312 as well. In all instances, however, the outer wall 306 extends around at least a portion of the first heating element 310 and the second heating element 321 regardless of the particular configuration of the heating elements and the outer wall 306 .

[0050] Similar to the insulation 202 discussed above, the first heating element 310 and the second heating element 312 can be heated as discussed above, i.e., by penetrating a varying magnetic field, by resistive heating, and / or by conduction. The material requirements for the first heating element 310 and the second heating element 312 are similar to those discussed above, with the additional requirement that the material chosen must be capable of preventing the ingress of outside air into the insulation 308 (e.g., must be non-porous). Additionally, the material chosen must have sufficient strength to withstand any forces acting on the first heating element 310 and the second heating element 312 due to pressure differentials between the insulation region 308 and regions outside the insulation region 308 to prevent the insulation 302 from collapsing inwards.

[0051] The material requirements for the outer wall 306 are similar to those for the outer wall 206 discussed above. The inner wall should be made from a sensitive material and / or a conductive material. The material requirements for the hollow chamber 316 are similar to those for the hollow chamber 216 discussed above, with the additional requirement that in instances where at least a portion of the hollow chamber 316 participates in enclosing the insulating region 308, the material chosen must be capable of preventing ingress of outside air into the insulation 308 (e.g., must be non-porous).

[0052] A third aspect of the present disclosure describes an aerosol delivery system comprising an apparatus according to the first or second aspect of the present disclosure and an aerosol-generating material that, in use, is at least partially disposed within a heating zone of an inner wall of the insulation.

[0053] 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 as defined in the appended claims.

Claims

1. 1. A non-combustion aerosol delivery device for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material, comprising: a first heating element at least partially defining a heating zone for receiving at least a portion of the consumable containing the aerosol generating material; a second heating element extending from an axial end of the first heating element beyond the heating zone; It is a thermal insulation material, inner wall, Exterior walls, as well as an insulation material comprising an insulation region wrapped with the inner wall and the outer wall, the insulation region being evacuated to a pressure lower than that outside the insulation region; Equipped with A non-combustion aerosol delivery device, wherein the insulation is positioned to extend around at least a portion of the first heating element and at least a portion of the second heating element.

2. The non-combustion aerosol delivery device of claim 1 , wherein the insulation is disposed to surround at least a portion of the first heating element and at least a portion of the second heating element.

3. 3. The non-combustion aerosol delivery device of claim 1 or 2, wherein an air gap exists between the inner wall of the insulation and the first heating element.

4. The non-combustion aerosol delivery device of any one of claims 1 to 3, wherein an air gap exists between the inner wall of the insulation and the second heating element.

5. The non-combustion aerosol delivery device of any one of claims 1 to 4, wherein the inner wall of the insulation is not heatable by the penetration of a fluctuating magnetic field.

6. The non-combustion aerosol delivery device of claim 5 , wherein the inner wall comprises one or more of metal, glass, ceramic, or plastic.

7. The non-combustion aerosol delivery device of claim 6 , wherein the inner wall comprises a polymer having a melting point of at least 250° C.

8. 1. A non-combustion aerosol delivery device for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material, comprising: a first heating element at least partially defining a heating zone for receiving at least a portion of the consumable containing the aerosol generating material; a second heating element extending from an axial end of the first heating element beyond the heating zone; It is a thermal insulation material, inner wall, Exterior walls, as well as an insulation material comprising an insulation region wrapped with the inner wall and the outer wall, the insulation region being evacuated to a pressure lower than that outside the insulation region; wherein the inner wall comprises at least a portion of each of the first heating element and the second heating element.

9. The insulating region is 10 －３ The non-combustion aerosol delivery device of any one of claims 1 to 8, which is evacuated to a pressure of sub-1000 torr.

10. 10. The non-combustion aerosol delivery device of claim 1, wherein the outer wall of the insulation comprises a material that is not heatable by the penetration of a varying magnetic field.

11. The non-combustion aerosol delivery device of any one of claims 1 to 10, wherein the outer wall comprises one or more of metal, glass, ceramic, or plastic.

12. 12. The non-combustion aerosol delivery device of claim 11, wherein the outer wall comprises a polymer having a melting point of at least 250°C.

13. The non-combustion aerosol delivery device of any one of claims 1 to 12, wherein the first and / or second heating elements are heatable by conduction.

14. The non-combustion aerosol delivery device of any one of claims 1 to 13, wherein the first and / or second heating element are heatable by the penetration of a fluctuating magnetic field.

15. 15. The non-combustion aerosol delivery device of claim 14, further comprising a magnetic field generator for generating a varying magnetic field that penetrates the first and / or second heating elements to heat the first and / or second heating elements in use.

16. The non-combustion aerosol delivery device of any one of claims 1 to 15, wherein the first and / or second heating elements comprise mild steel or ferritic stainless steel.

17. The non-combustion aerosol delivery device of any one of claims 1 to 16, wherein the first and / or second heating elements are treated with a corrosion resistant coating.

18. 18. The non-combustion aerosol delivery device of any one of claims 1 to 17, further comprising a hollow chamber extending from an axial end of the first heating element, the hollow chamber surrounding at least a portion of the consumable when the consumable is inserted into the device, and an inner wall of the chamber and the at least a portion of the consumable defining an air channel therebetween.

19. 20. The non-combustion aerosol delivery device of claim 18, wherein the hollow chamber comprises the first or second heating element.

20. 20. The non-combustion aerosol delivery device of claim 19, wherein the hollow chamber is joined to the other of the first or second heating elements.

21. 20. The non-combustion aerosol delivery device of claim 18, wherein the hollow chamber is integral with or joined to the first or second heating element.

22. An apparatus according to any one of claims 1 to 20, an aerosol-forming material that, in use, is at least partially disposed within the heating zone of the first and / or second heating element; A non-combustion aerosol delivery system comprising:

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