Heat-not-burn device and method

Abstract

To provide a device wherein an induction heating source is provided for use to heat a consumable tobacco component.SOLUTION: The present invention provides a device for converting a consumable into an aerosol with high heat without burning the consumable by packaging the consumable containing an internal susceptor inside an encasement having a plurality of holes with an induction heating element wrapped around the consumable-containing package to heat the susceptor using a magnetic field generated by the induction heating element. Combustion of the consumable-containing package is minimized by limiting air inside the consumable-containing package by coating the encasement material that melts at high temperatures. The coating may also include a flavoring. The efficiency of the device may be enhanced by a self-resonating oscillator, a movable coil, a multipole susceptor, a sensor, heat dissipation, airflow control, an alignment mechanism, and the like.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This invention relates to devices used as alternatives to conventional smoking products such as electronic cigarettes and vapor inhalation systems, and more particularly to non-combustion heating devices.

Background Art

[0002] A non-combustion heating (HNB) device heats tobacco at a temperature lower than the temperature at which combustion creates an inhalable aerosol containing nicotine and other tobacco components and makes it available to the device user. Unlike conventional tobacco, the aim is not to burn the tobacco, but rather to heat the tobacco to a sufficient extent to release nicotine and other components through the generation of an aerosol. Lighting and burning tobacco produces undesirable toxins, which can be avoided by using an HNB device. However, there is a delicate balance between supplying enough heat to effectively release tobacco components in the form of an aerosol and not burning or lighting the tobacco. Current HNB devices have not yet found that balance and either heat the tobacco to a temperature that does not produce a sufficient amount of aerosol or overheat the tobacco, producing an unpleasant or "burnt" odor profile. In addition, with current methodologies, the internal components of conventional HNB devices are soiled by the by-products of burning tobacco and the by-products of accidental combustion.

[0003] For the reasons described above, there is a need for an aerosol generating device in which the user can control the strength of the device, which affects the temperature of the tobacco heated via a guiding method for reducing the risk of combustion while enhancing the efficiency and aroma profile of the generated aerosol - or even to a temperature sufficient for ignition.

Summary of the Invention

[0004] The present invention relates to a system and method in which consumable tobacco components are rapidly and progressively heated by induction, resulting in the generation of an aerosol that contains some of the components but no by-products such as smoke, ash, tar, and other potentially harmful chemicals most commonly associated with combustion. This invention includes positioning and the use of an induction heating element that provides an alternating electromagnetic field around the components to effect a progressive heating along the consumable tobacco components.

[0005] An object of the present invention is an apparatus in which an induction heating source is provided for use in heating a consumable tobacco component.

[0006] Another object of the present invention is a consumable tobacco component that includes several sealed, individual, enclosed, and coated containers that contain a consumable tobacco preparation - and an induction heating source. The container can be an aluminum shell with a pre-set opening. The container can be coated with a gel that seals the opening until the induction heating process melts the gel and clears the opening. In some embodiments, the gel can include a flavorant that adds flavor to or enhances the flavor of the tobacco aerosol.

[0007] In some embodiments, a plurality of containers are stacked inside a paper tube while maintaining a space therebetween, and excess aluminum packaging in the bottom end of each container and in a channel on either side forms an aerosol that can be generated. When the induction heating source is activated, a predetermined opening is cleared, the flavor is combined with the aerosol, and it moves through the tube and becomes available to the device user.

[0008] Using these methods and apparatus, the device can reduce the mass that requires heating, can heat rapidly, cool quickly, and conserve power, enabling extended use between subsequent charges. This contrasts with known, prior, commercialized non-combustion heating devices.

[0009] Another object of the present invention is a consumable component containing tobacco, comprising several sealed, individual, enclosed, and coated containers, and an induction heating source. The container is covered with a gel that seals the opening until the induction heating process can melt the gel and clear the opening. In some embodiments, it may include a flavoring agent that adds flavor to or enhances the flavor of the consumable tobacco component.

[0010] Another object of the present invention is to create a consumable-containing package that is easy to replace and minimizes deposits inside the case during use to reduce the effort for cleaning the case.

[0011] Another object of the present invention is to move a heating element relative to a susceptor or a consumable to heat a segment of the consumable independently of other segments.

[0012] Another object of the present invention is to maximize the efficiency of energy use in an apparatus for generating an aerosol.

[0013] Another object of the present invention is to control the heat of a heating element to maximize the longevity of the apparatus.

[0014] Another object is to enable changing the airflow through the apparatus to vary the flavor or formulation of the consumable. BRIEF DESCRIPTION OF THE DRAWINGS

[0015]

Figure 1

Figure 2A

Figure 2B

Figure 2C

Figure 2D

Figure 2E

Figure 3A

Figure 3B

Figure 3C

Figure 3D

Figure 4A

Figure 4B

Figure 5A

Figure 5B

Figure 5C

Figure 6A

Figure 6B

Figure 7A

Figure 7B

Figure 7C

Figure 7D

Figure 8A

Figure 8B

Figure 9A

Figure 9B

Figure 9C

Figure 10A

Figure 10B

Figure 11

Figure 12A

Figure 12B

Figure 12C

Figure 12D

Figure 12E

Figure 13A

Figure 13B

Figure 13C

Figure 13D

Figure 14A

Figure 14B

Figure 14C

Figure 15A

Figure 15B

Figure 15C

Figure 16A

Figure 16B

Figure 16C

Figure 16D

Figure 17A

Figure 17B

Figure 18A

Figure 18B

Figure 19

Figure 20

Figure 21

Figure 22

Figure 23

Figure 24A

Figure 24B

Figure 24C

Figure 25A

Figure 25B

Figure 25C

Figure 25D

Figure 25E

Figure 26A

Figure 26B

Figure 26C

Figure 26D

Figure 26E

Figure 26F

Figure 26G

DETAILED DESCRIPTION OF THE INVENTION

[0016] The following detailed description, in relation to the accompanying drawings, is intended as a description of the presently preferred embodiments of the invention and is not intended to represent the only form in which the invention may be constructed or utilized. The description sets forth the functions and the order of steps for constructing and operating the invention in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and orders may be achieved by different embodiments that are further contemplated within the spirit and scope of the invention.

[0017] The present invention is for an apparatus for generating an aerosol from a consumable-containing product and for a method of drawing the consumable-containing product using relatively high heat to minimally combust the consumable-containing product. For the purposes of this application, the term "consumable" should be broadly construed to include any kind of agent, drug, chemical compound, active agent, component, etc., regardless of whether the consumable is used to treat a disease or illness, for nutrition, is a dietary supplement, or is used for entertainment. By way of example only, consumables can include pharmaceuticals, dietary supplements, over-the-counter drugs, tobacco, cannabis, etc.

[0018] Referring to FIG. 1, the apparatus (100) includes a consumable-containing package (102) and an aerosol generating device (200). The apparatus (100) generates an aerosol through a non-combustion heating process in which the consumable-containing unit (104) is not combusted, but is heated to a temperature at which the consumable is released from the consumable-containing unit in an inhalable aerosol form. Thus, the consumable-containing unit (104) is any product that contains a consumable that can be released in aerosol form when heated to an appropriate temperature. This application discusses the application of the invention to tobacco products and provides specific examples. However, the invention is not limited to use with tobacco products.

[0019] Consumable-containing package

[0020] Referring to FIGS. 2A - 6B, the consumable-containing package (102) is a component that is heated to release the consumable in the form of an aerosol. The consumable-containing package (102) includes a consumable-containing unit (104), a metal (also called a susceptor) (106) for heating the consumable-containing unit (104) through an induction heating system, and a container (108) that houses the consumable-containing unit (104) and the susceptor (106). How well the consumable-containing package (102) is heated depends on the consistency of the product. The consistency of the product takes into account various factors such as the position, shape, orientation, and other characteristics of the consumable-containing unit (104). Other characteristics of the consumable-containing unit (104) may include the amount of oxygen contained within the unit. The goal is to maximize the consistency of the product by providing consistency in each of these factors during the manufacturing process.

[0021] When the form of the consumable-containing unit (104) is in direct physical contact with the susceptor (106) such that the contact area between each is maximized, it can be inferred that most of the thermal energy induced within the susceptor (106) will be transferred to the consumable-containing unit (104). Therefore, the shape and arrangement of the consumable-containing unit (104) relative to the susceptor (106) are important factors. In some embodiments, the consumable-containing unit (104) is generally cylindrical. As such, the consumable-containing unit (104) may have an annular or elliptical cross-section.

[0022] Furthermore, another objective regarding the design of the consumable-containing unit (104) is to minimize the amount of air to which the consumable-containing unit (104) is exposed. This eliminates or reduces the risk of oxidation or combustion during storage or the heating process. As a result, at certain settings, it is possible to heat the consumable-containing unit (104) to temperatures that would cause combustion when used with prior art devices that allow for more air exposure.

[0023] Therefore, in a preferred embodiment, the consumable-containing unit (104) is made of a consumable in powder form packed in pellets or rods. Compression of the consumable reduces the oxygen trapped inside the consumable-containing unit (104). In some embodiments, the consumable-containing unit (104) may further include additives such as a moisturizer, a fragrance, a filler to replace oxygen, or a vapor-generating substance. The additives may further assist in the absorption and transfer of thermal energy along with the removal of oxygen from the consumable-containing unit (104). In an alternative embodiment, the consumable may be mixed with a substance that does not interfere with the function of the device but replaces the air in the interstitial space of the consumable and / or surrounds the consumable to isolate it from the air. In yet another alternative embodiment, it may be formed into small pellets or other forms that can be encapsulated to further reduce the air available to the consumable.

[0024] As shown in FIGS. 2A-2D, in a preferred embodiment, the consumable-containing unit (104) can be one elongated unit defining a longitudinal axis L. For example, the consumable-containing unit (104) can be an elongated cylinder or tube having an annular cross-section or an elliptical cross-section. Thus, the consumable-containing unit (104) can be defined by two opposing ends (105, 107) and a sidewall (109) therebetween, extending from the first end (105) to the second end (107) therebetween and defining the length of the consumable-containing unit (104).

[0025] The susceptor (106) is similarly elongated and preferably can be embedded in the consumable-containing unit (104) along the longitudinal axis L, substantially extending along the length and width (i.e., diameter) of the consumable-containing unit (104). In the consumable-containing unit (104) having an elliptical cross-section, the diameter refers to the outer diameter defining the major axis of the ellipse.

[0026] The susceptor (106) can be extruded. Once extrusion has occurred, the consumable-containing unit (104) can be compressed around the susceptor (106) along the susceptor (106) length. Alternatively, the susceptor (106) can be pressed from flat metal stock or any other suitable manufacturing method prior to attaching the consumable-containing unit (104) around the susceptor (106). In some embodiments, as shown in FIG. 2E, the susceptor (106) may be made of steel wool. For example, the susceptor (106) can be composed of thin filaments of steel wool bundled in a pad shape. As such, the steel wool pad includes a number of thin edges. In some embodiments, the steel wool pad may be coated with or soaked in a moisturizing agent, a fragrance, a vapor-generating substance, a substance that delays oxidation (rusting) of the steel wool, and / or a filler that removes air between the steel wool filaments. As shown in FIG. 2E, cut-outs may be provided along the steel wool pad to divide the consumable-containing unit (104) into individual heating segments as described below. Alternatively, the individual pads of steel wool can be separated and / or spaced by the consumables such that each pad can be heated individually during use.

[0027] Advantages of steel wool include, but are not limited to, being environmentally easy to dispose of in that it begins to oxidize as soon as it is heated, thereby becoming brittle without sharp edges and degrading easily. It is composed of iron and carbon and is relatively non-toxic.

[0028] The susceptor (106) can be made of any metallic material that heats up when exposed to a varying magnetic field, such as in the case of induction heating. Preferably, the metal includes a steel material. To maximize the efficient heating of the consumable-containing unit (104), the susceptor (106) conforms to the shape of the largest cross-sectional area of the consumable-containing unit (104) so as to maximize the surface area where the consumable-containing unit (104) contacts the susceptor (106), although other configurations can also be used. In an embodiment where the consumable-containing unit (104) is an elongated cylinder, the largest cross-sectional area would be defined by dividing the elongated cylinder along the longitudinal axis L along the outer diameter so as to create a rectangular cross-sectional area. Thus, the susceptor (106) will also be rectangular, resulting in dimensions similar to those of the cross-sectional area of the elongated cylinder.

[0029] In some embodiments, the susceptor (106) can be a metal plate. In some embodiments, the susceptor (106) can be a metal plate having a plurality of openings (110), such as a mesh screen. Induction heating appears to be most effective and efficient at the edges of the susceptor (106). The mesh screen creates more edges in the susceptor (106) that can contact the consumable-containing unit (104), because the edges define the openings (110).

[0030] Preferably, susceptor (106) may be a strip patterned with a series of small openings (110), increasing the amount of edge that can be used in an efficient induction heating process, followed by a large gap (112) that allows the length of susceptor (106) where induction heating is not possible, the gap making induction heating impossible or at least weakening it and / or weakening conduction from the heated segments. This configuration allows for a consumable-containing package (102) to be heated in separate segments. The elongate susceptor (106) may be an elongate metal plate having a longitudinal direction, the elongate metal plate having a set of openings (110a, 110b) and a set of gaps (112a, 112b), where the set of openings (110a, 110b) are arranged alternately in order with the set of gaps (112a, 112b) along the longitudinal direction of the elongate metal plate such that each set of openings (110a, 110b) is adjacent to one of the gaps (112a, 112b). Thus, moving from one end of susceptor (106) to the opposite end, there is a first set of openings (110a), then a first gap (112a), then a second set of openings (110b), then a second gap (112b), and so on. In the region of the gaps (112), there is little metal material; thus, heat transfer is minimal. Therefore, even if the consumable-containing unit (104) is a single unit, it can still be heated in separate sections. Thereafter, the consumable-containing unit (104) and susceptor (106) are enclosed in a container (108).

[0031] In a preferred embodiment, the container (108) may be made of aluminum having a pre-punched opening (120). The consumable-containing unit (104) is placed inside the container (108) to retain the heat generated by the susceptor (106). The opening (120) of the container (108) allows the consumable aerosol to leak out when heated. The opening (120) creates a passage that allows air to enter the container (108) and expose the consumable-containing unit (104), so the opening (120) can be temporarily sealed using a coating. The coating may preferably be made of a composition that melts at the temperature at which the consumable aerosol is created. Thus, as the susceptor (106) is heated and due to the lack of air inside the container (108), the consumable-containing unit (104) can be raised to a very high temperature without combustion. When the susceptor (106) reaches a high temperature and the consumable aerosol begins to form, it cannot leak out. As the coating gradually melts and disappears, exposing the opening (120), the consumable aerosol can then leak out of the container (108) for inhalation. In a preferred embodiment, the coating can be a propylene glycol alginate ("PGA") gel. The coating may also contain a flavorant. Thus, as the coating gradually melts and disappears and the consumable aerosol is released, the flavorant is also released with the consumable aerosol. In some embodiments, the flavorant can be mixed with an additive.

[0032] In some embodiments, the opening (120) can be a plurality of holes or slits. The opening (120) can be formed along the length of the side wall (122) of the container (108), arranged radially around the side wall (122), arranged arbitrarily or uniformly through the side wall (122), etc. In some embodiments, the opening (120) can be a plurality of holes along the opposing ends (124, 126) of the container (108). In some embodiments having a rectangular consumable-containing unit (104), the container (108) also extends with an opening (120) in the form of one or more elongated slits that traverse the length of the container parallel to the longitudinal axis L, thereby creating a seam. The seam can be folded or corrugated, but still leave a gap through which the consumable aerosol can move, either along its entire length or in discrete regions. Like the opening (120) described above, the seam can be sealed with a coating.

[0033] The consumable-containing package (102) can further include a filter tube (140) for enclosing the consumable-containing unit (104), the susceptor (106), and the container (108). The filter tube (140) may be made of a filter material to capture any unwanted debris while allowing the consumable aerosol released from the heating of the container to move laterally through the filter. The filter tube (140) can surround the container (108) and further cover the coated opening (120). Since the filter tube (140) may be made of a filter material, the consumable aerosol can move through the filter tube (140). Any suitable filter material can be used. By way of example only, the filter tube may be made of cellulose or cellulose acetate.

[0034] The consumable-containing package (102) may further include a housing (150) that houses the filter tube (140). The housing (150) can be a paper tube. The housing (150) is difficult for the consumable aerosol to pass through. Therefore, the housing (150) wrapped around the filter tube (140) creates a longitudinal path through the filter tube (140) through which the consumable aerosol passes rather than leaking radially from the filter tube (140). This enables the consumable aerosol to follow the inhalation path towards the user's mouth. One end (152) of the housing (150) can be covered by an endcap (154). The endcap (154) can be composed of a kind of filter material. There is a mouthpiece (158) at the opposite end (156) of the housing (150), and the user sucks on it to draw the heated consumable aerosol from the container (108) along the filter tube (140) towards the mouthpiece (158) and into the user's mouth. Therefore, the mouthpiece (158) can also be a kind of filter similar to that of the endcap (154). The consumable-containing package (102) includes a path through which the consumable aerosol passes, and the path is directly connected to the mouthpiece (158) which is also part of the consumable-containing package (102). If the path is isolated from the case (202), the case (202) will remain free of any residues or by-products formed during the operation of the device. In this configuration, the case (202) remains clean and does not require the user to periodically clean the case (202).

[0035] In some embodiments, the container (108) may be made of a two-piece unit having a first container section (108a) and a second container section (108b). The consumable-containing unit (104) may be insertable into the first container section (108a), and the second container section (108b) may be placed on top of the first container section (108a) to cover the consumable-containing unit (104). A pre-set opening (120) may be formed in the container (108) before enclosing the consumable-containing unit (104).

[0036] The general principles of the consumable-containing package (102) were established, and variations that achieve the same purpose were also considered. For example, in one embodiment, it may include two elongated sections (104a, 104b). The two elongated sections (104a, 104b) of the consumable-containing unit (104) may be parallel to the longitudinal axis L along the diameter and defined by a plane cut through the longitudinal axis L along the diameter. Thus, the two elongated sections (104a, 104b) may be semi-cylindrical sections that form a complete cylindrical consumable-containing unit (104) when fitted together.

[0037] In some embodiments, as shown in FIGS. 3A - 3D, the consumable-containing unit (104) may be in the form of pellets or tablets. Unlike the consumable-containing unit (104) which is an elongated cylinder or tube where the length of the side wall (109) is much longer than the diameter, the tablet may be a short cylinder defining a longitudinal axis L, where the length of the side wall (109) is closer to or shorter than the size of the diameter. The susceptor (106) may be flat and circular in order to match the cross-sectional shape of the tablet when cut horizontally perpendicular to the longitudinal axis L. The consumable-containing unit (104) may be compressed around the susceptor (106). To mimic a cigarette, a plurality of consumable-containing units (104) may be stacked end-to-end along the longitudinal axis L so as to form an elongated cylinder. Thus, each consumable-containing unit (104) can be heated separately, effectively mimicking segments of each consumable-containing unit (104) having an elongated tubular body.

[0038] Other shapes such as squares or rectangles may also be used, and the susceptor (106) will be of the corresponding shape. However, the cylindrical shape is preferred because it is an easy shape to mimic the shape of an actual cigarette.

[0039] In some embodiments, the consumable-containing unit (104) can be formed from two sections (104a, 104b) of the consumable-containing unit (104) that are combined together to form a whole, as shown in FIGS. 4A and 4B. The two sections (104a, 104b) are defined by dividing the consumable-containing unit (104) horizontally in half along a plane perpendicular to the longitudinal axis L. The susceptor (106) can be sandwiched between the two sections (104a, 104b). With the susceptor (106) sandwiched between the two consumable-containing sections (104a, 104b), the consumable-containing unit (104) can be housed by a container (108). This process can be repeated to create a plurality of consumable-containing units (104), each with a respective susceptor (106) sandwiched therein and each housed in a respective container (108). The plurality of consumable-containing units (104) can be stacked one on top of the other to create a consumable-containing package (102) that can heat each individual consumable-containing unit (104) separately at one time.

[0040] In some embodiments, the container (108) can be aluminum wrapped around the consumable-containing unit (104). The aluminum can have extra folds (130, 132) at opposite ends, as shown in FIG. 3D. These extra folds (130, 132) create a gap between adjacent consumable-containing units (104) when stacked on top of each other.

[0041] In some embodiments, as shown in FIGS. 4A and 4B, the container (108) can be two-piece and have a first container section (108a) and a second container section (108b) that serves as a cover or cap for housing the consumable-containing unit (104) within the first container section (108a). As previously described, the opening (120) on the container (108) can be disposed along the sidewall (122) or at the ends (124, 126). As previously described, the susceptor (106) can be any type of metal that is inductively heated, including steel wool, as shown in FIG. 4B. In a preferred embodiment, a plurality of edges are created on the susceptor (106) by creating a plurality of holes (110) or using an overall compressed steel wool filament. The steel wool filaments can range from thin to medium. As discussed above, the steel wool pad may be soaked in, coated with, or filled with additives, fragrances, protectants, and / or fillers.

[0042] In some embodiments, as shown in FIGS. 5A-6B, a plurality of consumable-containing units (104) can be housed in a single elongated container (108). The container (108) can be formed with compartments (111) to receive each individual consumable-containing unit (104). In some embodiments, the individual compartments (111) can be joined to each other by bridges (121). In some embodiments, the bridge (121) can define a path (125) that enables a fluid connection between one compartment (111) and another. In some embodiments, the bridge (121) can be corrugated to prevent a fluid connection through the bridge between one compartment (111) and another. In some embodiments, the elongated container (108) can be a two-piece assembly that is divided laterally along a longitudinal axis L, as shown in FIGS. 6A-6B. The consumable-containing unit (104) can be installed in a compartment (111) of one of the container sections (108a). Subsequently, a second container section (108b) can be fitted to the first container section (108a) to cover the consumable-containing unit (104). The division between the first container section (108a) and the second container section (108b) can be used as an opening (120). Alternatively, a pre-set opening (120) can be formed in one or both of the container sections (108a, 108b).

[0043] In some embodiments, as shown in FIGS. 7A - 7D, the container (108) can be made of a material that enables the container (108) to serve as a susceptor. For example, the container (108) may be made of steel, or otherwise steel, or any other metal that can be heated using induction heating. In such embodiments, it may not be necessary for the internal susceptor (106) to be embedded within the consumable-containing unit (104). The container (108) can still include a plurality of holes (120) and can be covered with an additive and / or a sealant such as PGA. Such embodiments can be in the form of an elongated tube as shown in FIG. 7A, or a tablet or disk as shown in FIG. 7B. The container (108) can be a two-piece container having a first container section (108a) and a second container section (108b), as previously discussed.

[0044] In some embodiments, the container (108) may have a lateral slit (123) generally perpendicular to the longitudinal axis L and traversing the container (108), as shown in FIGS. 7C and 7D. The slit (123) creates segmentation within the container (108) such that only one small segment of the consumable-containing unit (104) is heated per actuation. The lateral slit (123) can be a through-hole, whereby the consumable-containing unit (104) is exposed downward. In such embodiments, the segments can be filled with a coating or other stuffing to seal the holes, either permanently or with a material that melts upon heating to allow aerosol to leak through the slit (123). In some embodiments, the stuffing can be made from a material that functions as a substance that is not easily heated, via a heat sink plate and / or induction that reduces the heating effect at the lateral slit (123). In some embodiments, the lateral slit (123) can be a recess or a protrusion in the container (108). In other words, the lateral slit (123) can be a thinner portion of the container (108). As such, the lateral slit (123) can define a space above the well. The space above the well can be filled with a heat sink plate and / or stuffing that can function as a substance that is not easily heated, via induction, to reduce heat conduction along the lateral slit (123).

[0045] Inductive heating

[0046] Heating of the consumable-containing unit (104) is achieved by an induction heating process that provides non-contact heating to a metal, preferably a steel material, by placing the metal in the presence of a varying magnetic field generated by an induction heating element (160), as shown in FIGS. 8A-8B. In a preferred embodiment, the induction heating element (160) is a conductor (162) wound around a coil that generates a magnetic field when current passes through the coil. The metal susceptor (106) is placed in a location sufficiently close to the conductor (162) so as to be within the magnetic field. In a preferred embodiment, the coil is wound in a manner that defines a central cavity (164). This enables the consumable-containing package (102) to be inserted into the cavity (164), and the coil surrounds the susceptor (106) without touching the susceptor (106). The current passing through the coil is alternating current, creating a rapidly alternating magnetic field. The alternating magnetic field may create eddy currents in the susceptor (106), thereby causing heat to be generated within the susceptor (106). Thus, the consumable-containing package (102) is generally heated from the inside out. In embodiments where the container (108) further serves as a susceptor, the consumable-containing package (102) is heated from the outside in.

[0047] In a preferred embodiment, segments of the consumable-containing package (102) will be heated individually. For this purpose, the conductor (162) may also be provided as individual sets (162a-f) of coiled conductors, as shown in FIG. 8A. Each conductor coil (162a-f) may be attached to a controller (166) that can be controlled to activate one conductor coil (162a-f) at a time. Six conductor coils (162a-f) are shown in FIG. 8A, but more or fewer coils may be used. In an alternative embodiment, a single conductor coil (162) may be used in conjunction with a mechanical mechanism that moves the coil along the consumable-containing package (102) to heat each segment of the consumable-containing package (102) individually.

[0048] Each of the conductor coils (162a-f) can match a separate segment of the consumable-containing package (102), as shown in FIGS. 3A-6B. Alternatively, the conductor coils (162a-f) can each correspond to a specific length of a continuous consumable-containing package (102) and can heat only that specific length, as shown in FIGS. 2A-2D, 7A, and 7D. In preliminary tests of such embodiments, adjacent non-heated consumables appear to act as insulators, and heating along separate lengths of the consumable-containing package (102) does not heat the adjacent portions of the consumable-containing package (102) appreciably. Thus, structures that limit heat conduction are discussed herein and may be useful, but are not necessarily required.

[0049] The conversion efficiency of electrical power to heat in the susceptor (106) is referred to herein as the "conversion efficiency" and is based on various factors such as the bulk resistance of the metal, the dielectric of the metal, the shape and heat loss of the metal, the consistency of the power supply, the shape of the coil, and losses associated with operation and the overall operating frequency - some of these factors are identified. The device (100) is designed and configured to maximize the conversion efficiency.

[0050] Aerosol generating device

[0051] To enable heating and conversion of the consumable to an aerosol, a housing (150) including a filter tube (140) wound around the consumable-containing unit (104) is placed inside the aerosol generating device (200), as shown in FIGS. 9A-9C. The aerosol generating device (200) includes a case (202) that houses a consumable-containing package (102), an induction heating element (160) that heats the susceptor (106), and a controller (166) that controls the induction heating element (160).

[0052] The case (202) is designed for ergonomic use. For the sake of simplicity of terminology, the case (202) is described using terms such as front, back, side, top, bottom, etc. These terms are not intended to be limiting, but rather are used to describe the relative positions of the various components. For the purpose of the description of the present invention, the front (210) is the part of the case (202) that faces the user when used as intended as described herein. As intended, when the user grasps the case (202) for use, the user's fingers wrap around the back (212) of the device (100), and the thumb wraps around the front (210).

[0053] The case (202) defines a cavity (214) (see FIG. 1) in which the components of the device (100) are housed. Thus, the case (202) is designed to house a substantial portion of the consumable-containing package (102), the controller (166), the induction heating element (160), and the power supply (220). In a preferred embodiment, the upper front portion of the case (202) defines an orifice (216). The mouthpiece portion (158) of the consumable-containing package (102) protrudes out from the orifice (216) such that the user can touch the consumable-containing package (102). The mouthpiece (158) protrudes sufficiently out from the case (202) such that the user can place their lips around the mouthpiece (158) and inhale the consumable aerosol.

[0054] The case (202) is intended to be user-friendly and easily portable. In a preferred embodiment, the case (202) can have dimensions of approximately 85 mm in height (measured from the top surface (222) to the bottom surface (224)), 44 mm in depth (measured from the front (210) to the back (212)), and 22 mm in width (measured from side surface (226) to side surface (228)). This can be manufactured by proto-molding for higher quality / more robust plastic parts.

[0055] In some embodiments, the consumable-containing package (102) can be held in a retractor that allows the consumable-containing package (102) to be stored inside the case (202) for storage and movement. Due to the configuration of the consumable-containing package (102), the case (202) does not require a through-hole for cleaning, such as in some other devices where some combustion still spreads and produces by-product residues from the combustion. In embodiments where the consumable-containing package (102) includes a mouthpiece (158) and a filter tube (140) for the user, when by-products are produced during operation, they remain in the disposable consumable-containing package (102), which is replaced when the user inserts a new consumable-containing package (102) and, if necessary, the filter tube (140) into the case (202). Thus, the interior of the case (202) remains clean during operation.

[0056] In a preferred embodiment, the upper surface (222) of the case (202) includes a user interface (230). Placing the user interface (230) on the upper surface (222) of the case (202) allows the user to easily check the status of the device (100) prior to use. The user can potentially view the user interface (230) even while inhaling. The user interface (230) may be a multi-color LED (RGB) display for displaying the status of the device in use. A light conductor can be used to provide a wide viewing angle for this display. As just one example, the user interface (230) has a 0.96-inch (diagonal) OLED display with a 128x32 format and an I2C (or SPI) interface. The user interface (230) enables tactile feedback (vibration) and audio feedback (piezoelectric transducer). In some embodiments, a transparent plastic (PC or ABS) cover can be placed over the OLED glass to protect it from damage / scratches.

[0057] The back (212) of the case includes a trigger (232) which is a finger-operated activation (push hard) button for turning the device on / starting inhalation. Preferably, the trigger (232) is adjacent to the upper surface (212). In this configuration, the user can hold the case (202) as intended with the index finger on or near the trigger (232) for convenient activation. In some embodiments, a locking mechanism is disposed on the trigger (232) - either mechanically or through an electrical connection that requires the case (202) to be opened before the trigger (232) can be electrically enabled. In some embodiments, a tactile feedback motor (234) can be mechanically coupled to the trigger (232) to improve the recognition of tactile feedback by the operating user. Activation of the trigger (232) powers the induction heating element (160) to heat the susceptor (106).

[0058] The device (100) is powered by a battery (220). Preferably, the battery (220) is a dual cell lithium ion battery pack (series connected) with a continuous current draw performance of 4A and a rated current of 650 - 750 mAh. The dual cell pack may include a protection circuit. The battery (220) can be charged using a USB Type "C" connector (236). The USB Type "C" connector (236) can also be used for communication. The controller (166) can also provide battery voltage monitoring (238) for battery status indication regarding charging / discharging.

[0059] The trigger (232) is operably connected to the induction coil driver (240) via the controller (166). The induction coil driver (240) activates the induction heating element (160) to heat the susceptor (106). The present invention eliminates the motor-driven coil design of the prior art. The induction coil driver (240) can provide drive / multiplexing for a number of coils. For example, the induction coil driver (240) can provide drive / multiplexing for six or more coils. Each coil is wound around one segment of the consumable-containing package (102) and can be activated at least once or more. Thus, one segment of the consumable-containing package (102) can be heated, for example, twice. In an apparatus (100) having six coils, the user can perform twelve "inhales" from the apparatus (100).

[0060] In a preferred embodiment, the induction coil drive circuit can be directly controlled by a microprocessor controller (166). A special peripheral device (numerical control oscillator) in this processor enables the processor to generate a drive waveform frequency that minimizes the CPU processing overhead. The induction coil circuit can have one or more capacitors connected in parallel, whereby the circuit becomes a parallel resonance circuit.

[0061] The drive circuit can include current monitoring with a "peak detector" that feeds back to an analog input on the processor. The function of the peak detector is to capture the maximum current value of any voltage cycle of the drive circuit that provides a stable output voltage for conversion by an analog-to-digital converter (part of the microprocessor chip), which is then used in the induction coil drive algorithm.

[0062] The induction coil drive algorithm is implemented in firmware that runs on the microprocessor. The resonance frequencies of the induction coil and the capacitor will be known with reasonable accuracy by design as follows:

[0063] Resonant frequency (Hertz) = 1 / (2 * π * SQRT{L * C})

[0064] At this time, π = 3.1415…, and

[0065] SQRT represents the square root of the content within the parentheses (...), and

[0066] L = the measured inductance of the induction coil, and

[0067] C = the known capacitance of the capacitor in parallel connection.

[0068] There will be manufacturing tolerances for the values of L and C (from above), and that will result in some variation between the actual resonant frequency and that calculated using the above formula. Furthermore, based on what is located inside this coil, there will be variations in the inductance of the induction coil. In particular, if there is a steel material inside (or very close to) this coil, some amount of the inductance will change, resulting in a small change in the resonant frequency of the L - C circuit.

[0069] The firmware algorithm for driving the induction coil sweeps the frequency of operation beyond the maximum expected frequency range while simultaneously monitoring the current and searching for the frequency at which the current draw is minimized. This minimum value will occur at the resonant frequency. Once this "center frequency" is found, the algorithm continues to sweep the frequency in small amounts on either side of the center frequency and adjusts the value of the center frequency as necessary to maintain the minimum current value.

[0070] The electronic device is connected to a controller (166). The controller (166) enables processor-based frequency control to optimize the heating of the susceptor (106). The relationship between frequency and temperature is rarely directly correlatable, mainly due to the fact that temperature is a result of frequency, duration, and the way the consumable-containing package (102) is configured. The controller (166) may further provide current monitoring to determine power supply and peak voltage monitoring across an induction coil to establish resonance. As an example, the controller may provide a frequency of about 400 kHz to about 500 kHz, preferably 440 kHz, with a 3-second preheat cycle to raise the temperature of the susceptor (106) to over 400 degrees Celsius in 1 second. In some embodiments, the temperature of the susceptor (106) can be raised to over 550 degrees Celsius in 1 second. In some embodiments, the temperature can be raised to 800 degrees Celsius. Thus, the present invention has an effective range of 400 degrees Celsius - 800 degrees Celsius. In prior art devices, such temperatures would burn the consumables, so the prior art devices were not useful at these temperatures. In the present invention, such high temperatures can also be used to improve the efficiency of aerosol generation and enable faster heating times.

[0071] The device (100) may further include a communication system (242). In a preferred embodiment, a Bluetooth Low Energy radio may be used to communicate with peripheral devices. The communication system (242) may be serially interfaced to the main processor, for example, to communicate with a telephone. A commercially available RF module (certified: FCC, IC, CE, MIC) may also be used. One example is to utilize Laird's BL652 module, as SmartBasic support enables rapid application development. The communication system (242) enables the user to program the device (100) to suit personal preferences related to, for example, aerosol density, the amount of flavor released, etc., by controlling the frequency and three-stage duty cycle, specifically, the preheating stage, heating stage, and relaxation stage of the induction heating element (160). The communication system (242) may have one or more USB ports (236).

[0072] In some embodiments, an RTC (Real Time Clock / Calendar) with battery backup may be used to monitor usage information. The RTC may measure and store relevant user data used with an external app downloaded to a peripheral device such as a smartphone.

[0073] In some embodiments, a micro USB connector (or a USB Type-C connector, or other suitable connector) may be located on the bottom surface of the case (202). Support connectors with plastic products may be arranged on all surfaces to reduce the load on the connector due to the cable's force.

[0074] As an example, the device (100) can be used as follows. Power for the device can be turned on from the momentary activation of the trigger (232). For example, a short press of the trigger (< 1.5 seconds) can turn on the device (100) but does not start a heating cycle. During this time, if a second short press (< 1 second) is made on the trigger (232), the device (100) is kept on for a long time and starts a Bluetooth notification if there is no active (connected) Bluetooth connection to the phone. A long press of the trigger (> 1.5 seconds) starts a heating cycle. Power to the device (100) can be on for a short time (e.g., 5 seconds) after each heating cycle and displays the updated unit status on the OLED user interface (230) before powering off. In some embodiments, the device (100) can be powered on when the consumable-containing package (102) is deployed from the case (202). In some embodiments, another power switch (246) can be used to turn the device on and off.

[0075] When an active connection to the smartphone is confirmed and the custom application is running on the smartphone, the device (100) stays powered on for up to two minutes and then powers off. When the battery level is too low to operate, the user interface display (230) blinks several times (while indicating that the battery icon is "0%") before the unit turns off.

[0076] In some embodiments, the user interface (230) displays segmented tobacco and indicates which segments remain (solid) and which are used (dotted) as an indicator of how much consumable-containing package (102) still contains consumables that can be dispensed. The user interface (230) also displays a battery icon updated with the current battery state, a charging icon (lightning bolt) when the device is plugged into a power source, and a Bluetooth icon when there is an active connection to a smartphone. The user interface (230) may show a Bluetooth icon that blinks slowly when there is no connection but the device (100) is issuing a notification.

[0077] The device may also have an indicator (248) to notify the user of the power state. The indicator (248) can be an RGB LED. As just one example, the RGB LED turns on a green LED when the device is first powered on, blinks a red LED during a preheat time, turns on a red LED during a "draw" time, and blinks a blue LED while charging. The duty cycle of the blinking indicates the battery charge state relative to 20% increments (20 - 100%) (when filled in blue, it means a full charge state). When an active Bluetooth connection is detected (a phone is connected to the device and a custom application on the phone is running), the blue LED can blink rapidly.

[0078] Haptic feedback can provide additional information to the user during use. For example, two short pulse signals can be sent as soon as power is turned on from the (finger-operated trigger button). At the end of the preheat cycle, an extended pulse signal can be sent to indicate that the device is moving to an inhalation (start of the HNB "draw" cycle). A short pulse signal can be sent when a USB power source is first connected or disconnected. A short pulse signal can be sent when an active smartphone application running on the smartphone and an active Bluetooth connection are established.

[0079] After powering on from a short press (less than 1.5 seconds) of the Finger Grip Button, Bluetooth connection can be initiated. If there is no "bonded" BLE (Bluetooth Low Energy) connection, when a second short press is detected after the first short press to power on the device, the device may slowly start the notification (pairing mode). Once the connection with the smartphone application is established, the Bluetooth icon on the user interface display (230) stops blinking and the blue LED turns on (lights up). When the device (100) is powered on and has a "bonded" connection with the smartphone, the device may start notifications to try to re - establish the connection with this phone until it is powered off. If this connection with the smartphone can be re - established, the unit will stay powered on for up to 2 minutes and then power off. To delete the bonded connection, the user can power on the device with a short press and then press it again. While the BLE icon is blinking, the user can keep pressing the trigger (232) until the device (100) vibrates and the Bluetooth icon disappears.

[0080] Therefore, strict control of the aforementioned conversion efficiency factor and product consistency factor makes it possible to provide a controlled heat supply to the consumable - containing unit (104). This controlled heat supply includes a microprocessor controller (166) for monitoring the induction heating system (160) to maintain various levels of power supply to the susceptor (106) during controlled time intervals. These characteristics enable the user control function, thereby allowing the selection of the flavor of the consumable as determined by the temperature at which the consumable aerosol is generated.

[0081] In some embodiments, a microprocessor or configurable logic block may be used to control the frequency and power supply of the induction heating system. As shown in FIG. 10A, the induction heating system (160) may include a wire coil (162) in parallel with one or more capacitors (260) to and from a self-resonant oscillator. The inductance of the coil (162) combined with the capacitance of the capacitor (260) largely defines the resonant frequency at which the circuit operates. However, in this embodiment, a microprocessor / microcontroller (166) may be used instead to drive the power switch and thus control the oscillation frequency of the circuit. In this approach, peak voltage and current are used as feedback to enable a microprocessor control program to provide closed-loop tuning to find resonance. The advantage of this approach is that it can efficiently control the power supplied to the susceptor and provide optimal on / off switching of the power control element driving the induction coil system by synchronously switching the on and off of the oscillation of the circuit under the control of the microprocessor (166) control program.

[0082] Based on these concepts, many variations have been considered by the inventors. Thus, as discussed above, the present invention includes a consumable-containing unit (104), a susceptor (106) embedded within the consumable-containing unit (104), a heating element (160) configured to at least partially surround the consumable-containing unit (104), a controller (166) for controlling the heating element (160), and a case (202) housing the consumable-containing unit (104), the susceptor (106), the heating element (160) and the controller (166). Preferably, the consumable-containing unit (104), together with the susceptor (106), is housed in a consumable-containing package (102). As such, since some embodiments do not necessarily require packaging of the consumable-containing unit (104), any description of the relationship between the other components of the present invention and the consumable-containing package (102) may also apply to the consumable-containing unit (104).

[0083] In some embodiments, as shown in FIG. 10A, the apparatus includes a self-resonant oscillator for controlling the induction heating element (160). The self-resonant oscillator includes a capacitor (260) operably connected in parallel to the induction heating element (160). In some embodiments, as shown in FIG. 10B, a plurality of heating elements (160) may be connected in parallel to respective capacitors (260a, 260b). Preferably, the heating element is in the form of coil wires (162a, 162b).

[0084] A plurality of heating elements (160) and / or movable heating elements (160) may be used to enable a single consumable-containing package (102) to generate an aerosol multiple times. Thus, the heating element (160) includes a plurality of coil wires (162a, b), where each coil wire may be operably connected to a controller (166) for activation without being affected by other coil wires.

[0085] In some embodiments, the heating element (160) can be movable. In such embodiments, the consumable-containing package (102) may be an elongate member that defines a first longitudinal axis L, and the heating element (162) can be configured to move axially along the first longitudinal axis L. For example, as shown in FIG. 11, the heating element (160) can be attached to a carrier (270). The carrier (270) can be operably connected to the housing (202) such that the heating element (160) moves along the length of the consumable-containing package (102) while remaining wound as a coil around the consumable-containing package (102). The span S of the coil (measured as the straight-line distance from the first turn of the coil (272) to the last turn of the coil (274)) can be of a length sufficient to cover one segment of the consumable-containing package (102). Once the heating element (160) is activated in that segment, the carrier (270) advances along the consumable-containing package (102) along the longitudinal axis L to another segment of the consumable-containing package (102). The distance the carrier (270) moves is the distance at which the first turn of the coil (272) stops adjacent to where the last turn of the coil (274) previously was. Thus, a new segment of the same size as the previously heated segment is ready to be heated. This can continue until the carrier (270) moves from the first end (105) of the consumable-containing package (102) to the opposite end (107).

[0086] In embodiments where the consumable-containing package (102) houses a plurality of consumable-containing units (104), the span S of the coil can be approximately the same size as the length of the consumable-containing unit (104). The carrier (270) is configured to align the coil with the consumable-containing unit (104) such that the coil can heat the entire consumable-containing unit (104). The carrier (270) can be configured to move the coil from one consumable-containing unit (104) to the next, thereby also configuring the single consumable-containing package (102) to be heated multiple times, with an aerosol being released each time.

[0087] As shown in FIGS. 12A - 12E, to assist in properly aligning the heating element (160) around the consumable-containing package (102), the apparatus (200) may include a package aligner. For example, the package aligner may be a magnet (280). Preferably, the magnet (280) is a cylindrical magnet that defines a second longitudinal axis M. In an embodiment where the heating element (160) is a cylindrical coil wound around the consumable-containing package (102), the cylindrical coil defines a third longitudinal axis C. The cylindrical magnet (280) and the heating element (160) are configured to maintain alignment such that the second longitudinal axis M is collinear with the third longitudinal axis C. Preferably, the cylindrical magnet (280) is a round ring magnet and its center is a path for the air flow. Preferably, any magnet (280) will be of the rare earth neodymium type. It will be magnetized axially.

[0088] In an embodiment using the magnet (280) for alignment, one end (105) of the consumable-containing package (102) may include a magnetically attracting element (281). Preferably, the magnetically attracting element (281) is a press-worked sheet of first iron that is incorporated into one end (105) of the consumable-containing package (102). The cylindrical magnet (280) may be part of the aerosol generating device (200), and the consumable-containing package (102) may have a magnetically attracting element (281) or a washer at its end (105) such that the consumable-containing package (102) is attracted to the magnet (280) attached to the aerosol generating device (200). Other combinations of the magnet (280) and the magnetically attracting element (281) may be used at various positions to achieve the desired alignment.

[0089] In some embodiments, preferably embodiments using a consumable-containing package (102) comprising a filter tube (140) and a housing (150), the package aligner can be a receiving portion (151), such as a snug-fitting cylinder (if the housing (150) is cylindrical), that can be used to align the consumable-containing package (102), and the coil (162) can be positioned outside the receiving portion (151) as shown in FIG. 12E. Preferably, the receiving portion (151) is made of a non-conductive material such as borosilicate glass, quartz glass, pyrosilicate glass, Robax glass, and high-temperature plastics such as Vespel, Torlon, polyimide, PTFE (polytetrafluoroethylene), PEEK (polyetheretherketone), or other suitable materials to avoid induction heating. Alternatively, the cylinder may be made of a conductive material having a lower resistance than the susceptor (106) within the consumable-containing package (102), in which case some induction heating of the receiving portion (151) is possible, but not as much as for the susceptor (106). Other materials may be used, but examples of lower-resistance materials can include copper, aluminum, and brass if the susceptor (106) is made of a higher-resistance material such as iron, steel, tin, carbon, or tungsten. In some embodiments, a receiving portion (151) having a resistance greater than the susceptor (106) may be used, in which case the receiving portion (151) heats up via induction and the outside of the consumable-containing package (102) is heated. The receiving portion (151) can be fixed to the apparatus (200) and is properly aligned with the coil (162) such that the susceptor (106) is properly aligned with the coil (162) when the consumable-containing package (102) is inserted into the coil (162).

[0090] In some embodiments, the housing (150) may function as a receptacle. Thus, the housing (150) has the above-described characteristics rather than another receptacle (151), and the insertion into the coil (162) may function as an alignment process, or the housing may be fixed within a filter tube (140) that includes the coil (162) and the consumable-containing unit (104), and the susceptor (106) may be inserted into the housing (150).

[0091] In some embodiments, multiple activations of a single consumable-containing package may be effected with a susceptor (106) having multiple poles (290) as shown in FIGS. 13A-D. A multi-pole susceptor is a susceptor (106) having two or more poles (290). In some embodiments, the susceptor may have three poles (290a, 290b, 290c). In some embodiments, the susceptor (106) may have four poles. In some embodiments, the susceptor (106) may have more than four poles. In a preferred embodiment, the multi-pole susceptor (106) has three or four poles.

[0092] The multiple poles (290a, 290b, 290c) of the multi-pole susceptor (106) are generally parallel to each other as shown in FIGS. 13C and 13D. The multi-pole susceptor (106) is configured and can be embedded into the consumable-containing package (102) in such a way that each pole (290a, 290b, 290c) is parallel to the longitudinal axis L of the consumable-containing package (102), is equally spaced from the longitudinal axis L, and is equally spaced from each other along the outer circumference of an imaginary circle. Thus, as shown in FIGS. 14A-C, in cross-section, the poles (290a, 290b, 290c) of the susceptor are equally spaced from each other around the circular face of the consumable-containing package (102). Such an arrangement allows for the maximization of non-overlapping heating zones for each pole when each pole (290a, 290b, 290c) is activated to the maximum extent. In other words, when the susceptor poles (290a, 290b, 290c) are heated, they radiate heat radially from the susceptor poles (290a, 290b, 290c), creating circular heating zones centered on the susceptor poles (290a, 290b, 290c). Each susceptor pole (290a, 290b, 290c) heats its respective circular heating zone, although some overlap may be unavoidable. Collectively, the entire cross-sectional area of the consumable-containing unit (104) can be heated, with one cross-sectional segment being heated at a time.

[0093] When the heating element (160) is a coil on a cylinder wound around the susceptor (106), the maximum amount of energy is transmitted to the center of the cylindrical coil. Thus, when the susceptor (106) is aligned with the center of the cylindrical coil, the susceptor (106) will receive the maximum amount of energy from the electricity passing through the coil. In other words, when the susceptor poles (290a, 290b, 290c) are in line with the cylindrical coil, the susceptor poles (290a, 290b, 290c) will receive the maximum amount of energy from the cylindrical coil. Therefore, in order to heat each susceptor pole (290a, 290b, 290c) independently, the susceptor poles (290a, 290b, 290c), and the center of the coil must be moved relative to each other such that the center of the coil aligns in turn with one of the susceptor poles (290a, 290b, 290c). This can be accomplished by moving the susceptor poles relative to the coil, or the coil relative to the susceptor poles, or both.

[0094] In a preferred embodiment, the heating element (160) moves relative to the susceptor (106). For example, as shown in FIGS. 14A - 16D, a cylindrical coil is wound around the consumable-containing package (102), and each of the poles (290a, 290b, 290c) is configured to rotate along an eccentric path such that each is aligned with the center of the coil at a separate timing during a single rotation of the cylindrical coil. The consumable-containing package (102) may be an elongated member defining a first longitudinal axis L, where the heating element (160) is a coil wound around the consumable-containing package (102) to form a cylinder defining a second longitudinal axis C, and where the heating element (160) is configured to rotate around the consumable-containing package (102) along an eccentric path such that the second longitudinal axis C aligns with each of the poles (290a, 290b, 290c) of the multi-pole susceptor at a point during movement of the heating element around the consumable-containing package. Thus, the multi-pole susceptor (106) is stationary and the coil rotates in an eccentric path such that the coil center aligns in sequence with the linear axis of each susceptor pole (290a, 290b, 290c) during rotation. Electrical slip rings will supply energy to the rotating coil design along the eccentric path.

[0095] Rotation of the heating element (160) can be enabled by a series of gears (300a, 300b) operably connected to the motor (302). For example, as shown in FIGS. 17A - B, the heating element (160) can be mounted on the first gear (300a) such that the heating element can rotate with the first gear (300a). The second gear (300b) can be operably connected to the first gear (300a) such that the second gear (300b) causes rotation of the first gear (300a). The second gear (300b) can be operably connected to the motor (302) to rotate the second gear (300b). The heating element (160) is mounted on the first gear (300a) in such a way that rotation of the first gear (300a) moves the longitudinal axis C of the heating element (160) along an eccentric path, rather than rotating the heating element about a fixed and non - movable center. Thus, the center of the heating element (160) can be repositioned to align with different poles (290a, 290b, 290c).

[0096] In some embodiments, the heating element (160), gears (300a, 300b), and motor (302) can be mounted on a carrier (270) as shown in FIG. 19. The carrier (270) enables the heating element, gears (300a, 300b), and motor (302) to move axially along the length of the consumable - containing package (102). The carrier (270) can be operably connected to a driver (306) that is operably connected to a second motor (304). For example, the driver (306) can be threaded. The carrier (270) can have a threaded hole (276) into which the driver (306) is inserted. When the second motor (304) is activated, the driver (306) rotates. When the driver (306) rotates, the carrier (270) moves along the driver (306) as indicated by the two arrows in FIG. 19.

[0097] In some embodiments, rather than rotating the heating element (160) along an eccentric path, the heating element (160) can be translated along the X-Y axis as viewed in cross-section. Thus, the consumable-containing package (102) may be an elongate member defining a longitudinal axis L, where the heating element (160) is configured such that a cylindrical coiled heating element (160) moves radially with respect to the longitudinal axis L when viewed in cross-section so as to align in turn with each of the poles (290a, 290b, 290c) of the multipolar susceptor (106). In an X-Y axis positioning scenario, coil energy can be supplied via a flexible conductor or by movement of electrical contacts.

[0098] For example, the heating element (160) can be operably mounted on a pair of translation plates (310, 312) as shown in FIG. 20. Specifically, the heating element (160) may be mounted directly on the first translation plate (310), and the first translation plate (310) may be mounted on the second translation plate (312). The first translation plate (310) can be configured to move in the X or Y direction, and the second translation plate (312) can be configured to move in the Y or X direction, respectively. In the embodiment shown in FIG. 20, while the second translation plate (312) is configured to move in the Y direction, the first translation plate (310) is configured to move in the X direction. This configuration can be switched such that the first translation plate (310) is configured to move in the Y direction and the second translation plate (312) is configured to move in the X direction. The first and second translation plates (310, 312) can be operably connected to respective motors for moving the translation plates in the appropriate directions, for example via gears. Between the two translation plates (310, 312), the heating element (160) can be moved such that its longitudinal axis C can be aligned in a straight line with any of the poles (290a, 290b, 290c).

[0099] In other arrangements, the coil assembly can move along the linear axis of the susceptor, independent of the rotational or non-rotational movement mechanisms discussed above. Thus, a three-pole susceptor can enable the apparatus to heat the consumable-containing package (102) three times at the same linear position by heating three different poles (290a, 290b, 290c), after which the apparatus can move to the next linear position and heat three more times there. For a consumable-containing package (102) having four linear positions, one consumable-containing package should be able to provide twelve separate "draws", i.e., three poles times four positions along the length of the consumable-containing package (102).

[0100] In some embodiments, rather than moving the heating element (160) relative to the consumable-containing package (102), the consumable-containing package (102) can be moved relative to the heating element. Thus, the consumable-containing package (102) is configured to rotate within the heating element (160) in an eccentric path such that the second longitudinal axis C defined by the coil is aligned collinearly at some point with each of the poles (290a, 290b, 290c) of the multi-pole susceptor during rotation of the consumable-containing package (102) within the heating element (160). Alternatively, the consumable-containing package (102) is configured to move radially within the heating element (160) such that the second longitudinal axis C is aligned collinearly at some point with each of the poles of the multi-pole susceptor during movement of the consumable-containing package (102) within the heating element (160). In some embodiments, both the consumable-containing package (102) and the heating element (160) can move. For example, the heating element (160) can be moved linearly along the longitudinal axis of the consumable-containing package (102), and the consumable-containing package (102) can be moved in an eccentric path or a radial path to move the susceptor (106) into position relative to the heating element (106), such that all of the consumable is heated continuously as the user takes each draw. Other variations regarding movement may be used.

[0101] The above-described movement mechanism is merely an example. The mechanism of the X-Y-Z movement scenario can be accomplished using various combinations of motors, linear actuators, gears, belts, cams, solenoids, and the like.

[0102] Referring to FIG. 21, the closed-loop control of the induction heating system can be based on the sensing of the magnetic flux density created by the induction heating system. The induction heating system operates by creating a concentrated alternating magnetic field inside the induction coil heating element. This magnetic field creates a heating effect in the metal susceptor by virtue of the eddy currents and magnetic flux reversals (assuming a ferromagnetic susceptor material) that occur within the susceptor material. Induction heating is generally "open-loop" in that the means for monitoring the susceptor temperature inside the operating induction coil is limited. Under controlled conditions, the magnetic flux outside the induction coil and reasonably close to the coil can be used to determine the magnetic flux intensity inside the coil. For example, a small coil (310) can be placed reasonably close to the induction coil type heating element (160) such that its axis is substantially parallel to the magnetic field lines of the magnetic flux passing through the small coil (310), and further, means are provided for detecting the magnitude of the magnetic flux of the induction coil type heating element that exists by virtue of the voltage induced beyond the small coil (310) by the alternating magnetic flux passing through the small coil (310). Subsequently, the magnitude of this external magnetic flux can be calibrated to correlate with the magnetic flux density inside the heating element (160) and can be used as a means for closed-loop control of the induction system to ensure consistent performance as long as the susceptor (106) is being heated. The magnetic flux exists symmetrically around the axis of the induction coil. The measurement of the magnetic flux density existing at any location near the induction coil can be used to extrapolate the magnetic flux density inside the heating element based on the characterization of the relative magnitudes of the magnetic flux at each location (inside the induction coil and inside the parasitic sensing coil). In practice, it is not necessary to quantify this because magnetic flux sensing is instead used to infer the proportion of heat generated in the susceptor (106) present in the magnetic field. Thus, the small coil (310) configured in this way functions as a magnetic flux sensor.

[0103] Thus, in some embodiments, the apparatus may further include a magnetic flux sensor adjacent to the induction heating element (160) and configured to measure the magnetic flux created by the induction heating element (160). The magnetic flux sensor may be operably connected to a controller (166) for controlling activation of the induction heating element (160) based on feedback from the magnetic flux sensor.

[0104] In some embodiments, it may be desirable for the consumable-containing unit (104) or a portion thereof to be able to detect whether it has been heated. If the consumable-containing unit (104) has already been heated, the heating element (160) may heat the next consumable-containing unit (104) or the next segment of the consumable-containing unit (104) to prevent energy from being wasted in the used portion of the consumable-containing unit (104). Thus, in some embodiments, as shown in FIG. 11, the apparatus is provided with a method for detecting segments of a used consumable-containing package (102) to enable the apparatus to autonomously determine the next unused segment available for use. For example, the apparatus may include a usage sensor (320) for detecting whether a portion of the consumable-containing package (102) being sensed has been heated above a predetermined temperature. In some embodiments, the usage sensor (320) may detect a visible change in the consumable-containing package (102) indicative of heating. In some embodiments, the usage sensor (320) may detect a thermal change in the consumable-containing package (102) indicative of heating. In some embodiments, the usage sensor (320) may detect a change in the texture of the consumable-containing package (102) (i.e., a change in texture) indicative of heating. In some embodiments, the usage sensor (320) may be a controller that records the location of the heating element (160) along the consumable-containing package (102) and when it was heated in relation to its movement along the consumable-containing package (102). For example, the controller may include a memory for storing the location of the portion of the consumable-containing package (102) that has been heated to a predetermined temperature.

[0105] In a preferred embodiment, the usage sensor (320) is a light reflection sensor. The light reflection sensor can be configured to detect a change from the original state of the consumable-containing package (102) as compared to the state when the consumable-containing package (102) is exposed to significant heat (i.e., above its normal temperature for that day). More preferably, the consumable-containing package (102) can contain a heat-sensitive dye that changes color when heated to a predetermined temperature. Such a color change can be detectable by the light reflection sensor.

[0106] The heat-sensitive dye can be printed around the outer surface of the consumable-containing package (102). When a segment of the consumable-containing package (102) is heated, the band (322) closest to the heated segment changes color. For example, the band (322) can change from white to black. The usage sensor (320) on which the heating element (160) is mounted has an optical system (324) focused above or below the heating element to provide a side view of the consumable-containing package (102) over the entire range of movement of the moving heating element (160).

[0107] In some embodiments, a limit switch (326) is also incorporated into one end (105) of the consumable-containing package (102) and is used to detect when the consumable-containing package (102) has been removed and reinserted into the device. When the consumable-containing package (102) is reinserted, the device activates the motor-driven heating element assembly and moves it over its full range of movement, and the usage sensor (320) can detect whether there is a previously heated segment by detecting the dark band (322) of the heat-sensitive dye. Thus, the device can further include a limit switch (326) for resetting the memory when a new consumable-containing package (102) is inserted into the housing.

[0108] In some embodiments, to manage heat dissipation from the heating element (160), the apparatus may further include a heat sink (330) operably connected to the induction heating element (160). Inductive heating involves the circulation of a high current in an induction coil, which results in resistive heating in the wire used to form the coil. Heat dissipation utilizes a material with high thermal conductivity that is electrically insulating to form the heat sink (330). Preferably, the heat sink (330) can be formed through either an injection molding or potting processes. Since the preferred embodiment utilizes a cylindrical coil as the heating element (160), the heat sink (330) may also be a cylinder formed around the induction coil, encapsulating the coil as shown in FIG. 22. The cylindrical heat sink (330) encapsulating the heating element (160) is present within a vertical cavity inside the case (202), forming a kind of "chimney" where air convection occurs internally. The chimney requires ventilation to assist the airflow. This method also removes electromagnetic field fringing and enables a very focused heating method on each segment of the consumable-containing package (102). As a result of such focusing, there is no need to encapsulate the consumable-containing unit (104) inside the consumable-containing package (102) made of a non-conductive foil or other similar material, and paper or other similar materials are sufficient.

[0109] In a preferred embodiment, the heat sink (330) is a finned cylinder that includes the induction heating element (160). The finned cylinder is a cylindrical heat sink having fins (332) that project laterally away from its outer surface (334). Preferably, each fin (332) extends substantially the length of the cylinder and provides a substantial surface area through which heat from the heating element (160) can dissipate. The heat conductive material of the heat sink (330) may be a polymer. The thermally conductive polymer may be a thermosetting or thermoplastic molding or embedding resin. The heat sink (330) may be machined, molded, or formed from these materials. The materials may be rigid or elastic. Some examples of thermally conductive composites used in thermally conductive polymers are aluminum nitride, boron nitride, carbon, graphite, and ceramics. In a preferred embodiment, the heating element (160) is an induction coil encapsulated in a finned cylinder of thermally conductive polymer molded around the coil, with an open center providing ventilation through a chimney-like effect.

[0110] In some embodiments, as shown in FIG. 23, the apparatus may further include an airflow controller (340) for providing means to adjust the flavor robustness of the consumable-containing unit (104) by controlling the airflow drawn through the consumable-containing package (102). The design of the consumable-containing package (102) is such that the amount of vapor / flavor introduced into the airflow path is a function of the duration and intensity of the inductive heating and results in a pressure difference between the air passages through the consumable-containing package (102). This pressure difference draws vapor out of the consumable-containing package (102) and into the airflow. If the airflow into the first end (105) of the consumable-containing package (102) can be controlled, it is possible to vary this pressure difference and introduce more (or less) vapor into the airflow, effectively varying the flavor robustness. Since this vapor is created by the temperature rise of the consumable, this ability to vary the flavor robustness is closely integrated with the heating of the consumable-containing package (102). By precise control of the heating process (time and rate) and the airflow through the first end (105) of the consumable-containing package (102), a wide range of flavor robustness experiences can be created.

[0111] For example, the airflow controller (340) may include an adjustable fluid control valve (342), such as a needle valve, butterfly valve, ball valve, or adjustable aperture. The adjustable fluid control valve allows the user to control the airflow during use. However, the airflow controller (340) may further be a membrane (344) with a fixed aperture, such as a porous or fibrous membrane or element. The membrane (344) may also serve as an intake particle filter. Thus, the fluid control mechanism may or may not be user-adjustable. In embodiments of the membrane (344), multiple membranes (344) with different sized apertures may be provided. Thus, the user can select the desired aperture size and apply the membrane (344) to the first end (105) of the device. If the user prefers more or less airflow, the user can respectively select another membrane (344) with a larger or smaller aperture. In some embodiments, the airflow controller (340) may use both the control valve (342) and the membrane (344). For example, the membrane (344) may be placed first to control the airflow and filter particles before the control valve (342), and then the control valve (342) may further control the airflow for fine-tuning control of the airflow.

[0112] In some embodiments, rather than flowing the aerosol from the consumable-containing unit (104) through the opening (120) of the container (108) into the filter tube (140) and towards the mouthpiece (158), as shown in FIGS. 25A-E, the airflow flows into the susceptor (106), extracts activity from the consumable-containing unit (104), and as a result, creates an aerosol that flows through the susceptor (106) towards the mouthpiece (158). In such embodiments, the susceptor (106) may have one or more hollow poles with at least one inlet (352) along the length of each pole (350) and at least one outlet (354). The pole (350) includes a joining end (356) operatively connected to the susceptor base (358) and an open end (360) facing the susceptor base (358). The hollow pole (350) is connected to the susceptor base (358) at the joining end (356). The outlet (354) of the hollow pole (350) is located towards the open end (360). For example, the outlet may be at the tip (362) of the open end (360), or a plurality of outlets (354) may be angularly spaced around the outer peripheral surface of the hollow pole (350) on the open end (360) side.

[0113] In some embodiments, the tip (362) of the open end (360) may be pointed or sharp to facilitate entry into the consumable-containing unit (104). The particle size, density, binder, filler, or any component used in the consumable-containing unit (104) may be manipulated to allow entry of the susceptor poles (290, 350) and / or the piercing needle without causing excessive compression or a change in the density of the consumable-containing unit (104). A change in density from the "packed" compression of the consumable-containing unit (104) can have an adverse effect on the air or vapor passing through the consumable-containing unit (104).

[0114] After the susceptor (106) enters, particles of the consumable that can be pushed through the container (108) remain trapped in the cavity (368) between the consumable-containing unit (104) and the mouthpiece (158). Since the tips (362) of the poles (290, 350) are sharp, there is a low likelihood that the consumable will be discharged from the container (108).

[0115] In some embodiments, the outlet (354) and / or the inlet (352) may be covered with a coating that melts and disappears at the heating temperature. In a preferred embodiment, the consumable-containing unit (104) is long enough to cover the entire hollow pole (350) except for the outlet (354).

[0116] The susceptor base (358) may include an opening (364) corresponding to the hollow pole (350). In embodiments having a plurality of hollow poles (350a-d), each hollow pole (350a-d) has an opening (364) corresponding to itself.

[0117] In some embodiments, there may be a plurality of hollow poles (350a-d). The hollow poles (350a-d) may be arranged in a ring so as to fit the moving heating element (160) or the moving consumable-containing package (102). In some embodiments, there may be a single hollow pole (350) placed at the center of the susceptor base (358). In some embodiments, there may be a central hollow pole (350) surrounded by a plurality of hollow poles (350a-d). Other arrangements of the hollow poles (350) can also be used.

[0118] Each hollow electrode (350) may have at least one inlet (352) and at least one outlet (354). Preferably, the hollow electrode (350) includes a plurality of inlets (352) and a plurality of outlets (354). The inlets (352) may be arranged continuously along the length of the hollow electrode (350). In some embodiments, the inlets (352) may be arranged annularly around the outer periphery of the hollow electrode (350). Increasing the number of inlets (352) on the hollow electrode (350) increases the number of points through which the generated aerosol leaks out of the consumable-containing unit (104) and out of the consumable-containing package (102). Similarly, there may be a plurality of outlets (354) arranged annularly around the outer periphery of the electrode (350) on the open end (360) side.

[0119] In some embodiments, the consumable-containing unit (104) does not extend from one end (105) of the consumable-containing package (102) to the mouthpiece (158). Therefore, a cavity (368) exists between the consumable-containing unit (104) and the mouthpiece (158). This cavity (368) may be filled with a thermally conductive material, a flavorant, etc.

[0120] As shown in the cross-sectional view of FIG. 25E, in use, the susceptor (106) is embedded in the consumable-containing unit (104). When the susceptor (106) is heated by induction heating by the heating element (160), the consumable-containing unit releases an aerosol. When the user sucks on the mouthpiece (158), due to the pressure difference inside the consumable-containing package (102), the aerosol enters the hollow electrode (350) through the inlet (352) and exits through the outlet (354) (see the arrow indicating the air flow). Then the aerosol enters the cavity (368) of the consumable-containing package (102) and is filtered through the mouthpiece (158) for inhalation by the user. Therefore, the container (108) does not need to have an opening (120).

[0121] In some embodiments, as shown in FIGS. 26A - G, a single hollow pole (350) located at the center on the susceptor base (358) may have a plurality of poles (290a - d) surrounding the hollow pole (350). In such embodiments, the hollow pole (350) may be heated via induction heating, but it is not necessarily heated. In this embodiment, the consumable-containing unit (104) can have a central hole and can be inserted through the central hole for a snug fit with the hollow pole (350).

[0122] As shown in FIG. 26G, when the susceptor pole (290) is heated during use, the generated aerosol enters through the inlet (352) of the hollow pole (350) and exits through the outlet (354) into the mouthpiece (158), as indicated by the airflow arrows.

[0123] The aerosol generated by the methods and devices described in this specification is efficient and reduces the amount of toxic by-products found in conventional tobacco and other non-combustion heating devices.

Example

[0124] As shown in FIGS. 24A - C, a consumable-containing package (102) was prepared by compressing powdered tobacco mixed with a humectant and PGA to form a consumable-containing unit (104) around a susceptor (106), wrapped in a foil cover as a container (108), inserted into a filter tube (140) in such a way that there are openings (120) as air paths on three sides, covered with a standard tobacco paper as a housing (150), one end covered with a high-flow proximal filter as a mouthpiece (158), and the other end covered with a distal filter tip as an end cap (154). The susceptor (106) is in the form of a helically wound metal plate. The consumable-containing unit (104) and the container (108) have a triangular cross-section. The filter tube (140) is a helical paper tube.

[0125] The tests in Durham, North Carolina were conducted using a prototype device and it was confirmed that the susceptor was heated to 611 °C by the benefit of the correction of the power used in the test process.

[0126] The Durham tests were performed using a 20-port linear analytical smoking machine, SM459, and were conducted by technicians who were proficient in the equipment and all related accessories. The technicians placed three consumable-containing packages (102) in the smoking machine. The consumable-containing packages (102) were then “puffed” 6 times each, for a total of 18 times. The resulting aerosol was then collected on filter pads. The “smoking” regimen was at a puff volume of 55 mL with a 2-second puff time every 30 seconds, collected using a bell curve profile. Analysis of the collected aerosol confirmed that, despite the fact that combustion was generally assumed to occur at temperatures above 350 °C, there was 0.570 mg of carbon monoxide (CO) in the aerosol of each consumable stick, well below the level at which combustion could be assumed to have occurred.

[0127] The second set of tests was conducted in Richmond, Virginia. The Richmond tests were performed using a prototype device calibrated to heat the susceptor (106) at three separate settings of 275°C, 350°C and 425°C, with similarly configured consumable-containing packages (102). CO data was generated by Enthalpy Analytical (EA) LLC (Richmond, Virginia, USA) in accordance with EA method AM-007. The consumable-containing packages (102) were smoked using an analytical smoking machine in accordance with the established Canadian Intense smoking procedure. The vapor phase of the smoke (i.e., aerosol) was collected in a gas sampling bag attached to a smoking machine configured with the required inhalation parameters. A non-dispersive infrared absorption method (NDIR) was used to measure the CO concentration in the vapor phase as a percentage by volume (volume percent). Using the number of consumable-containing packages (102), number of inhalations, inhalation volume, and ambient conditions, the percent of CO was converted to milligrams per consumable-containing package (mg / cig).

[0128] It was confirmed that no CO was found in the aerosol generated at each of the settings, despite the fact that it is generally assumed that combustion would occur at temperatures above 350°C at the calibrated temperature settings.

[0129] The tests conducted were industry standard tests. In similar industry standard tests, commercially available non-combustion heating products have reported 0.436 mg / cig of CO. Standard combustible tobacco has reported 30.2 mg / cig of CO.

[0130] The foregoing description of the preferred embodiments of the invention is presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined not by this detailed description, but rather by the claims appended hereto and the equivalents of those claims.

Claims

1. 1. An apparatus for generating an aerosol comprising: a. a consumable-containing unit; b. a susceptor embedded within said consumable-containing unit; c. a container enclosing the consumable-containing unit and the susceptor, the container having a first end and a second end opposite the first end, the container including an opening; d. a coating that seals the opening; 13. An apparatus comprising:

2. The apparatus of claim 1 , further comprising a filter configured to surround the container in a manner that eliminates gaps between the filter and the container.

3. The device of claim 2 , wherein the filter covers the blocked opening.

4. The apparatus of claim 3 further comprising a housing for containing the filter.

5. 5. The device of claim 4, further comprising a plurality of containers and an induction heating element configured and programmed to selectively heat each container at a predetermined temperature selected by a user a predetermined number of times, the predetermined temperature being sufficient to melt the coating and release an aerosol from the consumable-containing unit of each container being heated.

6. and an aerosol generation device configured to hold the housing and the inductive heating element, the housing including a mouthpiece protruding from the aerosol generation device, the aerosol generation device comprising: a. a switch operably connected to the induction heating element for activating the induction heating element; b. a user interface operably coupled to the switch and the induction heating element for providing status information; c. a controller including a processor-based control of the frequency delivered to the induction heating element; The apparatus of claim 5 , comprising:

7. The device of claim 1 , wherein one of the first end or the second end of the container includes a fold to space it from an adjacent container.

8. The apparatus of claim 7 further comprising a plurality of openings in the container, the plurality of openings being located at the first end and the second end of the container.

9. The device of claim 1 , wherein the consumable-containing unit comprises two pellets of a powdered consumable.

10. The apparatus of claim 9 , wherein the susceptor is sandwiched between the two pellets.

11. The apparatus of claim 1 , wherein the susceptor is a metal plate.

12. The apparatus of claim 11 , wherein the metal plate includes a plurality of openings.

13. 12. The apparatus of claim 11, wherein the susceptor is an elongated metal plate having a longitudinal direction, the elongated metal plate including a set of openings and a set of gaps, the sets of openings alternating with the sets of gaps along the longitudinal direction of the elongated metal plate such that each set of openings is adjacent one of the gaps.

14. The device of claim 1 , wherein the coating comprises propylene glycol alginate.

15. The device of claim 1 , wherein the coating comprises a flavoring.

16. The apparatus of claim 1 , wherein the susceptor comprises steel wool.

17. The apparatus of claim 16 , wherein the susceptor comprises an additive.

18. 17. The apparatus of claim 16, wherein the susceptor is an elongated pad having a longitudinal direction, the elongated pad including sets of openings and sets of gaps, the sets of openings alternating with the sets of gaps along the longitudinal direction of the elongated pad such that each set of openings is adjacent one of the gaps.

19. 10. A method of using the device of claim 1, comprising releasing an aerosol form of consumable from said consumable-containing unit without producing toxic by-products associated with combustion.

20. 20. The method of claim 19, further comprising applying heat to the consumable-containing unit by heating the susceptor with an inductive heating element to release the aerosol form of the consumable from the consumable-containing unit without combusting the consumable-containing unit.

21. 21. The method of claim 20, wherein heat melts the coating and releases the consumable from the container in the form of an aerosol.

22. 1. A method of manufacturing an apparatus for generating an aerosol, comprising the steps of: a. embedding a susceptor into a consumable-containing unit; b. placing the consumable-containing unit and the susceptor in a container, the container having a first end and a second end opposite the first end, the container including an opening; c. applying a coating to the opening; d. placing the container into a filter; e. placing the filter into a housing containing the container; A method comprising:

23. 23. The method of claim 22, wherein the consumable-containing unit is pressed into the pellet to minimize oxygen within the pellet.

24. 24. The method of claim 23, wherein the consumable-containing unit is mixed with an additive to minimize oxygen within the pellets.

25. 25. The method of claim 24, further comprising stacking a plurality of containers within the filter.

26. 26. The method of claim 25, wherein the containers are separated from one another by creases created in one or more ends of the containers.

27. 1. An apparatus for generating an aerosol comprising: a. a consumable-containing unit; b. a susceptor embedded within said consumable-containing unit; c. a heating element configured to at least partially surround the consumable-containing unit; d. a controller for controlling the induction heating element; e. a case for housing the consumable-containing unit, the susceptor, the induction heating element, and the controller; 13. An apparatus comprising:

28. 28. The apparatus of claim 27, further comprising a self-resonant oscillator for controlling the heating element.

29. 30. The apparatus of claim 28, wherein the self-resonant oscillator comprises a capacitor operably connected to the heating element.

30. 30. The apparatus of claim 29, wherein the heating element includes a plurality of coils of wire, each coil operably connected to the controller for activation independent of the other coils.

31. 28. The apparatus of claim 27, wherein the heating element is movable.

32. 32. The apparatus of claim 31, wherein the consumable-containing unit is an elongate member defining a first longitudinal axis, and the induction heating element is configured for axial movement along the first longitudinal axis.

33. 33. The device of claim 32, wherein the consumable-containing unit includes a cylindrical magnet at one end of the consumable-containing unit, the cylindrical magnet defining a second longitudinal axis, and wherein the heating element is a cylindrical coil wrapped around the consumable-containing unit, the cylindrical coil defining a third longitudinal axis, and wherein the cylindrical magnet and the heating element are configured to maintain the second longitudinal axis aligned in a line with the third longitudinal axis.

34. The apparatus of claim 31 , wherein the susceptor is a multi-polar susceptor.

35. 35. The apparatus of claim 34, wherein the heating element is configured to rotate around the consumable-containing unit.

36. 36. The apparatus of claim 35, wherein the multi-polar susceptor has multiple poles parallel to one another and is embedded within the consumable-containing unit.

37. 37. The apparatus of claim 36, wherein the consumable-containing unit is an elongated member defining a first longitudinal axis, and wherein the heating element is a coil wrapped around the consumable-containing unit to form a cylinder defining a second longitudinal axis, and wherein the heating element is configured to rotate about the consumable-containing unit in an eccentric path such that the second longitudinal axis is aligned collinearly at one point with each of the poles of the multi-polar susceptor during rotational movement of the heating element about the consumable-containing unit.

38. 35. The apparatus of claim 34, wherein the consumable-containing unit is an elongate member defining a longitudinal axis, and the induction heating element is configured for radial movement relative to the longitudinal axis.

39. The apparatus of claim 27 , wherein the susceptor is a multi-polar susceptor.

40. 40. The apparatus of claim 39, wherein the multi-polar susceptor includes multiple parallel poles and is embedded within the consumable-containing unit.

41. 41. The apparatus of claim 40, wherein the consumable-containing unit is an elongated member defining a first longitudinal axis, wherein the heating element is a coil wrapped around the consumable-containing unit to form a cylinder defining a second longitudinal axis, and wherein the consumable-containing unit is configured to rotate within the heating element in an eccentric path such that the second longitudinal axis is aligned collinearly at a point with each of the poles of the multi-polar susceptor during rotation of the consumable-containing unit within the heating element.

42. 40. The apparatus of claim 39, wherein the consumable-containing unit is an elongated member defining a first longitudinal axis, wherein the heating element is a coil wrapped around the consumable-containing unit to form a cylinder defining a second longitudinal axis, and wherein the consumable-containing unit is configured to move radially within the heating element such that the second longitudinal axis is aligned collinearly at a point with each of the poles of the multi-polar susceptor during movement of the consumable-containing unit within the heating element.

43. 30. The apparatus of claim 27, further comprising a magnetic flux sensor adjacent to the heating element and configured to measure a magnetic flux produced by the heating element.

44. 44. The apparatus of claim 43, wherein the magnetic flux sensor is operably connected to a controller for controlling activation of the induction heating element based on feedback from the magnetic flux sensor.

45. 30. The apparatus of claim 27, further comprising a usage sensor for detecting whether the portion of the consumable-containing package being sensed has been heated beyond a predetermined temperature.

46. 46. ​​The apparatus of claim 45, wherein the occupancy sensor is a light reflective sensor.

47. 47. The device of claim 46, wherein the consumable-containing unit is contained in a consumable-containing package, the consumable-containing package including a heat-sensitive dye that changes color when heated to a predetermined temperature, and wherein the color change can be detected by the light reflective sensor.

48. 48. The apparatus of claim 47, wherein the controller further comprises a memory for storing locations of portions of the consumable-containing unit that have been heated to a predetermined temperature.

49. 49. The device of claim 48, further comprising a limit switch that resets the memory when a new consumable-containing unit is inserted into the case.

50. 30. The apparatus of claim 27, further comprising a heat sink operably connected to the heating element.

51. 51. The apparatus of claim 50, wherein the heat sink is a finned cylinder covering the heating element.

52. 30. The apparatus of claim 27, further comprising an airflow controller.

53. 53. The apparatus of claim 52, wherein the susceptor comprises a hollow pole.

54. 54. The apparatus of claim 53, wherein the hollow pole includes an inlet and an outlet.

55. 30. The apparatus of claim 27, further comprising a consumable-containing package aligner.

Images