Aerosol supply device

Abstract

To provide an aerosol supply device, an aerosol supply system, a method of generating aerosol, and a method of manufacturing the aerosol supply device.SOLUTION: An aerosol supply device includes: one or more inductor coils 14 wound around one or more stators 15; one or more susceptors; and a power supply 13 connected to the one or more inductor coils 14. The power supply 13 is configured to supply a vibration current to the one or more inductor coils 14.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device, an aerosol delivery system, a method for generating an aerosol, and a method for manufacturing an aerosol delivery device. [Background technology]

[0002] (background) Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide substitutes for these articles by creating products that release compounds without combustion. Examples of such products are so-called "non-combustion heating" products or tobacco heating devices or products that release compounds by heating but not burning a material. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] Aerosol delivery devices covering the above-mentioned devices or products are known. A typical aerosol delivery device uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. Often, the medium used needs to be replaced or changed to provide a different aerosol for inhalation. To generate an aerosol from a suitable medium, it is known to use an induction-heated aerosol delivery device as a heater. An induction-heated aerosol delivery device generally consists of a magnetic field generating device for generating a fluctuating magnetic field and a susceptor or heating material that is heatable by the penetration of the fluctuating magnetic field and heats the suitable medium.

[0004] One problem with conventional designs is that the inductor designs are relatively large and therefore not particularly suitable for miniaturization.

[0005] Another problem with conventional designs is that the inductor designs have relatively low magnetic field strength.

[0006] Another problem with conventional designs is that the inductor design provides a magnetic field that is limited to a particular area.

[0007] It would be desirable to provide an improved device that does not suffer from the above problems. Summary of the Invention

[0008] (overview) According to one aspect, an aerosol delivery device is provided, comprising: one or more inductor coils wound around one or more stators; one or more susceptors; and a power source connected to the one or more inductor coils, the power source configured to supply an oscillating current to the one or more inductor coils.

[0009] The aerosol delivery device may be positioned to enhance the generated magnetic field. Additionally, the magnetic field may be positioned to be moved to different locations. The aerosol delivery device is particularly suited to miniaturization, and the inductor arrangement may have a relatively high magnetic field strength.

[0010] Optionally, the one or more inductor coils comprise one or more mandrel coils.

[0011] Optionally, one or more mandrel coils may include a single turn of the coil, or alternatively, one or more mandrel coils may include multiple turns, for example, 2, 3, 4, 5, 6, 7, 8 or more turns.

[0012] Optionally, one or more of the stators are laminated.

[0013] One or more stators may be constructed from iron or ferrite, with multiple laminations between them.

[0014] Optionally, the aerosol delivery device further comprises a magnetic flux concentrator.

[0015] Optionally, the magnetic flux concentrator comprises ferrite material and / or a continuous sheet or strip of ferrite material.

[0016] Optionally, the one or more inductor coils are configured to generate a varying magnetic field.

[0017] Optionally, the aerosol delivery device further comprises one or more isolators disposed between the one or more inductor coils and the one or more stators.

[0018] Optionally, the one or more stators are arranged to enhance the magnetic field generated by the one or more inductor coils.

[0019] Optionally, one or more of the susceptors are heatable by the penetration of a varying magnetic field.

[0020] Optionally, the aerosol delivery device comprises a non-combustible aerosol delivery device.

[0021] According to another aspect, there is provided an aerosol generation system comprising the aerosol delivery device described above and an article for use with the aerosol delivery device.

[0022] Optionally, the article is for use with an aerosol delivery device having one or more inductor coils wound around one or more stators, the one or more inductor coils configured to generate a varying magnetic field, and the one or more susceptors positioned and adapted to be heated by the varying magnetic field.

[0023] Optionally, the article comprises an aerosol-forming material.

[0024] Optionally, the aerosol-forming material is provided (i) as a solid, (ii) as a liquid, (iii) in the form of a gel, (iv) in the form of a thin film substrate, (v) in the form of a thin film substrate having multiple regions, or (vi) in the form of a thin film substrate having multiple regions comprising aerosol-forming material, at least two of the regions having different compositions.

[0025] According to another aspect, a method of generating an aerosol is presented, comprising providing an aerosol delivery device as described above and inserting into the aerosol delivery device an article for use with the aerosol delivery device that includes an aerosol-generating material.

[0026] According to another aspect, there is provided an aerosol generation system including an aerosol delivery device having one or more inductor coils wound around one or more stators, one or more susceptors, and an article for location within and use with the aerosol delivery device during use.

[0027] According to another aspect, there is provided an aerosol generation system comprising: an aerosol delivery device; and an article for use with the aerosol delivery device, the article being located within the aerosol delivery device in use, the article comprising one or more inductor coils wound around one or more stators.

[0028] According to another aspect, a method for generating an aerosol is presented, comprising: providing an aerosol delivery device comprising one or more inductor coils wound around one or more stators and one or more susceptors, and the one or more susceptors; inserting an article including an aerosol-generating material into the aerosol delivery device; and supplying an oscillating current to the one or more inductor coils.

[0029] According to another aspect, a method for manufacturing an aerosol delivery device is presented, the method including: forming a device housing with one or more inductor coils wound around one or more stators and one or more susceptors; and connecting a power source configured to supply an oscillating current to the one or more inductor coils.

[0030] The article may comprise a substantially flat article. The article may comprise a plurality of discrete portions of aerosol-forming material. The article may comprise a substantially flat consumable. [Brief explanation of the drawings]

[0031] Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings. [Figure 1] 1 illustrates a schematic diagram of an example of an inductor coil configuration wrapped around a stator, according to various embodiments. [Figure 2] 1 shows a schematic cross-sectional side view of an example aerosol delivery device. [Figure 3] 1 shows a schematic perspective view of an example of an aerosol delivery device. [Figure 4] 1 shows a schematic perspective view of an example of an aerosol delivery device. [Figure 5A] 1 shows a planar view of a planar aerosol production article. [Figure 5B] 1 is an end view of the aerosol production article showing multiple susceptors embedded within the aerosol production article. [Figure 5C] 1 is a side view of an aerosol production article showing multiple susceptors embedded within the aerosol production article. DETAILED DESCRIPTION OF THE INVENTION

[0032] (Detailed explanation) As used herein, the term "aerosolizable material" or "aerosol-generating material" includes materials that provide volatile components upon heating, typically in the form of a vapor or aerosol. An "aerosolizable material" may be a non-tobacco-containing material or a tobacco-containing material. An "aerosolizable material" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. An aerosolizable material may be in the form of snuff, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, gelled sheet, powder, or agglomerate. An "aerosolizable material" may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. An "aerosolizable material" may include one or more humectants (e.g., glycerol or propylene glycol).

[0033] As used herein, the term "sheet" refers to an element having a width and length that is substantially greater than its thickness. A sheet may be, for example, a strip.

[0034] As used herein, the terms "heating material" or "heater material" refer to a material that can be heated by the penetration of a varying magnetic field.

[0035] The susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The heating material can be a conductive material, which causes induction heating of the heating material when the varying magnetic field penetrates it. The heating material can be a magnetic material, which causes magnetic hysteresis heating of the heating material when the varying magnetic field penetrates it. The heating material can be both conductive and magnetic, which allows the heating material to be heated by both heating mechanisms.

[0036] Induction heating is a process in which a conductive object is heated by penetrating a varying magnetic field into the object. This process is explained by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another, one or more eddy currents are generated within the object when the varying magnetic field generated by the electromagnet penetrates the object. The object has resistance to the flow of current. Therefore, when such eddy currents are generated within the object, they flow against the object's electrical resistance, causing the object to heat. This process is called Joule heating, Ohmic heating, or resistive heating.

[0037] The stator generally forms the stationary part of a rotating aerosol delivery device, such as that found in devices such as generators and electric motors. In use, the stator can concentrate magnetic flux, for example, the magnetic flux generated by an alternating current passing through an inductor coil, to create a stronger magnetic field. This magnetic field can be focused in a region of interest. Furthermore, the stator can direct the magnetic flux toward its intended target.

[0038] In one example, the susceptor is in the form of a closed circuit, which has been found to enhance magnetic coupling between the susceptor and the electromagnet during use, resulting in greater or improved Joule heating.

[0039] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by subjecting the object to a varying magnetic field. Magnetic materials can be thought of as comprising a large number of atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the orientation of the magnetic dipoles aligns with the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the applied varying magnetic field. This change in orientation of the magnetic dipoles generates heat within the magnetic material.

[0040] If an object is both conductive and magnetic, then subjecting the object to a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can enhance the magnetic field, thereby increasing Joule heating.

[0041] Because the heat is generated within the object itself, rather than by an external heat source via thermal conduction, each of the above processes can achieve rapid temperature rise and more uniform heat distribution in the object, particularly by selecting the appropriate object material and shape and the appropriate magnitude and orientation of the varying magnetic field relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the object, which may allow for greater design freedom and control of the heating profile, and may lower costs.

[0042] 1, a schematic diagram of one example of a component 12 used in an aerosol delivery device to generate a magnetic field is shown. Component 12 is used with an aerosol delivery device such as that described below with reference to FIG. 2. Component 12 includes a power supply 13, an inductor coil 14, a stator 15, a device 16 for applying a varying current, such as an alternating current, to inductor coil 14, a controller 17, a user interface 18 for user operation of controller 17, and a temperature sensor 19.

[0043] Although only one inductor coil 14 and one stator 15 are shown, in other configurations there may be multiple inductor coils 14 wound around each of multiple stators 16. Multiple inductor coils 14 wound around multiple stators 16 may be positioned in various locations on the aerosol delivery device depending on the characteristics and requirements of the device.

[0044] In configurations where two or more inductor coils are present, it will be understood that the inductor coils may, in some instances, have at least one characteristic that differs from one another. For example, a first inductor coil may have at least one characteristic that differs from a second inductor coil, and so on. More specifically, in one instance, the first inductor coil may have a different value of inductance than the second inductor coil. In another instance, the first and second inductor coils may be of different lengths, such that the first inductor coil is wound over a smaller section of each stator 15 than the second inductor coil. Thus, the first inductor coil may have a different number of turns than the second inductor coil (assuming the turn spacing of each is substantially the same). In yet another instance, the first inductor coil may be made of a different material than the second inductor coil. In some instances, the inductor coils may be substantially identical.

[0045] The power source 13 may include a rechargeable battery. The power source 13 may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power supply.

[0046] The inductor coil 14 can take any suitable form. For example, the inductor coil 14 can be in the form of a mandrel coil. The mandrel coil can include one turn or, alternatively, multiple turns, e.g., 2, 3, 4, 5, 6, 7, 8, or 9 or more turns. Alternatively, the inductor coil 14 can be in the form of a helical coil of a conductive material, such as copper. The inductor coil 14 is wound or wrapped around a portion of the stator 15. The inductor coil 14 may be wound around only a portion (i.e., not all) of the stator.

[0047] The stator 15 concentrates the magnetic flux generated by the inductor coil 14 during use, creating a stronger magnetic field. Furthermore, the stator 15 helps direct the magnetic flux toward its intended target. As described below with reference to Figures 2-4, the intended target is the susceptor 30, 30a, which defines the heating region of the aerosol delivery device. The susceptor 30, 30a includes a heating material that can be heated by the penetration of a varying magnetic field.

[0048] The stator 15 may have a high magnetic permeability and a low electrical conductivity, the latter helping to prevent the generation of eddy currents within the stator 15 during use, which in turn helps to prevent the stator 15 from heating up during use.

[0049] The stator 15 may include or be composed of ferrite. The ferrite may contain, for example, iron oxide combined with nickel and / or zinc and / or manganese. The ferrite may have a low coercivity and be considered a "soft ferrite," or may have a high coercivity and be considered a "hard ferrite." An example of a soft ferrite that can be used is a ferrite of the formula Mn a Zn (1-a) Manganese zinc ferrite with Fe2O4, and formula Ni a Zn (1-a) Nickel-zinc ferrite with Fe2O4. However, in each variant, the stator 15 may be made of one or more different materials.

[0050] For example, stator 15 may include multiple layers of conductive material insulated from one another by non-conductive material, e.g., stator 15 may be a laminated stator, i.e., stator 15 may have tens or even hundreds of layers of conductive material 20 insulated from one another by non-conductive material.

[0051] A device 16 for applying a varying current to the inductor coil 14 can be electrically connected between the power source 13 and the inductor coil 14. A controller 17 is also electrically connected to the power source 13 and communicatively connected to the device 16 for controlling the device 16. More particularly, the controller 17 is for controlling the device 16 to control the supply of power from the power source 13 to the inductor coil 14. The controller 17 can include an integrated circuit (IC), such as an IC on a printed circuit board (PCB).

[0052] In other configurations, controller 17 may take different forms. The apparatus may have a single electrical or electronic component comprising device 16 and controller 17. Controller 17 may be operated by user manipulation of user interface 18. User interface 18 may be located external to the aerosol delivery device in which configuration 12 is incorporated.

[0053] The user interface 18 may include push buttons, toggle switches, dials, a touch screen, etc. In other configurations, the user interface 18 may be remotely connected to the rest of the device wirelessly, such as via Bluetooth®.

[0054] Upon user operation of user interface 18, controller 17 causes device 16 to pass an alternating current through inductor coil 14 so as to generate an alternating magnetic field in inductor coil 14.

[0055] In the configuration described below with reference to Figures 2-4, when an article 2 on which aerosol-generating material 2a is placed is located within heating zone 211 adjacent to susceptor 30, the components of aerosol-supply device 12 and susceptor 30 of the aerosol-supply device are appropriately positioned such that the alternating magnetic field generated by inductor coil 14 is directed by stator 15, causing the magnetic field to penetrate the heating material of susceptor 30 and heat susceptor 30 by induction heating, thereby heating the aerosol-generating material 2a placed inside the article 2.

[0056] It will thus be apparent that configuration 12 can be used to advantageously focus the magnetic field to a small area. This is particularly advantageous when the physical patch or area of the medium (e.g., item 2) that needs to be heated is small or compact, as standard inductor coil configurations are unlikely to effectively heat the small area. Stator 15 can direct and enhance the magnetic field to the small area of susceptor 30, which heats the small area of the medium to be heated, thus providing a sufficient amount of aerosol for the end user.

[0057] In this manner, the inductor coil 14 can be isolated from the susceptor 30 and placed in a location on the device that allows for a compact configuration because the magnetic field generated by the inductor coil 14 can be manipulated by the stator 15 and directed to a selected area, and the inductor coil 14 does not need to be in close proximity to or surround the susceptor 30.

[0058] As mentioned above, if the heating material of the susceptor 30 is an electrically conductive material, this may cause one or more eddy currents to be generated within the heating material. The eddy currents flow within the heating material against the electrical resistance of the heating material, causing the heating material to heat by Joule heating. As mentioned above, if the heating material is made of a magnetic material, the orientation of the magnetic dipoles within the heating material changes with changes in the applied magnetic field, thereby generating heat within the heating material.

[0059] The temperature sensor 19 may be positioned to sense the temperature of the heating zone 211 during use. The temperature sensor 19 is communicatively connected to the controller 17 such that the controller 17 can monitor the temperature of the heating zone 211. In some configurations, the temperature sensor 19 may be configured to take optical temperature measurements of the heating zone 211 or the item 2.

[0060] Article 2 may include a temperature detector, such as a resistance temperature detector (RTD), for detecting the temperature of article 2. Article 2 may further include one or more terminals connected (e.g., electrically connected) to the temperature detector. The terminal(s) may be for connection, such as electrical connection, with a temperature monitor of the aerosol delivery device when the article is within heating zone 211.

[0061] The controller 17 may also include a temperature monitor such that the device's temperature monitor can determine the temperature of the item 2 during use of the item 2 with the device.

[0062] It is contemplated that by ensuring that the heating material of susceptor 30 has an appropriate resistance, the response of the heating material to temperature changes may be sufficient to provide information about the temperature inside article 2. Temperature sensor 19 may include a probe for analyzing the heating material.

[0063] Based on one or more signals received from temperature sensor 19 or a temperature detector, controller 17 may cause device 16 to adjust the characteristics of the fluctuating or alternating current passing through inductor coil 14 as needed to ensure that the temperature of heating zone 211 remains within a predetermined temperature range. The characteristics may be, for example, amplitude or frequency.

[0064] Within a predetermined temperature range, during use, the aerosol-forming material 2a material within the article 2 located within the heating zone 211 is heated sufficiently to volatilize at least one component of the aerosol-forming material 2a without burning the aerosol-forming material 2a.

[0065] Thus, the controller 17 and the entire device are configured to heat the aerosol-forming material 2a to volatilize at least one component of the aerosol-forming material 2a without burning the aerosol-forming material 2a1.

[0066] The temperature range may be about 50°C to about 300°C, e.g., about 50°C to about 250°C, about 50°C to about 150°C, about 50°C to about 120°C, about 50°C to about 100°C, about 50°C to about 80°C, or about 60°C to about 70°C. In some configurations, the temperature range may be about 170°C to about 220°C. In other configurations, the temperature range may be outside of this range.

[0067] In some configurations, the temperature sensor 19 may be omitted.

[0068] 2, there is shown a schematic cross-sectional side view of an example aerosol delivery device 2000. The aerosol delivery device 2000 comprises an apparatus 200 and a heating assembly that can be inserted into the apparatus 200. An article 2 including an aerosol-generating material 2 a is shown inserted into the aerosol delivery device 2000.

[0069] The article 2 may include an aerosol-generating material 2a in the form of a rod. The article 2 may include a cover around the aerosol-generating material 2a. The cover may surround the aerosol-generating material 2a and may help protect the aerosol-generating material 2a from damage during transportation and use of the article 2. The cover may include an adhesive (not shown) that adheres the overlapping free ends of the wrapper to one another. The adhesive helps prevent the overlapping free ends of the wrapper from separating. In other configurations, the adhesive and / or the cover may be omitted. In still other configurations, the article 2 may take a form different from any of those described above. The article 2 may include at least one filter (not shown). The article 2 includes a downstream end and an upstream end, the upstream end being insertable into the cavity 20 (see FIG. 2 ) of the heating assembly before the downstream end. The article 2 is configured so that a user inhales the volatile component(s) of the aerosol-generating material through the downstream end of the article 2.

[0070] Item 2 can be inserted into cavity 20 of the heating assembly in the direction indicated by F2. The direction of insertion of item 2 is the same as the direction of insertion of the heating assembly into the aerosol delivery device to heat susceptor 30 of the heating assembly. Thus, item 2 is inserted into the heating assembly in the upstream direction. Similarly, the heating assembly is inserted into the apparatus in the upstream direction.

[0071] Article 2 includes a mouth end and a distal end. The distal end is the upstream end, and the mouth end is the downstream end. The distal end of article 2a is initially inserted into cavity 20 (see FIG. 3) through open end 40. Thus, the heating assembly has a downstream end (e.g., distal end) and an upstream end (e.g., proximal end). When fully inserted into cavity 20, article 2 abuts the downstream end but protrudes away from the proximal end.

[0072] The heating assembly includes a susceptor 30 for use in heating the aerosol-generating material. The apparatus 200 includes the components 12 as described with reference to Figure 1. The susceptor 30 is formed from a heating material that is heatable by the penetration of a varying magnetic field.

[0073] The device 200 comprises a housing 210 that defines a heating zone 211. The heating zone 211 is a chamber into which a heating assembly can be inserted. The chamber of the device 200 is therefore a receptacle. The chamber may comprise a surface that is complementary in shape to a mating surface of the heating assembly.

[0074] Alternatively, the heating assembly may form part of the housing and is not removable. Instead, only the article 2 containing the aerosol-forming material 2 a is inserted into the aerosol delivery device 2000 and positioned in the heating zone 211 of the aerosol delivery device 2000.

[0075] 2, the article 2 may be first inserted into the heating assembly before the heating assembly and article 2 are inserted as a unit into the heating zone 211 of the apparatus 200. However, the heating assembly may also be first inserted into the heating zone 211 of the apparatus 200 before the article 2 is inserted into the cavity 20 of the heating assembly (see FIG. 3). The combined heating assembly and article 2 are inserted in direction X, which corresponds to the longitudinal dimension of the apparatus. Once inserted, the heating assembly may be restrained by the apparatus 200 to prevent movement of the heating assembly relative to the apparatus 200 in direction Y, which is perpendicular to direction X.

[0076] In other examples, the heating assembly may take a different form, with the susceptor 30 or susceptors located at different positions relative to the article 2, for example, having susceptors surrounding the heating zone 211 on all sides.

[0077] In this example, the heating assembly is shown having coupling regions, e.g., first surface 10a, second surface 10b, and third surface 10c. Each coupling region may be referred to as a coupler. While a single coupler 10a, 10b, 10c may be required to engage with each of the apparatus's retainers 200a, 200b, 200c, multiple couplers may be provided. The couplers 10a, 10b, 10c may be adapted to restrict movement, e.g., longitudinal movement, of the heating assembly relative to the apparatus 200 when the heating assembly is mounted therein. Thus, the couplers 10a, 10b, 10c and / or the retainers 200a, 200b, 200c act as blocking members to restrict movement of the heating assembly and hold the heating assembly within the apparatus 200 against movement in at least one direction, e.g., direction X and / or direction Y. Such directional movement may be axial movement, i.e., movement in the axial direction of the heating assembly corresponding to direction X. The couplers 10a, 10b, 10c and / or the retainers 200a, 200b, 200c can resist translational movement of the heating assembly corresponding to the Y direction.

[0078] Alternatively or additionally, each coupler 10a, 10b, 10c and / or each respective retainer 200a, 200b, 200c may resist rotation of the heating assembly relative to the device 200 about the longitudinal axis.

[0079] The couplers 10a, 10b, 10c and / or the retainers 200a, 200b, 200c may be abutting members for abutting at least one surface of the device 200 or heating assembly, respectively. The couplers 10a, 10b, 10c and / or the retainers 200a, 200b, 200c may limit the degree of movement of the heating assembly.

[0080] The couplers 10a, 10b, 10c may be blockable by corresponding abutment members or portions of the device 200 to prevent movement of the heating assembly within the device 200, particularly when an article containing the aerosol-generating material is removed from the heating assembly.

[0081] Referring to Figure 3, a cross-sectional side view of one example of an aerosol-delivery device 2000 according to one configuration is shown. The aerosol-delivery device 2000 includes an apparatus 200 and a heating assembly insertable into the apparatus 200, the heating assembly including a susceptor 30 for use in heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material. The apparatus 200 includes components 12 as described with reference to Figure 1, and a device 16 configured to pass a varying electric field through an inductor coil that generates a varying magnetic field. The magnetic field penetrates a stator 15, where it is strengthened and directed toward the susceptor 30.

[0082] The susceptor 30 is formed from a heating material that is heatable by the penetration of a varying magnetic field, which in turn heats the article containing the aerosol-forming material.

[0083] More specifically, device 200 includes housing 210. A mouthpiece (not shown) may be connected to housing 210 and / or heating assembly. The mouthpiece may be made of any suitable material, such as a plastic material, cardboard, cellulose acetate, paper, metal, glass, ceramic, or rubber. The mouthpiece may define a channel therethrough. When the heating assembly is inserted into heating zone 211, the mouthpiece may be positionable relative to housing 210 to cover an opening into heating zone 211 or heating assembly cavity 20. When the mouthpiece is so positioned relative to housing 210, the channel in the mouthpiece is in fluid communication with heating zone 211. During use, the channel acts as a passageway to allow volatile material to pass from the aerosol-generating material of an article inserted into heating zone 211 to the exterior of device 200. The mouthpiece of device 200 may be engageable and detachable with housing 210 to connect the mouthpiece to housing 210. In other configurations, the mouthpiece and housing 210 may be permanently connected, such as by a hinge or flexible member. In some configurations, such as configurations in which the article itself includes a mouthpiece, the mouthpiece of device 200 may be omitted.

[0084] Device 200 can define an air inlet (not shown) that fluidly connects heating zone 211 with the exterior of device 200. Such an air inlet can be defined by housing 210 and / or any mouthpiece. A user can inhale the volatile component(s) of the aerosol-generating material by drawing the volatile component(s) through a channel in the optional mouthpiece. Once the volatile component(s) have been removed from the article, air can be drawn into heating zone 211 through the air inlet of device 200.

[0085] 1, comprising components 12, such as a power supply 13, an inductor coil 14, a device 16 for applying a varying current, such as an alternating current, to the inductor coil 14, a controller 17, and a user interface 18 for user operation of the controller 17. The apparatus 200 further comprises a temperature sensor 19 for sensing the temperature of the heating zone 211.

[0086] The device 200 further includes a sensor 216 for detecting information regarding use of the device 200 when the device 200 is coupled to the heating assembly. The information may be stored in the device's memory 217. The memory may include a data storage device. The sensor 216 may also perform an action when the information meets a predetermined criterion. In some configurations, the sensor 216 may provide an indication when the information meets the predetermined criterion. The predetermined criterion may be total power-on time. For example, the information detected by the sensor 216 may be elapsed time. Thus, the total power-on time corresponds to the elapsed time since the device 200 was turned on. The device 200 may be considered to be turned on when the susceptor 30 is first penetrated by the fluctuating magnetic field. Alternatively or additionally, the sensor 216 may detect information regarding multiple sessions of use of the device. A single session may include a predetermined number of puffs by a user on an article. Alternatively, a single session may include a predetermined time from the first time the user puffs on an article or from the first time the susceptor 30 is activated.

[0087] The controller 17 may be configured to control the device 16 based on the information. The information may be analyzed by an analyzer 220 of the apparatus 200. The analyzer 220 receives information from at least one sensor 216 or temperature sensor 19, and the information is transmitted to the controller 17, which determines how to control the configuration of the inductor 14 and stator 15 based on the information analyzed by the analyzer 220. For example, the heating device 16 may be configured to measure the number of sessions, which may be the number of activations of the power-on button or puff sensor, or the total power used or the total power-on time. When a threshold is reached, the heating device 16 may indicate to the user that the susceptor 30 needs to be replaced and / or the heating device 16 may not enable heating of the susceptor 30.

[0088] In this configuration, power supply 13 is a rechargeable battery. In other configurations, power supply 13 may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power supply.

[0089] The inductor coil 14 can take any suitable form. In this configuration, the inductor coil 14 is a mandrel coil. As described above, the inductor coil 14 can be wrapped around the stator 15 such that the stator 15 concentrates the magnetic flux generated by the inductor coil 14 during use, creating a stronger magnetic field. As a result, the aerosol delivery device 2000 can be made more compact, capable of heating smaller items that may contain, for example, small amounts of gel or any other suitable aerosol-generating material, because the magnetic flux can be concentrated in the susceptor 30 to heat a small or specific area.

[0090] The stator 15 may be made of, for example, iron. In some configurations, the stator 15 may extend only partially along the length of the inductor coil 14 to concentrate the magnetic flux only in certain areas. In some configurations, the inductor coil 14 may be a planar coil; that is, the inductor coil 14 may be a two-dimensional spiral.

[0091] Referring to Figure 4, a schematic perspective view of an example system 2000 is shown. System 2000 includes apparatus 200 and a heating assembly insertable into the apparatus, the heating assembly including a susceptor 30a for use in heating an aerosol-generating material. Features in Figure 4 that have the same reference numbers as Figure 3 are the same. The difference between Figure 3 and Figure 4 is that the susceptor 30 in Figure 3 is on only one side of the heating assembly, whereas in Figure 4 the susceptor 30a is tubular.

[0092] The heating susceptor 30a shown in FIG. 4 is hollow. The susceptor 30a may be formed from a sheet. The susceptor 30a may be a single piece. The sheet may have a constant thickness. The susceptor 30a may have a constant cross-sectional shape. For example, the susceptor 30a may have a substantially circular, square, or rectangular cross section along the length of the susceptor 30a. The length of the susceptor 30a may be greater than the width of the susceptor 30a perpendicular to the length. In other configurations, the length and width may be substantially equal. In yet other configurations, the susceptor 30a may have a length that is less than its width.

[0093] The susceptor 30a shown in FIG. 4 is generally cylindrical with a substantially circular cross-section. In other configurations, the susceptor 30a may have an oval or elliptical cross-section, or may be other than cylindrical. In some configurations, the susceptor 30a may have a polygonal, quadrilateral, rectangular, square, triangular, star-shaped, or irregular cross-section, for example. In this configuration, the susceptor 30a is a tube. The susceptor 30a includes a chamber, which is a hollow interior region of the tube. The chamber 20 can correspond to the heating zone 211 when the susceptor 30a is disposed within the apparatus 200. The chamber 20 is configured to receive the aerosol-generating material.

[0094] The susceptor 30a may include an extruded member formed by an extrusion process. The extruded member may be tubular such that the cross section of the body is a seamless ring.

[0095] The susceptor 30a in Figure 4 is open at both a first end and a second end opposite the first end. Thus, the first end includes a first opening, and the second end includes a second opening. The first and second openings may be axially aligned on the longitudinal axis. The first and second openings may be parallel to one another.

[0096] Aerosol-generating material may be insertable into cavity 20 through opening 40. Opening 40 is thus the first pass of the aerosol-generating material into cavity 20. The longitudinal wall(s) of susceptor 30a extend between first and second ends of susceptor 30a. Alternatively, susceptor 30a may have a single open end.

[0097] The thickness of the susceptor 30a may be less than 100 μm. The thickness may be 10 μm to 40 μm. The thickness may be 20 μm to 30 μm. The thickness may be approximately 25 μm.

[0098] The one or more removable susceptors may include one or more ferrite elements. The one or more ferrite elements may comprise a ceramic material. The one or more ferrite elements may be formed by mixing iron (III) oxide (Fe2O3) with one or more additional metal elements to form a mixture and then heating the mixture to form a ceramic. The one or more additional metal elements may be selected from the group including (i) barium, (ii) manganese, (iii) nickel, and (iv) zinc. The ferrite elements may be non-conductive. The ferrite elements may comprise an electrical insulator. The ferrite elements may be either (i) magnetizable, (ii) ferromagnetic, or (iii) ferrimagnetic.

[0099] The one or more inductor coils may be arranged to generate a varying magnetic field, and the one or more susceptors may be arranged to be heated by the varying magnetic field.

[0100] The one or more susceptors may be positioned and adapted to heat, without combustion, an aerosol-generating material provided in an article for use with an aerosol delivery device.

[0101] The one or more susceptors may be positioned and adapted to generate an aerosol from an aerosol-forming material provided in an article for use with an aerosol delivery device.

[0102] An article for use with an aerosol delivery device may include an aerosol-generating material and may be provided (i) as a solid, (ii) as a liquid, (iii) in the form of a gel, (iv) in the form of a thin film substrate, (v) in the form of a thin film substrate having multiple regions, or (vi) in the form of a thin film substrate having multiple regions, at least two of the regions comprising an aerosol-generating material having a different composition.

[0103] An aerosol delivery device is disclosed that includes one or more inductor coils, which may be configured and adapted (i) to receive an article for use with the aerosol delivery device that is located within the aerosol delivery device during use, and (ii) to receive one or more removable susceptors that are located within the aerosol delivery device during use.

[0104] A method of generating an aerosol is disclosed, the method including the steps of providing an aerosol delivery device having one or more inductor coils, placing an article for use with the aerosol delivery device within the aerosol delivery device, and placing one or more removable susceptors within the aerosol delivery device.

[0105] An aerosol delivery system is disclosed that includes an aerosol delivery device and an article for use with the aerosol delivery device, the article for use with the aerosol delivery device being located within the aerosol delivery device during use. The article for use with the aerosol delivery device may include one or more inductor coils and / or one or more susceptors.

[0106] The one or more susceptors may include one or more ferrite elements. The one or more ferrite elements may include a ceramic material. The one or more ferrite elements may be formed by mixing iron (III) oxide (Fe2O3) with one or more additional metal elements to form a mixture and then heating the mixture to form a ceramic. The one or more additional metal elements may be selected from the group including (i) barium, (ii) manganese, (iii) nickel, and (iv) zinc.

[0107] The one or more ferrite elements may be non-conductive. The one or more ferrite elements may be electrical insulators. The one or more ferrite elements may be either (i) magnetizable, (ii) ferromagnetic, or (iii) ferrimagnetic. The one or more inductor coils may be arranged to generate a varying magnetic field, and the one or more susceptors may be arranged to be heated by the varying magnetic field.

[0108] The one or more susceptors may be positioned and adapted to heat an aerosol-generating material provided in an article for use with the aerosol delivery device. The one or more susceptors may be positioned and adapted to generate an aerosol from an aerosol-generating material provided in an article for use with the aerosol delivery device. The aerosol delivery device may comprise a non-combustible aerosol delivery device.

[0109] Also disclosed is a method of manufacturing an aerosol delivery device that includes forming one or more inductor coils and one or more susceptors in the aerosol delivery device, where at least one of the susceptors may include one or more ferrite elements.

[0110] Also disclosed is a method of manufacturing a susceptor that includes forming one or more removable susceptors that are located within an aerosol delivery device during use and that can be easily removed from the aerosol delivery device.

[0111] Also disclosed is a method of manufacturing an article for use with a non-combustion aerosol delivery device, comprising forming an article for use with the aerosol delivery device that is located within the aerosol delivery device during use, wherein the article for use with the non-combustion aerosol delivery device may include one or more inductor coils and / or one or more susceptors.

[0112] Article 2 includes a consumable item or an item for use with a non-combustible aerosol delivery device. Once all or substantially all of the volatilizable component(s) of the aerosol-generating material 2a within Article 2 have been consumed, a user can remove Article 2 from the cavity 20 of the heating assembly and discard Article 2. The user can then use the device 200 again with another Article 2. However, Article 2 may be non-consumable relative to the heating assembly. That is, the heating assembly and Article 2 may be discarded together once the volatilizable component(s) of the aerosol-generating material 2a have been consumed.

[0113] Article 2 may be sold, supplied, or otherwise provided separately from device 200 with which it can be used. Device 200 and one or more of articles 2 may be provided together as a system, such as a kit or assembly, possibly with additional components such as cleaning implements.

[0114] The aerosol delivery device may include a hybrid aerosol delivery device that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. The hybrid aerosol delivery device may include a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0115] The aerosol delivery device may comprise an aerosol delivery device and an article for use with the aerosol delivery device. However, it is contemplated that an article that itself comprises means for powering an aerosol generating component may itself form the aerosol generating aerosol delivery device. The aerosol delivery device may comprise a power source and a controller. The power source may be, for example, a power source.

[0116] An article for use with an aerosol delivery device may include an aerosol-generating material, an aerosol-generating component, an aerosol-generating region, a mouthpiece, and / or a region for receiving the aerosol-generating material. The aerosol-generating component may include a heater capable of interacting with the aerosol-generating material to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0117] The substance to be delivered may be an aerosol-generating material. An aerosol-generating material, which may also be referred to herein as an aerosolizable material, is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, nicotine and / or flavorings.

[0118] The aerosol delivery device and inductor coil are particularly useful when generating aerosol from a substantially flat article, especially an article that includes a substantially flat consumable item.

[0119] The substantially planar consumable may be provided in either an array or a circular format. Other configurations are also contemplated.

[0120] The substantially flat consumable may comprise a plurality of discrete portions of aerosol-generating material. The plurality of discrete portions of aerosol-generating material may be arranged in an array or grid configuration. The plurality of discrete portions of aerosol-generating material may be arranged in a circular pattern.

[0121] For example, in some configurations where a substantially planar consumable is provided in the form of an array, multiple heating regions may be provided, e.g., one heating region per portion, pixel or zone / segment of the consumable.

[0122] In another configuration, a substantially flat consumable may be rotated so that segments of the consumable can be heated by similarly shaped heaters, i.e., so that the heaters have a shape similar to that of the consumable. This configuration allows for a single heating zone to be provided.

[0123] The substantially planar consumable may be moved in one or more directions relative to the heating region.

[0124] In particular, the inductor coil may be provided as part of a non-combustible aerosol delivery device configured to heat the consumable without burning it as part of the aerosol delivery device. In particular, the consumable may include multiple separate portions of aerosol-generating material. The consumable may include a support on which the aerosol-generating material is provided. The support serves as a support on which the aerosol-generating material is formed, facilitating manufacturing. The support can provide tensile strength to the aerosol-generating material and facilitate handling. In some cases, multiple separate portions of the aerosol-generating material are deposited on such a support. In some cases, multiple separate portions of the aerosol-generating material are deposited on such a support such that each separate portion can be heated and aerosolized separately. The consumable may include multiple separate portions of the aerosol-generating material, the separate portions provided on a support, each containing less than 15 mg of water.

[0125] Preferably, the separate portions of aerosol-forming material are provided on a support such that each separate portion can be separately heated and aerosolized. Consumables having such a structure have been found to enable a consistent aerosol to be delivered to the user with each puff.

[0126] In some cases, the support may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or a combination thereof. In some cases, the support may comprise or consist of tobacco materials such as reconstituted tobacco sheets. In some cases, the support may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the support itself is a laminated structure comprising layers of materials selected from the aforementioned list. In some cases, the support can also function as a flavoring carrier. For example, the support may be impregnated with flavoring or tobacco extract.

[0127] In some cases, the support may be non-magnetic.

[0128] In some cases, the support may be magnetic. In certain cases, the support may be a paper-backed foil. The paper layer may abut against the aerosol-generating material, providing the properties discussed in the previous paragraph. The foil backing is substantially impermeable and provides control of the aerosol flow path. The metal foil backing may also serve to conduct heat to the aerosol-generating material.

[0129] In some cases, the support is formed from or includes a metal foil, such as aluminum foil. The metal support may allow for better conduction of thermal energy to the aerosol-generating material. Additionally or alternatively, the metal foil may function as a susceptor within the induction-heated aerosol-delivery device. The support may include a metal foil layer and a support layer (e.g., cardboard).

[0130] 5A-5C, an aerosol product article 204 for use with a consumable or aerosol delivery device may be provided, the aerosol product article 204 including a planar aerosol product article 204. The planar aerosol product article 204 may include a carrier component 242, one or more susceptor elements 224b, and one or more portions of aerosol-generating material 244a-244f, as shown and described in more detail with reference to FIGS.

[0131] FIG. 5A shows a top view of the aerosol product article 204, FIG. 5B shows an end view along the longitudinal (length) axis of the aerosol product article 204, and FIG. 5C shows a side view along the width axis of the aerosol product article 204.

[0132] One or more susceptor elements 224b may be formed from aluminum foil, although it should be understood that other metallic and / or conductive materials may be used in other implementations. As seen in FIG. 5C , carrier component 242 may include several susceptor elements 224b that correspond in size and position to the distinct portions of aerosol-generating material 244a-244f disposed on the surface of carrier component 242. That is, susceptor elements 224b may have widths and lengths similar to the distinct portions of aerosol-generating material 244a-244f.

[0133] The susceptor element 224b is shown embedded in the carrier component 242. However, the susceptor element 224b may be located or mounted on a surface of the carrier component 242. According to an alternative configuration, the susceptor may be provided as a single layer substantially covering the carrier component 244. The aerosol product article 204 may include a substrate or support layer, a single layer of aluminum foil acting as a susceptor, and one or more regions of aerosol-generating material 244 deposited on the aluminum foil susceptor layer.

[0134] An array of induction heating coils may be provided to energize distinct portions of the aerosol-forming material 244. However, a single inductor coil may be provided, and the aerosol product article 204 may be configured to move relative to the single inductor coil. Thus, there may be fewer inductor coils than distinct portions of the aerosol-forming material 244 provided on the carrier component 242 of the aerosol product article 204, such that relative movement between the aerosol product article 204 and the inductor coil(s) is required to enable each distinct portion of the aerosol-forming material 244 to be individually energized.

[0135] Alternatively, a single inductor coil may be provided and the aerosol product article 204 may rotate relative to the single inductor coil.

[0136] While the above describes implementations in which spatially separated, discrete portions of aerosol-generating material 244 are deposited on carrier component 242, it should be understood that in other implementations, aerosol-generating material 244 may not be provided in spatially separated, discrete portions, but may instead be provided as a continuous sheet, film, or layer of aerosol-generating material 244. In these implementations, specific regions of the sheet of aerosol-generating material 244 can be selectively heated to generate an aerosol in much the same manner as described above.

[0137] The aerosol-producing item 204 may include a disk-shaped or round consumable item.

[0138] To address various problems and advance the art, this disclosure provides, by way of example, various embodiments in which the claimed invention(s) may be practiced. The advantages and features of the present disclosure are merely representative examples of embodiments and are not exhaustive and / or exclusive. They are presented solely to aid in the understanding and teaching of the claimed invention(s). The advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limitations on the present disclosure as defined by the claims or to the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claims. Various embodiments may suitably comprise, consist of, or essentially consist of various combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein, and thus it is understood that features of the dependent claims may be combined with features of the independent claims in combinations other than those explicitly recited in the claims. The present disclosure may include other inventions not currently claimed but that may be claimed in the future.

Claims

1. one or more inductor coils wound around one or more stators; one or more susceptors; a power source coupled to the one or more inductor coils and configured to provide an oscillating current to the one or more inductor coils; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the one or more inductor coils include one or more mandrel coils.

3. The aerosol delivery device of claim 2 , wherein the one or more mandrel coils include a single-turn coil(s).

4. The aerosol delivery device of claim 2 , wherein the one or more mandrel coils comprise multiple turns.

5. The aerosol delivery device of any one of claims 1 to 4, wherein the one or more stators are stacked.

6. The aerosol delivery device of any one of claims 1 to 5, further comprising a magnetic flux concentrator.

7. 7. The aerosol delivery device of claim 6, wherein the magnetic flux concentrator comprises a ferrite material and / or a continuous sheet or strip of ferrite material.

8. The aerosol delivery device of any one of claims 1 to 7, wherein the one or more inductor coils are configured to generate a varying magnetic field.

9. The aerosol delivery device of any one of claims 1 to 8, further comprising one or more isolators disposed between the one or more inductor coils and the one or more stators.

10. The aerosol delivery device of any one of claims 1 to 9, wherein the one or more stators are positioned to enhance the magnetic field generated by the one or more inductor coils.

11. The aerosol delivery device of any one of claims 1 to 10, wherein the one or more susceptors are heatable by penetration of a varying magnetic field.

12. The aerosol delivery device of any one of claims 1 to 11, wherein the aerosol delivery device comprises a non-combustible aerosol delivery device.

13. An aerosol delivery device according to any one of claims 1 to 12; an article for use with an aerosol delivery device; An aerosol delivery system comprising:

14. 14. The aerosol delivery system of claim 13, wherein the article is for use with an aerosol delivery device having one or more inductor coils wound around one or more stators, the one or more inductor coils configured to generate a varying magnetic field, and the one or more susceptors positioned to be heated by the varying magnetic field.

15. 15. The aerosol delivery system of claim 13 or 14, wherein the article comprises an aerosol-forming material.

16. 16. The aerosol delivery system of claim 15, wherein the aerosol-generating material is provided in any of the following forms: (i) as a solid; (ii) as a liquid; (iii) in the form of a gel; (iv) in the form of a thin film substrate; (v) in the form of a thin film substrate having multiple regions; or (vi) in the form of a thin film substrate having multiple regions, at least two of the regions comprising aerosol-generating material having different compositions.

17. Providing an aerosol delivery device according to any one of claims 1 to 12; inserting into the aerosol delivery device an article for use with the aerosol delivery device that includes an aerosol-generating material; An aerosol generating method comprising:

18. an aerosol delivery device comprising one or more inductor coils wound around one or more stators; one or more susceptors; an article for placement within the aerosol delivery device in use and for use with the aerosol delivery device; An aerosol delivery system comprising:

19. an aerosol delivery device; an article for use with an aerosol delivery device, the article being located within the aerosol delivery device in use, the article comprising one or more inductor coils wound around one or more stators; An aerosol delivery system comprising:

20. providing an aerosol delivery device comprising one or more inductor coils wound around one or more stators and one or more susceptors; inserting an article containing an aerosol-forming material into the aerosol delivery device; supplying an oscillating current to the one or more inductor coils; An aerosol generating method comprising:

21. forming a device housing with one or more inductor coils wound around one or more stators and one or more susceptors; connecting a power source to one or more inductor coils configured to provide an oscillating current to the one or more inductor coils; A method for manufacturing an aerosol delivery device comprising:

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