Non-combustible aerosol provision device

Abstract

To provide a non-combustible aerosol provision device 100 for generating aerosol from an aerosol generating material.SOLUTION: The non-combustible aerosol provision device (100) comprises a housing, a chamber (102) within the housing for receiving a consumable comprising the aerosol generating material and a resilient material (114) that surrounds at least a portion of the consumable when the consumable is received within the chamber (102), and the resilient material (114) comprising a thickness that is adaptable in dependence upon a thickness of the consumable comprising the aerosol generating material, whereby consumables of different thicknesses are selectively snuggly receivable within the chamber (102).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a non-flammable aerosol delivery device. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning items by creating products that release compounds without burning. An example of such a product is a heating device that releases compounds by heating a material rather than burning it. The material may be, for example, a tobacco product or other non-tobacco product, and these products may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of some embodiments described herein, there is provided a non-combustible aerosol delivery device for generating an aerosol from an aerosol-generating material, the non-combustible aerosol delivery device comprising: a housing; a chamber within the housing for receiving a consumable including the aerosol-generating material; and an elastic material surrounding at least a portion of the consumable when the consumable is received in the chamber, the elastic material having a thickness that is adaptable according to the thickness of the consumable, thereby allowing consumables of different thicknesses to be selectively and snugly received in the chamber.

[0004] The housing may be configured to facilitate insertion of a consumable containing an aerosol-forming material into the chamber or removal of a consumable containing an aerosol-forming material from the chamber.

[0005] The housing may be configured to open along the length of the chamber to facilitate insertion of a consumable containing an aerosol-forming material into the chamber or removal of a consumable containing an aerosol-forming material from the chamber.

[0006] The housing may further comprise an opening into the chamber that allows the consumable containing the aerosol-forming material to protrude from the housing when the consumable containing the aerosol-forming material is received in the chamber.

[0007] The elastic material may be a thermally conductive material.

[0008] The elastic material may include metallic wool.

[0009] The non-combustible aerosol delivery device may further comprise an aerosol generator system for generating an aerosol from a consumable containing an aerosol-forming material when the consumable containing the aerosol-forming material is received in the chamber during use.

[0010] The aerosol generator system may include at least one heater for heating the aerosol-generating material in the aerosol-generating material-containing consumable to generate an aerosol when the aerosol-generating material-containing consumable is received in the chamber.

[0011] The at least one heater may comprise a layer of flexible heating foil.

[0012] The flexible heating foil may be made of metal.

[0013] The chamber may include a tube disposed between the at least one heater and the elastic material.

[0014] The chamber may further comprise an annular stepped bottom having a first portion having a first width and a second portion having a second width smaller than the first width, wherein the first portion defines a distal end point of the chamber for a first type of consumable containing an aerosol-generating material and the second portion defines a distal end point of the chamber for a second type of consumable containing an aerosol-generating material, and the first type of consumable containing an aerosol-generating material is thicker than the second type of consumable containing an aerosol-generating material.

[0015] The non-combustible aerosol delivery device may further comprise a thin film layer on the surface of the elastic material, in which case during use, the thin film layer contacts the consumable containing the aerosol-forming material when the consumable containing the aerosol-forming material is received in the chamber.

[0016] According to a second aspect of some embodiments described herein, there is provided a non-combustible aerosol delivery system comprising: a non-combustible aerosol delivery device according to the first aspect; and at least one consumable including an aerosol-generating material for receipt in the chamber.

[0017] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, made with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a block schematic diagram of a non-combustible aerosol delivery device for generating an aerosol from a consumable containing an aerosol-forming material. [Figure 2] FIG. 2 is a schematic perspective view of a second non-combustible aerosol delivery device in an open configuration. [Figure 3] FIG. 10 is a schematic diagram of a planar cross section of a heating arrangement of a second non-combustible aerosol delivery device. [Figure 4a] 1 is a schematic perspective view of a second non-combustible aerosol delivery device in an open configuration with a first type of consumable product installed therein. [Figure 4b] 1 is a schematic perspective view of a second non-combustible aerosol delivery device in an open configuration with a second type of consumable product installed therein. [Figure 4c] 1 is a schematic cross-sectional plan view of a heating configuration of a second non-combustible aerosol delivery device with a first type of consumable installed therein. [Figure 4d]A schematic cross-sectional plan view of a heating configuration for a second non-combustible aerosol delivery device with a second type of consumable installed therein. DETAILED DESCRIPTION OF THE INVENTION

[0019] 1 is a simplified schematic diagram of a non-combustible aerosol delivery device 100. Non-combustible aerosol delivery device 100 includes a chamber 102 configured to receive a consumable (not shown in FIG. 1) containing an aerosol-generating material.

[0020] An aerosol-generating material is a material capable of generating an aerosol when, for example, heated, illuminated with light, or activated in any other manner. The aerosol-generating material may or may not contain an active substance and / or a flavoring substance and may be in the form of, for example, a solid, liquid, or gel. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain any fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid, up to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0021] The aerosol-forming materials may include one or more active and / or flavoring agents, one or more aerosol former materials, and optionally one or more other functional materials.

[0022] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive agents. The active substance may be naturally occurring or artificially obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0023] In some examples, the active agent comprises nicotine. In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0024] The aerosol former material may include one or more components capable of forming an aerosol, in some embodiments, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0025] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0026] Non-combustible aerosol delivery device 100 is hereinafter referred to as device 100. Device 100 includes an aerosol generator 104 for generating an aerosol from a consumable aerosol-forming material received in a chamber 102.

[0027] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the or each aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the or each aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0028] Thus, in some examples, the aerosol generator includes a heating arrangement configured to provide energy to heat a first consumable aerosol-generating material received in the chamber 102. In some examples, the heating arrangement includes one or more resistive heating elements disposed within or in thermal contact with the chamber 102. The flow of electrical current against the electrical resistance of the one or more resistive heating elements generates heat. This process is referred to as Joule heating, ohmic heating, or resistive heating.

[0029] In some examples, the aerosol generator 104 is an induction heating arrangement configured to generate a varying magnetic field to inductively heat the susceptor. The induction heating arrangement may include one or more inductors through which an alternating current is passed to generate the varying magnetic field. In some examples, the aerosol generator 104 includes one or more susceptors. In other examples, the aerosol generator 104 does not include a susceptor, and one or more susceptors may instead be provided as part of or with a consumable intended for use with the device 100.

[0030] The susceptor is a material that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, so that penetration with a varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, so that penetration with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, so that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0031] The device 100 includes a power source 106. The power source 106 provides power to various components of the device 100. In some examples, the power source 106 is a battery. In some examples, the power source 106 includes a battery and a DC-DC converter, where power is provided from the battery through the DC-DC converter. The DC-DC converter may allow the power source 106 to provide power at a different voltage than the battery's voltage. In some examples, the device 100 may include a DC-to-AC converter to convert DC current, for example from a battery, to AC current to provide power to one or more inductors of the heating element 104, where the heating element 104 is an induction heating element. In the following examples, the power source 106 will be referred to simply as the battery 106.

[0032] 1, device 100 includes control circuitry 108 configured to control various aspects of the operation of device 100, including aerosol generator 104. In this example, control circuitry 108 is a control processor 108 in data communication with computer-readable memory 110. Control circuitry 108 controls various operations of the device, for example, by executing instructions stored in computer-readable memory 110. For example, control circuitry 108 controls the delivery of power from battery 106 to first aerosol generator 104 by controlling various electrical components, such as switches (not shown in FIG. 1).

[0033] The device 100 comprises a housing 101 which forms the outer cover of the device 100 and which surrounds and contains the various components of the device 100 .

[0034] Device 100 further includes a user input device 112 electrically connected to control circuitry 108 and which enables a user to operate device 100. Examples of suitable user input devices 112 include one or more buttons, a trackpad, and a touchscreen, although any suitable device may be used.

[0035] The housing 101 is openable to allow access to the interior of the housing 101 so that a consumable can be placed in the chamber 102 ready for use and then removed from the chamber 102 after use. In some examples, the housing 101 may be two pieces hinged together to allow the housing 101 to be opened and closed.

[0036] In this example, device 100 also includes an opening 105 at one end of housing 101 that allows a consumable received in chamber 102 to protrude from device 100. A portion of the consumable received in chamber 102 includes an aerosol-generating material from which device 100 is configured to generate an aerosol. The portion of the consumable that protrudes from opening 105 may include, for example, a filter, and a user may inhale the aerosol by sucking on the portion of the consumable that protrudes from opening 105.

[0037] In an alternative example, the consumable is received entirely within chamber 102, and device 100 includes a mouthpiece (not shown) connected to housing 101 and in fluid communication with chamber 102, through which the user draws to inhale the aerosol.

[0038] In this example, the chamber 102 includes a layer of elastic material 114 that surrounds at least a portion of the consumable (not shown) when the consumable is received within the chamber 102. The layer of elastic material 114 is configured to conform to the thickness of the consumable, thereby allowing consumables of different thicknesses to be selectively and snugly received within the chamber 102.

[0039] It should be understood that device 100 may include other components not shown in Figure 1, such as ventilation inlets / outlets, charging ports, etc. It should be noted that Figure 1 is merely a schematic sketch illustrating some components that may be included in device 100. Figure 1 is not intended to convey the specific locations of the various components.

[0040] 2 through 4b, there is shown a simplified diagram of a second example of a non-combustible aerosol delivery device 200, hereafter referred to as second device 200. Second device 200 may include any of the features of device 100 described above with reference to FIG. 1, and discussion of these features will not be repeated here. Similar drawing references are used to represent such features already described with reference to FIG. 1.

[0041] The second device 200 comprises a first end 220, referred to as the mouth or proximal end 220, and a second end 222, referred to as the distal end 222. Although not shown in Figures 2-4b, the second device 200 comprises a user input that allows a user to control the second device 200.

[0042] The second device 200 comprises a housing 101 configured to protect the internal components of the second device 200. In this example, the housing 101 is divided into two compartments: a first compartment 216 and a second compartment 218. The first compartment 216 is connected to the second compartment 218 by a hinge mechanism 224 that extends longitudinally between a mouth end 220 and a distal end 222. The housing 101 is thus configured to open along a length extending between the mouth end 220 and the distal end 222 to allow access to the chamber 102.

[0043] In this example, first section 216 of housing 101 contains therein a power supply (not shown), a processor (not shown), and a memory (not shown) as described above with respect to device 100 of FIG.

[0044] The housing 101 comprises a plurality of panels, including a first panel 226 and a second panel 228. In this example, one or more of the plurality of panels are entirely removable from the housing 101, thereby allowing access to the internal components for repair or replacement. The one or more panels may comprise any suitable material, such as a plastic material including glass-filled nylon or metal. The plastic panel may be formed by injection molding. Different ones of the plurality of panels may be made of different materials.

[0045] The first panel 226 of the second device includes an opening 230 at the mouth end 220 through which, in this example, a consumable (not shown) protrudes when received within the second device 200. This allows a user to place the mouth end of the consumable into their mouth to inhale aerosol emitted from the consumable when the second device is in use.

[0046] 2, in this example, chamber 102 comprises a first chamber portion 102a defined in a first compartment 216 of housing 101 and a second chamber portion 102b defined in a second compartment 218 of housing 101. First chamber portion 102a and second chamber portion 102b are each in the form of an elongated channel having a semicircular cross-section.

[0047] When the second device 200 is closed along the hinge 224, the first chamber portion 102a and the second chamber portion 102b overlap each other along their lengths, so that the entire chamber 102 takes the form of a hollow cylindrical tube.

[0048] The chamber 102 includes an aerosol generator, which in this example is a heating element 204 that extends substantially along the axial length of the chamber 102. As best illustrated in FIG. 3, when the second device 200 is closed, the heating element 204 comprises a plurality of cylindrical coaxial layers radially disposed within the chamber 102. Each of the coaxial layers comprises a first semi-cylindrical layer disposed in the first chamber portion 102a and a second semi-cylindrical layer disposed in the second chamber portion 102b. As best seen in FIG. 2, when the second device 200 opens along the hinge 224, the first semi-cylindrical layer separates from the second semi-cylindrical layer, allowing a user to insert a consumable into the chamber 102.

[0049] In order from radially "outermost" layer to radially "innermost" layer, the layers include an outer sealing layer 246, a vacuum insulating tube 248, an inner sealing layer 250, a heating element 244, a support tube layer 252, a layer of elastic material 114, and a protective inner foil layer 256.

[0050] The vacuum insulating tube 248 is between the outer sealing layer 246 and the inner sealing layer 250 and provides a thermal barrier to prevent heat from flowing from the chamber 102 to the housing 101 or to other internal components of the second device 200. In this example, the vacuum insulating tube 248 comprises a metal tube, for example steel (although non-metallic materials are possible), and comprises a radially outer wall and a radially inner wall connected to define a sealed volume space that is at least partially evacuated of air to prevent heat transfer through the vacuum insulating tube 248.

[0051] The outer sealing layer 246 and the inner sealing layer 250 each comprise a layer of rubber or other suitable sealant material that acts to seal the chamber 102 to prevent aerosol from escaping from the chamber 102 when the second device 200 is in use.

[0052] In this example, the heating element 244 comprises a layer of flexible heating foil, such as a metal foil, supported on a support tube layer 252. The heating element 244 is electrically connected to a power source and controls a processor of the second device 200, allowing the control processor to control the power supplied to the heating element 244 when the second device 200 is in use. Thus, in this example, the heating element 244 heats using resistive heating.

[0053] The support tube layer 252 comprises a heat conducting material, for example the tube is a metal tube, such as a steel tube, so that heat generated by the heating element 244 is easily transferred through the support tube layer 252 .

[0054] As described above with reference to the device 100 illustrated in FIG. 1, the layer of elastic material 114 is configured to surround at least a portion of the consumable when the consumable is received within the chamber 102 and to conform to the thickness of the consumable.

[0055] In this example, the layer of elastic material 114 comprises a pad of fine metal, for example steel monofilaments. The layer of elastic material 114 may, for example, comprise materials commonly known as wire wool or wire sponge.

[0056] The layer of elastic material 114 is in thermal contact with a protective inner foil layer 256, which may be aluminum foil. The protective inner foil layer 256 has a smooth inner surface that contacts the consumable when the consumable is placed in the chamber 102. The protective inner foil layer 256 protects the consumable from damage by the layer of elastic material 114 and allows for easy cleaning.

[0057] The user first opens the second device 200 by the hinge mechanism 224, firmly places the consumable item in the first chamber portion 102a defined in the first compartment 216 of the housing 101, and then closes the second device 200 by the hinge mechanism 224 and inserts the consumable item into the second device 200 by pressing the second compartment 218 of the housing 101 against the consumable item.

[0058] When the second device 200 is closed, the layer of elastic material 114 is compressed, thereby conforming to surround the consumable product. This conforming action of the layer of elastic material 114 surrounding the aerosol-generating product ensures that the aerosol-generating product is held snugly in place and provides an optimal thermal path between the heating element 244 and the consumable product. When the second device 200 is subsequently opened and the consumable product is removed, the layer of elastic material 114 relaxes to the uncompressed thickness it assumes when no consumable product is inserted into the second device 200.

[0059] The layer of elastic material 114 allows the second device 200 to be adaptable for use with different types of consumables, particularly different types of consumables having different thicknesses that a user can select for insertion into the second device 200.

[0060] This is illustrated in Figures 4a to 4d, where Figures 4a and 4c illustrate a first type of consumable 262 inserted into the second device 200, and Figures 4b and 4d illustrate a second type of consumable 260 inserted into the second device 200. The first type of consumable 262 and the second type of consumable 260 are different sizes. More specifically, in this example, the first type of consumable 262 has a thinner thickness than the second type of consumable (i.e., the first type of consumable 262 has a smaller width or diameter than the second type of consumable). In this example, the first type of consumable is also longer than the second type of consumable.

[0061] As can be seen by comparing Figures 4c and 4d, the layer of elastic material 114 is radially compressed to a greater extent when a relatively thick second type of consumable 260 is inserted into the second device 200 (Figure 4d) than when a relatively thin first type of consumable 262 is inserted into the second device 200 (Figure 4c).

[0062] In this example, the chamber 102 further includes an annular step 236 toward its distal end that includes an aperture 238. The annular step 236 is defined by an outer sealing layer 246, for example.

[0063] 4b, the width of the hole 238 is smaller than the width of the second type of consumable 260. When the second type of consumable 260 is inserted into the second device 200, the distal end of the second type of consumable 260 abuts against the upper annular edge of the annular step 236.

[0064] 4a, the width of the hole 238 is slightly larger than the width of the first type of consumable 262. When the first type of consumable 262 is inserted into the second device 200, the distal end of the first consumable extends through the hole 238 and abuts against the inner surface of the panel of the housing 101.

[0065] The diameter of the annular step 236 is selected so that the extent 264 that the mouth end or proximal end of each respective type of consumable extends out from the second device 200 is substantially the same, despite differences in the overall lengths of the first type of consumables 262 and the second type of consumables 260.

[0066] The above-described embodiments should be understood as illustrative examples of the present invention. Additional embodiments of the present invention are contemplated. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other features described, in combination with one or more features of any other of the embodiments, or in any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be utilized without departing from the scope of the present invention, which is defined in the appended claims.

Claims

[Claim 1] 1. A non-combustible aerosol delivery device for generating an aerosol from an aerosol-forming material, comprising: Housing and a chamber within the housing for receiving a consumable containing the aerosol-forming material; a resilient material surrounding at least a portion of the consumable when the consumable is received in the chamber, the resilient material having a thickness that is adaptable according to the thickness of the consumable including the aerosol-generating material, thereby enabling consumables of different thicknesses to be selectively and snugly received in the chamber.

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