Aerosol provision device

Abstract

To provide an aerosol provision device.SOLUTION: An aerosol provision device 100 is provided, comprising: an induction coil 216 for generating a varying magnetic field; and a heater assembly 200 having a heating chamber 202 for receiving at least a portion of an article 110 comprising aerosolizable material, a base 206, a heating element 208 heatable by the induction coil, the heating element protruding into the heating chamber from the base and defining an axis A, and a temperature sensor for sensing a temperature of the heating element. The temperature sensor is positioned in contact with the heating element in the base of the heater assembly and separated from the heating chamber.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device, and to an aerosol delivery system including an aerosol delivery device and an article including an aerosol-generating material. [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 articles by creating products that release compounds without combustion. An example of such a product is a heating device that releases compounds by heating a material without burning it. This material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Summary of the Invention

[0003] According to one aspect of the present disclosure, an aerosol delivery device is provided that includes an induction coil for generating a varying magnetic field, a heating chamber that receives at least a portion of an article including an aerosolizable material, a heating assembly having a base, a heating element that is heatable by the induction coil, the heating element protruding from the base into the heating chamber and defining an axis, and a temperature sensor for detecting the temperature of the heating element, wherein the temperature sensor is positioned in thermal contact with the heating element at the base of the heating assembly and is separated from the heating chamber.

[0004] In one embodiment of the above, the thermal sensor is a thermocouple.

[0005] In another embodiment of any of the above, the aerosol delivery device includes a sensor channel in the base that receives a thermal sensor.

[0006] In another embodiment of any of the above, the sensor channel is separate from the heating chamber.

[0007] In another embodiment of any of the above, the sensor channel is fluidly isolated from the heating chamber.

[0008] In another embodiment of any of the above, the sensor channel is radially offset from the axis of the heating element.

[0009] In another embodiment of any of the above, the sensor channel extends radially from the outer surface of the heating assembly into the base.

[0010] In another embodiment of any of the above, the sensor channel extends axially from the outer surface of the heating assembly into the base.

[0011] In another embodiment of any of the above, the aerosol delivery device includes an air passage in the base that communicates with the heating chamber.

[0012] In another embodiment of any of the above, the sensor channel is separate from the air passageway.

[0013] In another embodiment of any of the above, the sensor channel is fluidly isolated from the air passageway.

[0014] In another embodiment of any of the above, the axis of the air passage is offset from the axis of the heating element.

[0015] In another embodiment of any of the above, the air passage is a single air passage extending through the base.

[0016] In another embodiment of any of the above, the heating element comprises a stationary portion at the base, the sensor channel intersecting the stationary portion.

[0017] In another embodiment of any of the above, the temperature sensor is in thermal contact with the stationary portion of the susceptor.

[0018] In another embodiment of any of the above, the aerosol delivery device includes a device air passageway extending from an opening in the distal end of the device housing to the heating assembly.

[0019] In another embodiment of any of the above, the at least one induction coil includes two separately energizable induction coils.

[0020] In another embodiment of any of the above, the heating assembly is removably secured in the device housing.

[0021] According to one aspect of the present disclosure, there is provided a system comprising an aerosol delivery device as described above and a removable article received within a heating assembly of the aerosol delivery device.

[0022] According to one aspect of the present disclosure, there is provided a heating assembly for an aerosol delivery device, the heating assembly comprising: a heating chamber for receiving at least a portion of an article including an aerosolizable material; a base; a heating element protruding from the base into the heating chamber and defining an axis, the heating element configured to heat the portion of the article received therein in response to the penetration of a varying magnetic field generated by an induction coil; and a temperature sensor for detecting the temperature of the heating element, the temperature sensor being in thermal contact with the heating element and separated from the heating chamber.

[0023] 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 and with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0024] [Figure 1] FIG. 1 illustrates an aerosol delivery device according to one embodiment. [Figure 2] 2 is a cross-sectional view of the aerosol delivery device of FIG. 1. [Figure 3] FIG. 1 illustrates one embodiment of a heating assembly. [Figure 4] FIG. 10 illustrates another embodiment of a heating assembly. DETAILED DESCRIPTION OF THE INVENTION

[0025] [Detailed explanation] As used herein, the term "aerosol-generating material" includes materials that volatilize upon heating, typically in the form of an aerosol. Aerosol-generating materials include any tobacco-containing material, such as one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-generating materials also include other non-tobacco products, which may or may not contain nicotine. Aerosol-generating materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-generating materials may also be a combination or blend of materials, for example. Aerosol-generating materials are sometimes known as "smoking materials."

[0026] Devices are known that heat aerosol-generating materials to volatilize at least one component of the aerosol-generating materials, typically without burning or combusting the aerosol-generating materials, to form inhalable aerosols. Such devices may be referred to as "aerosol-generating devices," "aerosol-delivery devices," "non-combustion heating devices," "tobacco heating product devices," or "tobacco heating devices." Similarly, so-called e-cigarette devices exist that vaporize aerosol-generating materials, typically in liquid form (which may or may not contain nicotine). The aerosol-generating material may be in the form of, or provided as, a rod, cartridge, cassette, or other part that can be inserted into the device.

[0027] The aerosol delivery device can receive and heat an article containing an aerosol-generating material. In this context, an "article" is a component that comprises or contains the aerosol-generating material during use and is heated to volatilize the aerosol-generating material and, optionally, other components during use. After a user inserts the article into the aerosol delivery device, the aerosol-generating device may be heated to generate an aerosol that is subsequently inhaled by the user. The article may be of a predetermined size or a specific size configured, for example, to be placed in a heating chamber of a device sized to receive the article.

[0028] 1 shows an example of an aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. Generally, device 100 may be used to heat a replaceable item 110 containing an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0029] Device 100 includes a housing 102 (including an outer cover 108) that encloses and houses the various components of device 100. Device 100 has an opening 104 at one end through which an item 110 can be inserted and heated by a heating assembly 200 (see FIG. 2). In use, item 110 may be inserted, in whole or in part, into heating assembly 200 and heated by one or more components of heating assembly 200.

[0030] Device 100 may also include a user-operable control element (not shown), such as a button or switch, that, when pressed, activates device 100. For example, a user may turn device 100 on by operating a switch.

[0031] Device 100 may also include an electrical component, such as a connector / port (not shown), that can accept a cable to charge a battery in device 100. For example, the connector may be a charging port, such as a USB charging port. In some examples, the connector may additionally or alternatively be adapted to transfer data between device 100 and another device, such as a computing device.

[0032] The device includes a power source (not shown) (e.g., a battery, such as a rechargeable or non-rechargeable battery). Examples of suitable batteries include, for example, lithium batteries (e.g., lithium ion batteries), nickel batteries (e.g., nickel cadmium batteries), and alkaline batteries.

[0033] Device 100 defines a proximal end 114, which is generally the end at which a user can inhale the generated aerosol, and a distal end 116 of the device opposite proximal end 114. The device further defines an axis A, defined by the heating element (see FIG. 2), extending from proximal end 114 to distal end 116.

[0034] FIG. 2 is a cross-sectional view of the aerosol delivery device of FIG. 1 taken along line X, showing the configuration of heating assembly 200 in more detail.

[0035] The heating assembly 200 includes a heating chamber 202 into which the replaceable item 110 is inserted through an opening 104 in the device 100. The heating chamber 202 is defined by a chamber wall 204 that extends axially from the opening 104 at the proximal end 114 partway toward the distal end 116. In the illustrated example, the chamber wall 204 is annular about an axis A, defining a generally cylindrical shape for the chamber 202.

[0036] The heating assembly 200 includes a base 206 that bounds the heating chamber 202 at the axially distal or lower end of the chamber 202 and the wall 204. As described in more detail below, the base 206 comprises a generally solid portion of material having an aperture formed therein. The base 206 is connected to the chamber wall 204. In the illustrated example, the base 206 and the chamber wall 204 are integrally formed.

[0037] Heating assembly 200 may be connected to or integrally formed with device 100. Alternatively, heating assembly 200 may be removable and insertable into device 100 through opening 104, or may be secured to device 100 by any known removable means. In the example shown, the heating assembly comprises protrusions that are received by correspondingly shaped recesses in the device.

[0038] The device 100 may include an air passageway 120 that extends from an opening 122 at the distal end of the device to the heating assembly 200 to supply air to the heating assembly 200 .

[0039] Base 206 further includes a receiving slot 214 extending axially distally from a surface of base 206 that bounds heating chamber 202. In the illustrated example, receiving slot 214 has a generally rectangular cross-section along axis A. In the illustrated example, receiving slot 214 is centered relative to base 206; that is, base 206 includes a center point in a radial plane that is defined as the center of the cross-section of heating chamber 202.

[0040] Receiving slot 214 has a cross-sectional area that is smaller than the cross-sectional area of ​​heating chamber 202 so that a correspondingly shaped component can be received therein (as described below).

[0041] The heating assembly 200 further includes a heating element or susceptor 208 partially disposed within the chamber 202 and the base 206. The susceptor 208 defines an axis X extending from the distal end of the device 100 toward the proximal end of the chamber 202. The susceptor 208 includes a blade 210, or heating portion, and a fixture 212. The fixture 212 is received and secured in a receiving slot 214, e.g., by a sliding interference fit, to hold the susceptor 208 in place relative to the base 206. The fixture 212 is fully received in the receiving slot 214, and the blade 210 extends axially and outwardly into the heating chamber 202 in a proximal direction from the fixture 212 and base 206 to which the susceptor 208 is secured. As described in more detail below, at least a portion of the susceptor 208 is inductively heated by including a ferromagnetic material such as iron, nickel, or cobalt.

[0042] In another embodiment, the susceptor 208 is integrally formed with the base 206 such that the mounting portion 212 is embedded within the mount. This configuration may be achieved, for example, by injection molding the heating assembly 200.

[0043] The blade 210 is disposed within the heating chamber 202. In the illustrated example, the blade 210 is separated from and does not contact the chamber wall 204. In the illustrated example, the blade 210 is positioned in the chamber 202, approximately at the center of the base 206. When the replaceable article 110 is received in the device 100, and thus the chamber 202, through the opening 104, it can be inserted until it is adjacent to the base 206. The blade 210, or heating portion, of the susceptor 208 extends from the base 206 and therefore penetrates the inserted replaceable article 110. Thus, as described in more detail below, the susceptor 208 can heat the replaceable article 110 from within.

[0044] In the illustrated example, the blade 210 has a flat blade shape including two opposing sides separated by an edge that tapers to a tip. The flat surface improves heat distribution, while the edge and tip allow for easy piercing of the removable article 110 inserted into the heating chamber 202. In alternative examples not shown, the susceptor may have other shapes (e.g., pin or rod shape).

[0045] The device 100 further includes one or more induction coils 216. The coils extend helically around the chamber wall 204 along a portion of the axial length of the heating assembly 200, thereby surrounding the heating chamber 202 and the base 206.

[0046] The coil 216 is connected to a power source. A user can control the device 100, for example, by the user-operable control element 112, so that the power source provides energy to the coil 216. The coil 216 is energized by an alternating current that creates a varying magnetic flux in the heating chamber 202. The varying magnetic flux induces currents in the ferromagnetic material of the susceptor 208 and the blades 210. This current heats the blades 210, which in turn heats the replaceable article 110 from the inside and generates an aerosol that can be inhaled by a user.

[0047] In the illustrated example, there are two induction coils 216a, 216b that are configured to be separately energized to provide different levels of magnetic flux and, in turn, different levels of heating. In the illustrated example, the two coils 216 each extend along approximately half of the axial length of the chamber 202.

[0048] The one or more induction coils 216a, 216b are constructed from a conductive material. In this example, the induction coils 216a, 216b are constructed from litz wire / cable that is spirally wound to provide a helical coil. Litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in electrical conductors. In the exemplary device 100, the inductor coil 124 is constructed from copper litz wire that has a circular cross section. In other examples, the litz wire can have other cross sections, such as a rectangular cross section.

[0049] In addition to the susceptor 208 extending into the heating chamber 202, the device may further include additional susceptors. The additional susceptor(s) may be of different or similar configurations (e.g., pin-, blade-, or receptacle-type, etc.) as desired.

[0050] As discussed above, it is desirable to volatilize the aerosol-forming material of the replaceable article 110 without substantial combustion, and therefore it is desirable to control the temperature applied to the replaceable article 110 by precisely controlling the heating temperature of the susceptor 208.

[0051] 3 is a more detailed view of one embodiment of the heating assembly 200. As described above, the fixing portion 212 of the susceptor 208 is received in a receiving slot 214 formed in the base 206. The base 206 further includes a sensor channel 218 formed therein.

[0052] The sensor channel 218 extends from the radially outer surface 220 of the base 206. The sensor channel 218 extends radially inward into the base 206 and intersects with the fixed portion 212 of the susceptor 208, exposing the fixed portion 212 to the sensor channel 218. When the fixed portion 212 is received in the receiving slot 214, the sensor channel intersects with the receiving slot 214. With this configuration, the fixed portion 212 of the susceptor 208 is accessible through the sensor channel 218. A thermal sensor (not shown) is disposed in the sensor channel 218 and is in thermal contact with the susceptor 206. In some examples, this thermal contact may include direct contact between the thermal sensor and a portion of the susceptor 206. That is, a portion of the thermal sensor is in direct contact with a portion of the susceptor. In the example shown, the thermal sensor is in direct contact with the fixed portion 212 of the susceptor 208.

[0053] In the illustrated example, the sensor channel 218 extends from an opening 224 on the exterior surface of the heating assembly 200, allowing a thermal sensor to be inserted or removed from the sensor channel, and a wired connection between the thermal sensor and the controller can provide an accurate and precise measurement of temperature.

[0054] The thermal sensor is a thermocouple, which is particularly useful for measuring the temperature of the susceptor 208 through direct contact. In the illustrated example, the sensor channel 218 has a generally "W" shaped cross section in its extended radial direction, allowing a thermocouple-type sensor to be accommodated in the small volume of the base 206.

[0055] In use, the thermal sensor measures, monitors, or detects the temperature of the susceptor 208. The thermal sensor is in communication with a controller (not shown) of the device 100 and provides temperature data to the controller. The controller can control the energy supply to the coil 216, thereby controlling the temperature. The controller can be of any known type (e.g., a PID controller).

[0056] It has been found that replaceable article 110, when heated, produces residual by-products that can accumulate in heating chamber 202. It has further been found that the residual by-products have an undesirable effect on particularly sensitive components such as thermal sensors, the function of which can be impaired by the accumulation of residual by-products in chamber 202.

[0057] To reduce sensitivity to residual by-products in chamber 202, sensor channel 218 is separated from the cavity by being formed in base 206. Sensor channel 218 is fluidly isolated from heating chamber 202. Thus, any residue that may accumulate in heating chamber 202 is largely isolated from the thermal sensor, thereby reducing the effect of the residue on the thermal sensor.

[0058] Additionally, the location of the sensor channel 218 in the base 206 of the heating assembly 200 allows the thermal sensor to be located adjacent to the susceptor 208, even though the susceptor 208 is disposed toward the center of the heating chamber 202 and is separated from the wall 204. This location allows the thermal sensor to obtain more accurate and precise temperature measurements. The sensor channel 218 is radially offset from the susceptor 208 so that both the fixture 212 and the thermal sensor can be accommodated.

[0059] In the particular embodiment shown, the heating assembly 200 is provided with an air passage 220 that supplies air to the heating chamber 202 at a location generally adjacent the base 204. In the example shown, the air passage 220 extends axially through the base 204 of the heating assembly 200 from an opening 222 to the heating chamber 202. The air passage 220 and the heating chamber 202 collectively define an air flow path through the device.

[0060] In the illustrated example, the opening 222 is radially separated from the susceptor 208 such that the base 206 includes an area of ​​solid material between the air passage 220 and the receiving slot 214. This separation provides the receiving slot 214 with structural integrity to hold the susceptor 208 securely in place.

[0061] It has been found that, if air passage 220 is provided, residual by-products or similarly undesirable condensation by-products may enter air passage 220 and affect exposed components. For this reason, it may be desirable to separate sensor channel 218 from air passage 220, as well as from heating chamber 202. Thus, sensor channel 218 is fluidly isolated from air passage 220. This configuration further protects sensor channel 218 from the possible effects of residuals.

[0062] In the illustrated embodiment, air passage 220 is disposed off-center through base 206. That is, base 206 defines a center point, and opening 222 of air passage 220 is radially separated from the center point. Air passage 220 is radially opposite sensor channel 218 from the center point. That is, base 206 defines two notional radially separated halves, one containing air passage 220 and the other containing sensor channel 218.

[0063] The off-center placement of the air passage allows the sensor channel 218 to be isolated from the base 206 while being located on the opposite side thereof, as described above. This configuration allows both the air passage 220 and the thermal sensor to be located in the base 206 while remaining isolated. The region of solid material in the base 206 between the air passage 220 and the sensor channel 218 effectively provides a barrier between the air passage 220 and the thermal sensor.

[0064] Figure 4 shows another embodiment of a heating assembly 300 for use with device 100. This embodiment is generally similar to that described with respect to Figures 1, 2, and 3 and includes a heating chamber 302 with a base 306 and a susceptor 308 extending from the base 306.

[0065] In this embodiment, a sensor channel 318 is provided that extends axially through the base 306, instead of the radially extending channel described with respect to the previous embodiment. The sensor channel 318 receives a thermal sensor that senses the temperature of the susceptor 308, as described above. The sensor channel 318 includes an opening 324 at the outer lower (or distal) end of the heating assembly 300. The sensor channel 318 extends axially upward or proximally from the opening 324 and terminates at a location axially separated from the heating chamber 302. Thus, the sensor channel 318 is fluidly isolated from the heating chamber 302 because an area of ​​material in the base 304 separates the sensor channel 318 from the heating chamber 302.

[0066] As described with respect to the above embodiment, the channel is open to the outside of the heating assembly 300, allowing the thermal sensor to be inserted or removed from the sensor channel, and a wired connection between the thermal sensor and the controller can provide accurate and precise measurements of temperature.

[0067] In the illustrated embodiment, the sensor channel 318 intersects with the fixed portion 312 of the susceptor 308, thereby exposing the fixed portion 312 to the sensor channel 318. When the fixed portion 212 is received in the receiving slot 214, the sensor channel intersects with the receiving slot 214. With this configuration, the fixed portion 312 of the susceptor 308 is accessible through the sensor channel 318. A thermal sensor (not shown) is disposed in the sensor channel 218 and is in thermal contact with the susceptor 206. In the illustrated example, the thermal sensor is in direct contact with the fixed portion 212 of the susceptor 208. Therefore, by being in thermal contact with the fixed portion 312, the thermal sensor can accurately and precisely measure the temperature of the susceptor, as described above.

[0068] In one example, the susceptor 206 may include a generally L-shaped fixture 212. The L-shaped fixture includes an axial portion extending from the blade 208 and a radial portion extending from the opposite end of the axial portion. The thermal sensor may be attached to and in thermal contact with the radial portion, for example, by soldering. Providing an L-shaped fixture with a radial portion may allow the thermal sensor to be connected to the fixture in a robust and compact manner that is easy to assemble.

[0069] As mentioned above, the axially extending air passage 320 is located off-center. The sensor channel 318 is similarly located off-center in the base 306, radially opposite the air passage 320, such that both the sensor channel 318 and the air passage 320 can be located in the base 306 while separating and fluidly isolating the thermal sensor from the air passage 320.

[0070] The above-described embodiments are to be understood as illustrative examples of the invention. Other embodiments of the invention are contemplated. It is to be understood that any feature described with respect to any one embodiment can be used alone or in combination with other described features, and can also be used in combination with one or more features of any other embodiment or any combination thereof. Furthermore, equivalents and modifications not described above may be employed without departing from the scope of the invention as defined in the appended claims.

Claims

1. an induction coil for generating a varying magnetic field; a heating assembly; 1. An aerosol delivery device comprising: The heating assembly includes: a heating chamber that receives at least a portion of an article that includes an aerosolizable material; A base and a heating element heatable by the induction coil, the heating element protruding from the base into the heating chamber and defining an axis; An aerosol delivery device comprising: a temperature sensor for detecting the temperature of the heating element, the temperature sensor being positioned in thermal contact with the heating element at the base of the heating assembly and separated from the heating chamber.

2. The aerosol delivery device of claim 1 , wherein the thermal sensor is a thermocouple.

3. 3. The aerosol delivery device of claim 1, further comprising a sensor channel in the base for receiving the thermal sensor.

4. The aerosol delivery device of claim 3 , wherein the sensor channel is separated from the heating chamber.

5. The aerosol delivery device of claim 4 , wherein the sensor channel is fluidly isolated from the heating chamber.

6. The aerosol delivery device of any one of claims 3 to 5, wherein the sensor channel is radially offset from the axis of the heating element.

7. The aerosol delivery device of any one of claims 3 to 6, wherein the sensor channel extends radially from an outer surface of the heating assembly into the base.

8. The aerosol delivery device of any one of claims 3 to 6, wherein the sensor channel extends axially from an outer surface of the heating assembly into the base.

9. The aerosol delivery device of any one of claims 1 to 8, further comprising an air passage in the base that communicates with the heating chamber.

10. The aerosol delivery device of claim 9 , wherein the sensor channel is separated from the air passageway.

11. The aerosol delivery device of claim 10 , wherein the sensor channel is fluidly isolated from the air passageway.

12. The aerosol delivery device of any one of claims 9 to 11, wherein the axis of the air passage is offset from the axis of the heating element.

13. 13. The aerosol delivery device of any one of claims 9 to 12, wherein the air passage is a single air passage extending through the base.

14. The aerosol delivery device of any one of claims 1 to 13, wherein the heating element comprises a fixing portion at the base, the sensor channel intersecting the fixing portion.

15. The aerosol delivery device of claim 14 , wherein the temperature sensor is in thermal contact with the fixed portion of the susceptor.

16. The aerosol delivery device of any one of claims 1 to 15, further comprising a device air passageway extending from an opening in the distal end of the device housing to the heating assembly.

17. The aerosol delivery device of any one of claims 1 to 16, wherein the at least one induction coil comprises two separately energizable induction coils.

18. The aerosol delivery device of any one of claims 1 to 17, wherein the heating assembly is removably secured in the device housing.

19. An aerosol delivery device according to any one of claims 1 to 18; a removable article received within the heating assembly of the aerosol delivery device; and A system with.

20. 1. A heating assembly for an aerosol delivery device, comprising: a heating chamber that receives at least a portion of an article that includes an aerosolizable material; A base and a heating element protruding from the base into the heating chamber and defining an axis, the heating element configured to heat a portion of the article received in the heating chamber in response to penetration of a varying magnetic field generated by an induction coil; a temperature sensor for sensing the temperature of the heating element; Equipped with A heating assembly, wherein the temperature sensor is in thermal contact with the heating element and is separated from the heating chamber.

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