Aerosol provision device

Abstract

To inhibit or prevent the accumulation of condensation, during use, in a conduit that connects the device's heating chamber to the device's exterior.SOLUTION: At least a portion of such a conduit is defined by a component comprising a first susceptor 136, with the first susceptor being heatable by an inductor 126 that forms part of a heating assembly for heating the device's heating chamber 101; the susceptor in turn heats the conduit, thereby substantially preventing accumulation of condensation within the conduit.SELECTED DRAWING: Figure 3a

Description

[Technical Field]

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

[0002] Articles such as cigarettes, cigars, and the like, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these types of articles that burn tobacco by creating products that release compounds without burning. Devices are known that heat smoking material to volatilize at least one component of the smoking material, typically forming an inhalable aerosol without burning, i.e., combusting, the smoking material. Such devices are sometimes described as "heat-not-burn" devices or "tobacco heating products" (THPs) or "tobacco heating devices," or the like. A variety of different compositions are known for volatilizing at least one component of the smoking material.

[0003] The materials may be, for example, tobacco products or other non-tobacco products, or may be combinations such as blend mixes, which may or may not contain nicotine. Summary of the Invention

[0004] According to a first aspect of the present invention, there is provided an aerosol delivery device comprising a heating chamber for receiving an aerosol-generating material, an induction heating unit for heating the aerosol-generating material during use, and a conduit having an inner surface fluidly connecting the heating chamber with an exterior of the aerosol delivery device, wherein the aerosol delivery device is configured such that during use the inner surface of the conduit is heated, thereby substantially preventing the accumulation of condensate within the conduit.

[0005] According to another aspect of the present invention, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating chamber for receiving the aerosol-generating material; an induction heating unit for heating the aerosol-generating material when the aerosol-generating material is located within the heating chamber during use; and a conduit having an interior surface, the conduit fluidly connecting the heating chamber to an exterior of the aerosol delivery device, the aerosol delivery device being configured such that during use the interior surface of the conduit is heated such that at least a portion of the interior surface reaches a temperature of 85°C or greater.

[0006] According to yet another aspect of the present invention, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating chamber for receiving the aerosol-generating material; a heating unit for heating the aerosol-generating material during use; and a conduit having an interior surface fluidly connecting the heating chamber with an exterior of the aerosol delivery device, at least a portion of the interior surface having a thermal conductivity of 1 W / m / K or greater.

[0007] According to yet another aspect of the present invention, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating chamber for receiving the aerosol-generating material; a heating unit for heating the aerosol-generating material during use; and a conduit having an interior surface, the conduit fluidly connecting the heating chamber with an exterior of the aerosol delivery device, the aerosol delivery device being configured such that during use the interior surface of the conduit is heated such that at least a central portion of the interior surface, intermediate the proximal and distal ends of the conduit, reaches a temperature of 70°C or greater.

[0008] According to another aspect of the present invention, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating chamber for receiving the aerosol-generating material; a heating unit for heating the aerosol-generating material during use; a conduit fluidly connecting the heating chamber to an exterior of the aerosol delivery device; and an air heating unit for heating air within the conduit, thereby substantially preventing the accumulation of condensate within the conduit.

[0009] According to yet another aspect of the present invention, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating assembly including an inductor; a heating chamber for receiving the aerosol-generating material, wherein the aerosol-generating material can be heated within the heating chamber by the heating assembly; and a conduit fluidly connecting the heating chamber to an external opening of the aerosol delivery device, wherein at least a portion of the conduit is defined by a component including a first susceptor, the device being configured to heat the first susceptor by the inductor to heat the conduit, thereby substantially preventing accumulation of condensate within the conduit.

[0010] According to yet another aspect of the present invention, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating assembly including a heating element capable of being heated by the heating assembly; a heating chamber for receiving the aerosol-generating material, the aerosol-generating material being capable of being heated within the heating chamber by the heating element; and a conduit fluidly connecting the heating chamber to an exterior opening of the aerosol delivery device, at least a portion of the conduit being defined by a component including a thermally conductive material, the thermally conductive material of the component abutting the heating element such that the thermally conductive material can be heated by heat conduction from the heating element to heat the conduit, thereby substantially preventing accumulation of condensate within the conduit.

[0011] According to yet another aspect of the present invention, there is provided an aerosol delivery device for receiving an article containing an aerosol-generating material and for generating an aerosol from the aerosol-generating material, the aerosol delivery device comprising: a stopper that prevents a distal end of the article from moving distally beyond a restrictive position when the article is inserted into the aerosol delivery device; and a heating assembly for heating the aerosol-generating material during use, the heating assembly comprising a heating element, heat being generated within the heating element during use of the heating assembly. When the article is fully inserted into the device and the distal end of the article is in the restrictive position, there is a first portion of the length of the article that does not overlap with the heating element that can be heated to heat the article, the first portion extending either a first distance proximally from the distal end of the article or a first distance distally from the proximal end of the article.

[0012] According to yet another aspect of the present invention, there is provided an aerosol delivery device for generating an aerosol from an aerosol-generating material, the aerosol delivery device comprising: a heating assembly; and one or more components defining a heating chamber for receiving the aerosol-generating material, wherein the aerosol-generating material can be heated within the heating chamber by the heating assembly; and a conduit fluidly connecting the heating chamber with an exterior of the aerosol delivery device, the one or more components forming an airtight seal where the heating chamber and the conduit meet. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a front view of an example aerosol delivery device. [Figure 2] FIG. 2 is an enlarged cross-sectional view of a heating assembly in an aerosol delivery device. [Figure 3a] FIG. 3 is a detailed cross-sectional view of a modified version of the device of FIGS. 1 and 2 including a layer of thermally conductive material on the interior surface of the inlet conduit. [Figure 3b] FIG. 3 is a detailed cross-sectional view of an alternative modified version of the device of FIGS. 1 and 2. [Figure 3c] FIG. 3 is a detailed cross-sectional view of another modified version of the device of FIGS. 1 and 2. [Figure 3d] FIG. 3 is a detailed cross-sectional view of yet another modified version of the device of FIGS. 1 and 2. [Figure 4] FIG. 3 is a detailed cross-sectional view of a modified version of the device of FIGS. 1 and 2 including an air heating unit for heating the air in the inlet conduit of the device. [Figure 5a] FIG. 3 is a detailed cross-sectional view of a modified version of the device of FIGS. 1 and 2, including an inductively heated component defining an inlet conduit. [Figure 5b] 3 is a schematic diagram of an alternative modified version of the device of FIGS. 1 and 2, including respective inductively heated components defining inlet and outlet conduits; FIG. [Figure 6a]3 is a schematic diagram of another modified version of the device of FIGS. 1 and 2 in which the components defining the conduit and the heating chamber are sealingly coupled to one another. FIG. [Figure 6b] FIG. 6b is a schematic diagram of a modified version of the device of FIG. 6a in which respective inductors are provided to heat the components defining the inlet conduit, the outlet conduit and the heating chamber. [Figure 6c] 3 is a schematic diagram of yet another modified version of the device of FIGS. 1 and 2 in which a single component defines the inlet and outlet conduits and the heating chamber. FIG. [Figure 6d] FIG. 6c is a schematic diagram of a modified version of the device of FIG. 6c in which respective inductors are provided to heat the components defining the inlet conduit, the outlet conduit and the heating chamber. [Figure 7a] FIG. 3 is a detailed cross-sectional view of a modified version of the device of FIGS. 1 and 2, configured so that the distal end portion of the aerosol-forming material in the inserted article is not heated. [Figure 7b] 3 is a schematic diagram of an alternative modified version of the device of FIGS. 1 and 2 configured such that the proximal and distal end portions of the aerosol-forming material in the inserted article are not heated. [Figure 8] FIG. 2 is a front view of the aerosol delivery device of FIG. 1 with the outer cover removed. [Figure 9] 2 is a cross-sectional view of the aerosol delivery device of FIG. 1. [Figure 10] FIG. 2 is an exploded view of the aerosol delivery device of FIG. 1. [Figure 11AB] Figure 11A is a cross-sectional view of a heating assembly in an aerosol delivery device, and Figure 11B is a detailed view of a portion of the heating assembly of Figure 11A. Detailed Description

[0014] To facilitate the formation of an aerosol during use, aerosol-forming materials for aerosol delivery devices (e.g., tobacco heating products) typically contain more water and / or aerosol-forming substances than smoking material in combustible smoking articles. This higher water and / or aerosol-forming substance content can increase the risk of condensation building up within the aerosol delivery device during use, particularly at locations away from the heating unit(s).

[0015] The inventors believe that this problem may be more severe in devices having a sealed heating chamber. In such devices, the heating chamber may be fluidly connected to the exterior of the device by a conduit, such as an inlet or outlet conduit. Having studied test results of devices having such conduits, the inventors believe that there is a particular risk of condensate accumulation within the conduit.

[0016] Such accumulated condensate may, in some cases, leak from the device, creating an unpleasant smoking experience for the user. Additionally, or alternatively, such condensate may dry over time, potentially forming gum on the interior surfaces of the conduit. This gum may be difficult to remove and may therefore clump over time. Furthermore, if the aerosol-forming material is included in the consumable, the gum may adhere to the consumable, potentially discoloring the consumable or preventing removal of the gum after use.

[0017] However, the inventors have determined that by configuring a device such that the interior surface of a given conduit is heated during use, the buildup of condensate within that conduit can be limited, and in some cases substantially prevented. Specifically, the buildup of condensate on the interior surface of the conduit can be reduced.

[0018] 1, which is a side view of an example aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material. Broadly speaking, device 100 can be used to heat an exchangeable article 110 containing an aerosol-generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of device 100.

[0019] The device 100 includes a housing 102 (in the form of an outer cover) that surrounds and houses the various components of the device 100. The device 100 has an opening 104 at one end into which an item 110 can be inserted for heating by the heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly, where it can be heated by one or more components of the heater assembly.

[0020] Figure 2 depicts a cross-sectional view of selected internal components of device 100 of Figure 1. As shown, device 100 includes a heated chamber 101 for receiving aerosol-generating material 110a. Device 100 further includes an inlet conduit 103a that fluidly connects heated chamber 101 with the exterior of device 100. During use, air flowing along inlet conduit 103a can be drawn into device 100 before entering heated chamber 101.

[0021] 2, the width of the inlet conduit 103a may be different from the width of the heated chamber 101, for example, less than the width of the heated chamber 101. For example, the average width of the inlet conduit 103a may be less than the average width of the heated chamber 101. This may provide, for example, a user with a desired amount of draw, i.e., impedance to flow.

[0022] Device 100 further includes an outlet conduit 103b that fluidly connects heating chamber 101 with the exterior of device 100 (and device 100 includes extension chamber 144 in the particular example shown). During use, aerosol generated within heating chamber 101 can flow along outlet conduit 103b before exiting device 100.

[0023] 2, the width of the outlet conduit 103b may be different from the width of the heated chamber 101, for example wider than the width of the heated chamber 101. For example, the average width of the outlet conduit 103b may be greater than the average width of the heated chamber 101. This may, for example, allow for expansion of the aerosol, allowing it to cool before being inhaled by the user.

[0024] 2, device 100 includes two heating units 161, 162 for heating aerosol-generating material 110a. While the example shown includes two heating units 161, 162, it should be understood that this is not essential and device 100 may include only one heating unit or may include more than two heating units, as appropriate.

[0025] The inventors have studied test results of devices of similar construction to device 100 of Figures 1 and 2. Based on these test results, the inventors have foreseen a particular risk of condensate accumulation in the conduits fluidly connecting heating chamber 101 with the outside of the device, such as inlet conduit 103a and outlet conduit 103b.

[0026] A possible contributing factor is that in some cases, the unheated portions of the overall passageway through the device may experience a pressure drop compared to the heated portions, including, among other things, the heated chamber, and therefore, due to the pressure differential with the hot heated chamber, any condensate that forms within the device will tend to migrate toward the cooler regions upstream and downstream of the heated chamber, i.e., the inlet and outlet conduits 103a, 103b.

[0027] Another possible contributing factor is that in some cases, in order to regulate the flow of air through the device 100, the device 100 can be designed to provide resistance or impedance to the flow of air into the device, and such resistance / impedance can impede condensate-forming materials from exiting the inlet conduit 103a and / or outlet conduit 103b.

[0028] An additional contributing factor is that in the case of inlet conduit 103a, in many cases, condensate-forming materials will need to move in a direction opposite to the air flow along inlet conduit 103a during use in order to exit the inlet conduit 103a. (

[0029] Without seeking to be bound by this understanding of the contributing factors, the inventors have determined that by configuring device 100 so that the interior surfaces of one or both of inlet conduit 103a and outlet conduit 103b are heated during use, the accumulation of condensate within the conduit(s) can be limited, and in some cases substantially prevented. Such heating of the interior surfaces of inlet conduit 103a and / or outlet conduit 103b can promote re-evaporation of the condensate and can assist in the egress of condensate-forming materials from inlet conduit 103a and / or outlet conduit 103b. Additionally or alternatively, such heating of the interior surfaces of inlet conduit 103a and / or outlet conduit 103b can heat the air within the conduit, thereby increasing the amount of moisture retained by the air and, in turn, reducing the likelihood of condensate formation in the conduit.

[0030] In a device according to one embodiment of the present disclosure, the interior surface is heated so that at least a portion of the interior surface reaches a temperature of 85° C. or greater. The inventors believe that a temperature of 85° C. on at least a portion of the interior surface is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device may be configured so that at least a portion of the interior surface reaches a temperature of at least 90° C., in other cases at least 95° C., and in still other cases at least 100° C. As can be appreciated, this can facilitate re-evaporation of the condensate and aid in the egress of condensate-forming materials from the inlet conduit.

[0031] In a device according to another aspect of the present disclosure, the interior surface is heated such that a central portion of the interior surface, midway between the first and second ends of the conduit, reaches a temperature of 70°C or greater. This central portion temperature is believed to be technically significant because it may represent the degree of heating provided to the condensate by the interior surface, as compared to the temperatures of end portions, e.g., nearest the heating chamber, where the condensate may receive additional heating from residual heat from the heating chamber. The inventors believe that a temperature of at least 70°C at the interior surface central portion is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device may be configured so that the interior surface central portion reaches a temperature of at least 80°C, in other cases at least 90°C, and in still other cases at least 100°C.

[0032] As noted above, heating the interior surfaces of the inlet conduit 103a and / or the outlet conduit 103b can heat the air within the conduits, thereby increasing the amount of moisture retained by the air and, in turn, reducing the likelihood of condensation forming in the conduits. Accordingly, the inventors contemplate that, in some devices according to the above-referenced embodiments, heating the interior surfaces of the inlet conduit 103a and / or the outlet conduit 103b can heat the air within the conduits to temperatures of 120°C or greater. The inventors believe that reaching such air temperatures will often be sufficient to substantially reduce the likelihood of condensation forming in the conduits. However, the inventors believe that in other cases, it may be appropriate to configure the device so that the air is heated to temperatures of 150°C or greater, or in yet other cases, to temperatures of 170°C or greater, or in yet other cases, to temperatures of 200°C or greater.

[0033] 1 and 2, it should be noted that in the particular exemplary device shown, heating units 161, 162 are induction heating units. Induction heating units can provide rapid heating of the aerosol-generating material. However, the inventors believe that such rapid heating can be a risk for condensate buildup, for example, because induction heating units can generate condensate-forming substances at a rate faster than they can be removed.

[0034] In the particular exemplary device 100 shown in FIG. 2 , each induction heating unit 161, 162 includes a respective coil 124, 126 and a respective heating element 134, 136. In the particular example shown, the conductive heating elements 134, 136 of the two heating units 161, 162 correspond to respective sections of a single metal tube 132. However, in other examples, the individual heating elements may be separate and distinct. More generally, it should be understood that a device can include any suitable number of heating elements for heating the aerosol-generating material, for example, providing two, three, or more heating elements.

[0035] Generally, the coils of an induction heating unit can be configured to, for example, cause heating of one or more conductive heating elements, such as to direct thermal energy from such conductive heating elements to the aerosol-forming material, thereby heating the aerosol-forming material. The induction heating unit can be configured such that the coils generate a variable magnetic field that penetrates at least one heating element, thereby inductively heating the at least one heating element. In the device 100 shown in FIG. 2, the coils 124, 126 of each induction heating unit 161, 162 heat their corresponding conductive heating elements 134, 136. The individual heating elements 134, 136 then direct heat to the aerosol-forming material 110a.

[0036] It will be appreciated that in other examples, heating units other than induction heating units may be used. For example, the device may include one or more resistive heating units. By way of example, each of the induction heating units 161, 162 may be replaced with a resistive heating unit. The resistive heating unit may comprise (or consist essentially of) one or more resistive heating elements. By "resistive heating element" is meant that when a voltage is applied to an element, current flows through the element, and the electrical resistance of the element converts electrical energy into thermal energy, which heats the aerosol-generating substrate. The resistive heating element may be in the form of, for example, a resistive wire, a mesh, a coil, and / or multiple wires. The heat source may be a thin-film heating element.

[0037] Referring now to FIG. 3a, FIG. 3a is a detailed cross-sectional view of a modified version 100′ of the device 100 of FIGS. 1 and 2. In the device 100′ shown in FIG. 3a, a portion 1035 of the interior surface of the inlet conduit 103a is thermally conductive. Based on experimental testing, the inventors believe that this thermally conductive portion 1035 may suitably have a thermal conductivity greater than 1 W / m / K. For example, a thermally conductive ceramic such as zirconia or alumina may be used. Such thermal conductivity may aid in the transfer of heat by conduction from the heating chamber 101. The transferred heat may then facilitate the re-evaporation of the condensate and aid in the evacuation of the condensate-forming substances from the inlet conduit 103a.

[0038] In some cases, when the thermally conductive portion of the inner surface of the inlet conduit 103a is formed using, for example, a ceramic material with a higher thermal conductivity (e.g., alumina or aluminum nitride), the device 100 can be constructed so that the thermal conductivity of the thermally conductive portion is 5 W / m / K or greater. In some cases, when the thermally conductive portion of the inner surface of the inlet conduit 103a is formed using, for example, a metallic material, such as a metal or alloy, the device 100 can be constructed so that the thermal conductivity of the thermally conductive portion is greater than 10 W / m / K. Illustrative examples of suitable metallic materials include brass, copper, aluminum, and steel, such as stainless steel. (It may be noted that most metals and most steels have a thermal conductivity greater than 10 W / m / K.) In other cases, when metallic materials such as brass, copper, or aluminum are used, the device can be constructed so that the thermal conductivity of the thermally conductive portion is greater than 20 W / m / K or greater than 50 W / m / K. (It may be noted, for example, that aluminum and aluminum alloys typically have a thermal conductivity significantly greater than 100 W / m / K.)

[0039] While FIG. 3 a illustrates an example in which a portion 1035 of the interior surface of the inlet conduit 103 a is configured to be thermally conductive, it should be appreciated that a portion of the interior surface of the outlet conduit 103 b can also be configured to be thermally conductive using essentially the same approach, for example, by using the materials described above.

[0040] Thus, device 100' of Figure 3a can be viewed more generally as an example of a device in which the interior surface of the conduit is heated during use, at least in part, by conduction of heat generated by a heating unit. Even more generally, device 100' of Figure 3a can be viewed as only one way in which a device can be configured to heat the interior surface of the conduit during use.

[0041] Returning to the particular example shown in FIG. 3 a, it may be noted that the thermally conductive portion 1035 of the interior surface of the inlet conduit 103a is conveniently formed by coating the inlet conduit support 131 with a thermally conductive material. As shown in FIG. 3 a, this inlet conduit support 131 forms the remainder of the interior surface of the inlet conduit 103a, for example. In some examples, the inlet conduit support 131 may be constructed by molding and thus (or otherwise) may be suitably constructed from a moldable polymeric material such as polyetheretherketone (PEEK). Thus, or otherwise, the inlet conduit support 131 may in some examples be integrally formed (e.g., constructed from a single homogenous material), while in other examples the inlet conduit support 131 may comprise multiple components and / or may be a composite inlet conduit support.

[0042] Additionally, while device 100' includes only a single portion of thermally conductive material, i.e., coating 1035, in other examples, the device may include multiple portions of thermally conductive material, each of which forms a respective portion of the interior surface of conduit 103a, with different portions of the thermally conductive material including different (thermally conductive) materials.

[0043] 3a, it may be noted that the distal end of the coating 1035 is located near the distal end 1031 of the inlet conduit 103a. This may, for example, reduce the risk of a user touching a hot surface of the device. For the same reason, in a device having multiple portions of thermally conductive material forming part of the interior surface of the inlet conduit 103a, the distal ends of such portions of thermally conductive material may be located near the distal end 1031 of the inlet conduit 103a.

[0044] It may also be noted that in the particular device 100' shown in Figure 3a, the coating 1035 extends to the proximal end 1032 of the inlet conduit 103a. This may aid in heat transfer from the heated chamber 101 by the thermally conductive material of the coating, particularly (but not limited to) from the portion where the proximal end of the inlet conduit abuts the distal end of the heated chamber 101, as in Figure 3. Generally, in devices having one or more portions of thermally conductive material forming part of the interior surface of the inlet conduit 103a, at least some of these portions may extend to the proximal end of the inlet conduit to aid in heat transfer.

[0045] Referring again to FIG. 3a, it may be noted that the particular exemplary device 100′ shown includes a number of openings 141, each of which opens on one side toward the distal end 1031 of the inlet conduit 103a and on its opposite side toward the exterior of the device. Such openings 141 may thus be described as, for example, fluidly connecting the inlet conduit to the exterior of the device. During use of the device, air may enter the inlet conduit 103a through these openings 141. Such openings 141 may provide an appropriate impedance to the flow of air into the device, thereby regulating the flow of air through the device 100. However, such impedance may also increase the risk of condensate accumulation within the inlet conduit 103a. However, the configuration of the device 100′, according to one of the aspects of the present disclosure, may limit, and in some cases substantially prevent, the accumulation of condensate within the inlet conduit.

[0046] It should be appreciated that although reference is made herein to a coating 1035, this is merely an example of a layer (more particularly, a conformal layer) of thermally conductive material forming the thermally conductive portion 1035 of the interior surface of the inlet conduit 103a. Thus, the present teachings are not limited to layers formed by coating techniques. It will be appreciated that many techniques exist for forming conformal layers of material, such as physical or chemical deposition techniques, and as a particular example, plating techniques (e.g., electroplating) may be used to form a layer of thermally conductive material.

[0047] Furthermore, it should be appreciated that while in device 100' only a portion of the interior surface of inlet conduit 103a is thermally conductive, in other examples substantially the entire interior surface can be made thermally conductive, having a thermal conductivity of greater than 1 W / m / K, 5 W / m / K (or 20 W / m / K or 50 W / m / K, depending on the particular construction). Such an example is shown in Figure 3b, where coating 1035' extends all the way to the distal end 1031 of inlet conduit 103a.

[0048] Furthermore, it should be understood that it is not essential that the device include a conformal layer of thermally conductive material such as coating 1035. Indeed, there are a variety of structural approaches to forming the thermally conductive portion of the interior surface of inlet conduit 103a. As an example, the device could include a liner in inlet conduit 103a.

[0049] As another example, the device can include a tubular / cylindrical component 1036 constructed entirely of a thermally conductive material (e.g., a metallic material such as a metal or alloy, suitable illustrative examples of which include brass, copper, aluminum, and steel, e.g., stainless steel, or a thermally conductive ceramic material such as zirconia or alumina), with the thermally conductive portion of the interior surface of the inlet conduit 103a being formed by the tubular component. Such an example is shown in FIG. 3c, where the device includes a tubular component 1036 that defines the entire interior surface of the inlet conduit 103a. In a particular example, the tubular component 1036 can be suitably constructed entirely from a metallic material such as brass, aluminum, steel (e.g., stainless steel), and / or copper. In the particular example shown, the tubular component 1036 has generally the same shape as the inlet conduit support 131 shown in Figures 3a and 3b, and therefore connects to and supports other components of the device, including the metal tube 132 forming the two heating elements 134, 136, although this is of course not essential and the tubular component 1036 could have any suitable shape.

[0050] Yet another example of a structure forming a thermally conductive portion of the interior surface of the inlet conduit 103a is shown in FIG. 3d, in which a tubular component 1037 constructed entirely of a thermally conductive material (e.g., a metallic material such as a metal or alloy, suitable illustrative examples of which include brass, copper, aluminum, and steel, e.g., stainless steel, or a thermally conductive ceramic material such as zirconia or alumina) is provided as an insert within another component, which may be constructed of an insulating material, e.g., a polymeric material. In the particular example shown in FIG. 3d, the tubular component 1037 is provided as an insert within the inlet conduit support 131, which, as mentioned above, may be made of a moldable polymeric material such as polyetheretherketone (PEEK). The tubular component 1037 may be suitably constructed entirely of a metallic material, such as brass, aluminum, steel (e.g., stainless steel), and / or copper.

[0051] It should also be understood that any of the techniques described above for forming the thermally conductive portion 1035 of the interior surface of the inlet conduit 103a can similarly be employed to form the thermally conductive portion of the interior surface of the outlet conduit 103b. Thus, the outlet conduit 103b can include, for example, the coating 1035, the tubular / cylindrical component 1036, and / or the tubular insert 1037 described above.

[0052] Furthermore, while the coating 1035, the tubular / cylindrical component 1036, and the tubular insert 1037 are described as being formed from a thermally conductive material, it should be understood that they can also be formed from a conductive material, such as a metallic material, e.g., a metal or alloy. Illustrative examples of suitable metallic materials include brass, copper, aluminum, and steel (e.g., stainless steel). These should be understood as more general examples of devices in which at least a portion of the interior surface of the inlet conduit is formed from a conductive material. It should be further recognized that if such a device includes at least one induction heating unit (such as induction heating units 161, 162 of device 100′) that heats the heating chamber of the device, the induction heating unit will also inductively heat the conductive portion of the interior surface of the inlet conduit. Furthermore, this conductive portion may, in some instances, be formed from a ferromagnetic and / or ferrimagnetic material to experience additional heating as a result of magnetic steric losses.

[0053] Even more generally, such induction heating can be viewed as an additional (or alternative) method by which the interior surface of the conduit can be heated during use.

[0054] Other methods of heating the interior surfaces of the inlet or outlet conduits during use will become apparent with the benefit of the teachings of the present disclosure. For example, in other examples, one or more dedicated heating units may be provided to heat the interior surfaces of the conduits.

[0055] Furthermore, according to another aspect of the present disclosure, it is contemplated that a heating unit may be provided that heats the air in the inlet conduit or the outlet conduit. In this regard, reference is made to FIG. 4, which illustrates a device 100'' according to this aspect of the present disclosure. In general, device 100'' is a modified version of device 100 of FIGS. 1 and 2.

[0056] Notably, device 100'' includes an air heating unit 163 for heating the air in inlet conduit 103a. According to this aspect of the disclosure, this heating of the air in conduit 103a substantially prevents the accumulation of condensate within conduit 103a. In particular examples, the air is heated to a temperature of 120°C or greater. The inventors believe that reaching such air temperatures will, in many cases, be sufficient to substantially reduce the likelihood of condensate formation within the conduit. However, the inventors believe that in other cases it may be appropriate to configure device 100'' so that the air is heated to a temperature of 150°C or greater, or in yet other cases to a temperature of 170°C or greater, or in yet other cases to a temperature of 200°C or greater.

[0057] 4, the heating unit 163 is positioned to heat the air in the inlet conduit 103a of the device 100'', it should be understood that in other examples a similar heating unit could be provided to heat the air in the outlet conduit 103b. Indeed, in still other embodiments, respective air heating units could be provided for the inlet and outlet conduits 103a, 103b.

[0058] 4, the air heating unit 163 includes a resistive heating element 1034. Resistive heating elements may be suitable because they are relatively compact, although other example devices may utilize other types of heating elements.

[0059] 4, the heating element 1034 may, for example, define a portion of the interior surface of the inlet conduit 103a. However, this is not essential, and in other examples, other components may define the interior surface of the conduit. In such examples, the heating element may be positioned to transfer heat to the conduit-defining component, for example, by conduction. Thus, the conduit-defining component may be constructed from one of the thermally conductive materials discussed above.

[0060] As is apparent from Figure 4, the heating element 1034 extends circumferentially around the inlet conduit 103a. However, in other examples, the heating element(s) of the heating unit 163 can instead be provided at an end of the conduit 103a, e.g., the end furthest from the heated chamber 101. In such examples, the heating element(s) can be positioned such that air passes through or between the heating element(s) as it enters the conduit (in the case of the inlet conduit 103a) or as it exits the conduit (in the case of the outlet conduit 103b). In certain examples, the heating element(s) can also be provided on or in a cap 140 or door separating the conduit from the exterior of the device.

[0061] 4, the heating element 1034 is spaced apart from the exterior of the device such that it is inaccessible to a user while using the device 100'', for example. By locating the heating element(s) of the heating unit 163 so that they are spaced apart from the exterior of the device, the risk of a user touching a hot surface of the device 100'', for example, can be reduced.

[0062] In many examples, air heating unit 163 is controlled separately from heating unit(s) 161, 162 that heat the aerosol-generating material in heated chamber 101 of device 100''. Thus, air heating unit 163 can be operated at a different time than heating unit(s) 161, 162 for heated chamber 101. Generally, heating unit(s) 161, 162 for heated chamber 101 can be activated prior to air heating unit 163 for conduit 103a, for example, because condensate formation is not expected until the aerosol-generating material has been heated for a significant period of time.

[0063] It is further contemplated that the air heating unit 163 may also be controlled dependent on output from one or more sensors. Output from the one or more sensors may, in some examples, be provided to a controller, such as a microcontroller, which in turn controls the air heating unit 163 based on such output, or in other examples, output from the one or more sensors may be provided directly to the air heating unit 163, which may include appropriate logic circuitry, for example, for controlling the operation of the air heating unit 163.

[0064] In one example, the one or more sensors can include one or more sensors that sense whether aerosol-forming material is present in the heated chamber 101 during use. Such sensors can include, for example, pressure sensors positioned such that any aerosol-forming material present in the chamber applies pressure to those sensors, or such sensors can include, for example, light sensors positioned such that any aerosol-forming material reduces the amount of light reaching those sensors. Output from such sensors can be used to control the air heating unit 163 to heat the air in the conduit (e.g., to a temperature above a threshold temperature) in response to a sensor output indicating that aerosol-forming material has been removed from the heated chamber. In such an example, the air heating unit 163 can assist in removing moisture from the device 100″ generated by the user during use.

[0065] In another example, the one or more sensors can include one or more sensors that sense whether a user is inhaling aerosol generated by the device. Such a sensor can be, for example, an audio sensor (e.g., a microphone) or an air pressure sensor. Output from such a sensor can be used to control air heating unit 163 to heat the air in the conduit (e.g., to a temperature above a threshold temperature) in response to a sensor output indicating that the user has inhaled the aerosol. For example, air heating unit 163 can achieve the threshold temperature shortly after the user has finished inhaling. Thus, or otherwise, air heating unit 163 can operate between puffs by the user.

[0066] Attention is now directed to FIG. 5a, which illustrates a device 100''' according to another embodiment of the present disclosure, in which a component 1038a defining at least a portion of an inlet conduit 103a includes a susceptor 1039a that can be heated by an inductor 126. As shown in FIG. 5a, the susceptor 1039a can, for example, surround a portion of the inlet conduit.

[0067] In the particular example shown in Figure 5a, component 1038a is constructed entirely from the same conductive material. For example, component 1038a can be formed from a metallic material, such as a metal or metal alloy. Illustrative examples of suitable metallic materials include brass, copper, aluminum, and steel, such as stainless steel. However, in other examples, susceptor 1039a can be constructed from a different material compared to the rest of component 1038a.

[0068] As shown in Figure 5a, in some embodiments, the susceptor 1039a may simply correspond to the proximal portion of the component 1038a that is surrounded by the inductor 126. In yet other examples, the susceptor 1039a may comprise substantially the entire component 1038a. In one such example, the inductor 126 may extend beyond the distal end of the inlet conduit-defining component 1038a and surround the entire component 1038a, rather than just the proximal portion of the component 1038a, as in Figure 5a.

[0069] 5a, it may be noted that susceptor 1039a abuts susceptor 136. Thus, susceptor 1039a is additionally heated by thermal conduction from susceptor 136. However, this is not essential, and in other exemplary devices according to this embodiment, susceptor 1039a and susceptor 136 may be spaced apart from one another and, in fact, may be thermally insulated from one another.

[0070] 5a, it may be further noted that the proximal end of component 1038a circumferentially surrounds the distal end of susceptor 136. This may aid in reliable positioning of susceptor 136 during device assembly and / or may provide effective heat conduction from the susceptor to component 1038a.

[0071] As also shown in FIG. 5a, device 100''' can further include support 131 that includes (or is constructed substantially entirely of) a thermally insulating material. For example, support 131 can include (or be constructed substantially entirely of) a plastic or polymeric material such as a moldable polymeric material, e.g., polyetheretherketone (PEEK). As can be seen, support 131 includes a passageway extending between two ends of support 131, with component 1038a disposed within the passageway.

[0072] 5a, susceptor 1039a and component 1038a are generally spaced apart from the outermost ends of the passages in support 131. This can, for example, reduce the risk of a user touching a hot surface of the device.

[0073] It will be further noted that in the particular example shown in FIG. 5 a, the inductor 126 can operate to generate heat both in the susceptor 1039 a (thereby heating the inlet conduit 103) and in the susceptor 136 (thereby heating the heating chamber 101). However, in some embodiments according to this aspect of the disclosure, it is contemplated that the heating chamber 101 can instead be heated by a separate, dedicated heating unit. Thus, for example, a separate inductor can be provided to generate heat in the susceptor 136. Additionally or alternatively, the susceptor 1039 a can be configured to be inherently less sensitive to induction heating than the susceptor 136. For example, the susceptor 1039 a can be constructed from a material that is inherently less sensitive to induction heating than the material from which the susceptor 136 is constructed. In one example, the susceptor 1039 a can be constructed from stainless steel, and the susceptor 136 can be constructed from mild or carbon steel.

[0074] Furthermore, in some embodiments, the heating unit for the heating chamber 101 may optionally not be an inductive heating unit, but may instead be, for example, a resistive heating unit. Thus, the device may include a resistive heating element, such as, for example, a coil of resistive heating wire, or one or more interconnected conductive tracks (e.g., forming part of a film heating element) provided on a substrate.

[0075] More generally, it is contemplated that any of the techniques described above for inductively heating the inlet conduit 103a may additionally or alternatively be used to heat the outlet conduit 103b. In this regard, reference is made to Figure 5b, which is a schematic illustration of a device in which both the inlet conduit-defining component 1038a and the outlet conduit-defining component 1038b are inductively heated. While Figure 5b illustrates a device in which both the inlet conduit-defining component 1038a and the outlet conduit-defining component 1038b are inductively heated, it should be understood that the device could equally well be configured such that only the outlet conduit-defining component 1038b is inductively heated.

[0076] 5b, it can be seen that outlet conduit-defining component 1038b includes a portion (or portions) that acts as susceptor 1039b and is therefore inductively heated by inductor coil 126. In the particular example shown, inductor coil 126 inductively heats susceptor 136, which in turn heats heating chamber 101 (and any aerosol-generating material therein), and inductor coil 126 inductively heats susceptor 1039b of outlet conduit-defining component 1038b and inductively heats susceptor 1039a of outlet conduit-defining component 1038a. However, this is not essential, and in other embodiments, respective inductor coils can be provided to inductively heat inlet conduit-defining component 1038a and outlet conduit-defining component 1038b. Additionally, as mentioned above, the heating chamber 101 may also be equipped with a dedicated heating unit that does not have to be inductive, and thus in some embodiments the heating chamber 101 may be heated by one or more resistive heating elements.

[0077] Furthermore, in some embodiments, one or both of the susceptors 1039a, 1039b of the conduit-defining components 1038a, 1038b can be configured to be essentially less sensitive to induction heating than the susceptor 136 that heats the heating chamber 101. For example, one or both of the susceptors 1039a, 1039b of the conduit-defining components 1038a, 1038b can be constructed from a material that is essentially less sensitive to induction heating than the material from which the susceptor 136 is constructed. In one example, one or both of the susceptors 1039a, 1039b of the conduit-defining components 1038a, 1038b can be constructed from stainless steel, while the susceptor 136 can be constructed from mild or carbon steel.

[0078] Furthermore, in devices according to this aspect of the disclosure, heating the susceptor can cause the interior surface of the associated inlet or outlet conduit to reach a temperature of 85°C or greater. As noted above, the inventors believe that a temperature of 85°C on at least a portion of the interior surface is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device can be configured so that at least a portion of the interior surface reaches a temperature of at least 90°C, in other cases at least 95°C, and in still other cases at least 100°C.

[0079] Alternatively or additionally, in a device according to this aspect of the disclosure, heating the conduit can cause a central portion of the interior surface of the conduit, midway between the first and second ends of the conduit, to reach a temperature of 70°C or greater. This central portion temperature is believed to be technically significant because it may represent the degree of heating provided to the condensate by the interior surface, typically compared to the temperatures of end portions, e.g., nearest the heating chamber, where the condensate may be additionally heated by residual heat from the heating chamber. The inventors believe that a temperature of at least 70°C at the interior surface central portion is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device can be configured so that the interior surface central portion reaches a temperature of at least 80°C, in other cases at least 90°C, and in still other cases at least 100°C.

[0080] Returning to FIG. 5b, it may be noted that the width of the heating chamber 101 is substantially constant throughout its length. Thus, the width w2 of the heating chamber at its distal end is substantially the same as the width w3 of the heating chamber at its proximal end and the width w1 of the heating chamber at its center. However, this is not essential. In other examples, the width of the chamber may increase from the center of the chamber toward its proximal and / or distal ends (so that the chamber is, for example, hourglass-shaped). In particular (but not limited to), where a heating element for the chamber surrounds or otherwise defines the chamber, increasing the width of the proximal and distal end portions of the chamber may result in less heating being received by the proximal and / or distal ends of the smoking article. Reduced heating at the end portions of the smoking article, particularly the end portions of the aerosol-forming material within the smoking article, may result in these end portions acting to collect and / or absorb condensate. Furthermore, reduced heating at the proximal end of the smoking article may be particularly relevant if the smoking article includes a filter at its proximal end, as this may reduce the risk of damage to the filter.

[0081] It should be noted that the inventors view device 100''' of FIG. 5a and device 100''' of FIG. 5b as embodying other aspects of the present disclosure, which are described below.

[0082] As can be seen in FIG. 5a, component 1038a, which defines at least a portion of inlet conduit 103a of device 100''', abuts susceptor 136. It can therefore be appreciated that if component 1038a includes a thermally conductive material, component 1038a may be heated by thermal conduction from susceptor 136. Heating of component 1038a, in turn, may heat inlet conduit 103a, which may help prevent condensate buildup within inlet conduit 103a.

[0083] 5b, both inlet conduit-defining component 1038a and outlet conduit-defining component 1038b abut susceptor 136. Thus, if components 1038a and 1038b comprise a thermally conductive material, heat conduction from susceptor 136 can heat each of components 1038a and 1038b, which in turn heats inlet conduit 103a and outlet conduit 103b.

[0084] According to this embodiment, it is contemplated that such conductive heat can be used to heat the inlet conduit 103 a and / or outlet conduit 103 b, thereby preventing condensate buildup within the associated conduit(s) 103 a, 103 b, without the corresponding conduit(s) 1038 a, 1038 b needing to include any inductively heated portions, such as the susceptor 1039 a. Further, given that such inductive heating is optional in this embodiment of the disclosure, the inventors contemplate that the corresponding conduit-defining components 1038 a, 1038 b can be abutted against non-inductively heated elements. Thus, in a device according to this embodiment, the conduit-defining components 1038 a, 1038 b can be abutted against, for example, resistive heating elements, rather than against the susceptor 136 as shown in FIG. 5 .

[0085] 5a, component 1038a and susceptor 136 are not only abutting but are also "keyed" and rotationally locked or interlinked, however, in other embodiments, component 1038a and susceptor 136 may be secured to one another by soldering, welding, brazing, adhesive bonding, mechanical interlinking, etc. to prevent gross relative movement.

[0086] In some embodiments, when a thermally conductive ceramic such as zirconia or alumina is used, the thermally conductive material of the conduit-defining component can have a thermal conductivity of 1 W / m / K or greater. In other embodiments, when a ceramic material with a higher thermal conductivity (e.g., alumina or aluminum nitride) is used, the thermally conductive material can have a thermal conductivity of 5 W / m / K or greater. In still other embodiments, when a metallic material, such as a metal or alloy, is used, the thermally conductive material can have a thermal conductivity of greater than 10 W / m / K. Illustrative examples of suitable metallic materials include brass, copper, aluminum, and steel, such as stainless steel. (It may be noted that most metals and most steels have a thermal conductivity greater than 10 W / m / K.) In still other embodiments, when a metallic material such as brass, copper, or aluminum is used, the thermally conductive material can have a thermal conductivity greater than 20 W / m / K, or even greater than 50 W / m / K. (It may be noted that aluminum and aluminum alloys typically have a thermal conductivity significantly greater than 100 W / m / K.)

[0087] In some embodiments, substantially the entirety of the conduit-defining components 1038a, 1038b may be constructed from the thermally conductive materials described above.

[0088] In devices according to this aspect of the disclosure, the inlet and / or outlet conduits may be heated such that the interior surface(s) of the conduit(s) reach a temperature of 85° C. or greater. As noted above, the inventors believe that a temperature of 85° C. on at least a portion of the interior surface is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device may be configured so that at least a portion of the interior surface reaches a temperature of at least 90° C., in other cases at least 95° C., and in still other cases at least 100° C.

[0089] Alternatively or additionally, in a device according to this aspect of the disclosure, the inlet conduit and / or the outlet conduit may be heated such that a central portion of the interior surface(s) of the conduit(s) reaches a temperature of 70°C or greater (the central portion of the conduit being defined as the portion midway between the first and second ends of the conduit). This central portion temperature is believed to be technically significant because it may represent the degree of heating provided to all condensate by the interior surface, typically compared to the temperatures of end portions, e.g., nearest the heating chamber, where the condensate may receive additional heating from residual heat from the heating chamber. The inventors believe that a temperature of at least 70°C at the interior surface central portion is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device may be configured such that the interior surface central portion reaches a temperature of at least 80°C, in other cases at least 90°C, and in still other cases at least 100°C.

[0090] While FIG. 5a depicts the inlet conduit-defining component 1038a and the susceptor 136 as rotationally locked or interlinked, they may instead be secured together to prevent gross relative movement, as noted above. For example, they may be secured together by soldering, welding, brazing, adhesives, and mechanical attachments (e.g., crimping or push-fitting), or mechanical interlinking. According to yet another aspect of the present disclosure, it is contemplated that the inlet conduit-defining component 1038a and the susceptor 136 may be sealingly coupled to one another (e.g., by welding, soldering, brazing, adhesives, or mechanical attachments) such that a hermetic seal is formed where the heating chamber 101 and the inlet conduit 103a meet. Some embodiments may be described as forming a hermetic seal near the junction or junction of the heating chamber 101 and the inlet conduit 103a.

[0091] Indeed, the same approach can be used with respect to outlet conduit-defining component 1038b. For example, outlet conduit-defining component 1038b in Figure 5b can be sealingly coupled to susceptor 136 such that a hermetic seal is formed where heater chamber 101 and outlet conduit 103b meet. Some embodiments can be described as forming a hermetic seal near the junction or junction of heater chamber 101 and outlet conduit 103b.

[0092] It is believed that a particular risk of leakage of condensate-forming materials exists where the heating chamber meets the inlet or outlet conduits. Such materials could contaminate the space between, for example, the heating chamber 101 and an insulating member 128 (described below) radially outward of the heating chamber 101. Such a hermetic seal significantly reduces this risk.

[0093] Referring now to FIG. 6a, FIG. 6a illustrates a device 100 according to an embodiment of this aspect of the disclosure. As can be seen, device 100 includes a susceptor 136 that is welded or brazed at one end to an inlet conduit-defining component 1038a (indicated by the bold line 1033a) and at the other end to an outlet conduit-defining component 1038b (indicated by the bold line 1033b). As can be seen, the welds / brazing 1033a, 1033b are performed around the exterior of susceptor 136 and conduit-defining components 1038a, 1038b. This avoids the welding or brazing affecting the shape of the internal passages, including heating chamber 101 and inlet and outlet conduits 103a, 103b. However, in other embodiments, the welding or brazing can be performed internally in addition to or instead of externally.

[0094] In some embodiments, at least a portion of the inlet conduit-defining component 1038a and / or the outlet conduit-defining component 1038b includes (or is formed of) a thermally conductive material.

[0095] In some embodiments, when a thermally conductive ceramic such as zirconia or alumina is used, for example, the thermally conductive material of the convector defining component can have a thermal conductivity of 1 W / m / K or more. In other embodiments, when a ceramic material having a higher thermal conductivity (for example, alumina or aluminum nitride) is used, for example, the thermally conductive material can have a thermal conductivity of 5 W / m / K or more. In still other embodiments, when a metal material such as a metal or an alloy is used, for example, the thermally conductive material can have a thermal conductivity greater than 10 W / m / K. Illustrative examples of suitable metal materials include brass, copper, aluminum, and steel, such as stainless steel. (It can be noted that most metals and most steels have a thermal conductivity greater than 10 W / m / K). In still other embodiments, when a metal material such as brass, copper, or aluminum is used, for example, the thermally conductive material can have a thermal conductivity greater than 20 W / m / K or greater than 50 W / m / K. (It can be noted that aluminum and aluminum alloys, for example, typically have a thermal conductivity considerably greater than 100 W / m / K).

[0096] In some embodiments, the substantially entire convector defining components 1038a, 1038b can be constructed from the thermally conductive material described above. In other embodiments, only a portion of the inner surface of the inlet convector defining component and / or the outlet convector defining components 1038a, 1038b can be constructed from the thermally conductive material.

[0097] The heating chamber 101 is defined by the susceptor 136 in the embodiment of FIG. 6a, but this is not essential. In other embodiments, the heating chamber 101 can be defined by one or more components that do not act as susceptors at all. For example, the components defining the heating chamber 101 can include thermally conductive components (such as a tube formed of a thermally conductive material), and one or more resistive heating elements can be attached on the thermally conductive components.

[0098] <{ In the particular embodiment shown in Figure 6a, the inlet conduit-defining component 1038a and the outlet conduit-defining component 1038b each act as a susceptor and may be heated by the same inductor 126 that heats the susceptor 136. However, in other embodiments, such as the embodiment shown in Figure 6b, the inlet conduit-defining component 1038a and the outlet conduit-defining component 1038b may each be heated by a respective dedicated inductor 127a, 127b. In either case, the device may be configured to individually control the heating of the inlet conduit-defining component 1038a and the outlet conduit-defining component 1038b.

[0099] In still other embodiments, multiple inductors may be provided to heat different portions of the susceptor 136. For example, multiple inductors may heat different longitudinal portions of the susceptor 136, as in the device shown in FIG. 2 including inductors 124 and 126. In some embodiments in which multiple inductors are provided, a first inductor (or a first group of inductors) may be positioned to heat a portion of the susceptor defining the heating chamber and a portion of the susceptor defining one of the inlet or outlet conduits, while a second inductor (or a second group of inductors) may be positioned to heat a different portion of the susceptor defining the heating chamber and a portion of the susceptor defining the other of the inlet and outlet conduits.

[0100] Still other ways of configuring the aerosol delivery device so that the interior surfaces of the conduits are heated during use will be apparent from the above discussion. For example, heat can be transferred by heat transfer from a heating element (e.g., susceptor 136) for heating chamber 101. It will be understood, therefore, that it is not essential that inlet conduit-defining component 1038a and outlet conduit-defining component 1038b act as susceptors.

[0101] It should be understood that sealingly coupling a component defining a heating chamber to a component defining an inlet or outlet conduit is considered just one approach for forming a hermetic seal where the heating chamber mates with the inlet or outlet conduit. An alternative approach is shown in FIG. 6c, which illustrates a device including a single, integrally formed component 1011 defining the heating chamber 101, the inlet conduit 103a, and the outlet conduit 103b. As shown, a continuous passageway or lumen can extend through the single component 1011. In the illustrated embodiment, this passageway includes the heating chamber 101, the inlet conduit 103a, and the outlet conduit 103b. In some embodiments, the entire passageway can be hermetically sealed, thus substantially prohibiting leakage of the condensate-forming material, for example, except at the longitudinal ends of the passageway.

[0102] Although such passageways that are sealed along substantially their entire length are described with reference to embodiments including a single component, it should be understood that such substantially sealed passageways may likewise be present in embodiments such as those shown in Figures 6a and 6b in which multiple components define the heating chamber and inlet and / or outlet conduits.

[0103] Returning to the embodiment of Figure 6c, it should be appreciated that the unitary component 1011 can be formed by a variety of suitable processes. For example, the unitary component 1011 can be formed by a spin-forming process or a flow-forming process, especially if the unitary component 1011 is formed of a metal or alloy. In other examples, the unitary component 1011 can also be formed by an additive manufacturing / 3D printing process, by extrusion, or by casting.

[0104] In the particular embodiment shown in Figure 6c, a first portion 1361 of the integrally formed component 1011 defines the heating chamber 101 and acts as a first susceptor to heat the aerosol-generating material within the heating chamber 101. Second and third portions 1362, 1363 of the integrally formed component 1011 define the inlet and outlet conduits 103a, 103b, respectively, and can be inductively heated by the same inductor 126 that inductively heats the first portion 1361.

[0105] However, in other embodiments, such as the embodiment shown in Figure 6d, the second and third portions 1362, 1363 of the integrally formed component 1011 may be heated by respective inductors 127a, 127b. In such cases, the device may be configured to individually control the heating of the inlet conduit-defining component 1038a and the outlet conduit-defining component 1038b.

[0106] 6c and 6d, the same integrally formed component 1011 defines the heating chamber 101, the inlet conduit 103a, and the outlet conduit 103b, but in other embodiments, the integrally formed component may instead define only the heating chamber 101 and the inlet conduit 103a, or only the heating chamber 101 and the outlet conduit 103b. In such cases, one or more separate components may define the outlet conduit 103b or the inlet conduit 103a, respectively, and these components may be sealingly joined, for example, into a single component, for example, by welding (e.g., as described above), soldering, brazing, or adhesive bonding.

[0107] In devices according to this aspect of the disclosure, the inlet and / or outlet conduits may be heated such that the interior surface(s) of the conduit(s) reach a temperature of 85° C. or greater. As noted above, the inventors believe that a temperature of 85° C. on at least a portion of the interior surface is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device may be configured so that at least a portion of the interior surface reaches a temperature of at least 90° C., in other cases at least 95° C., and in still other cases at least 100° C.

[0108] Alternatively or additionally, in a device according to this aspect of the disclosure, the inlet conduit and / or the outlet conduit may be heated such that a central portion of the interior surface(s) of the conduit(s) reaches a temperature of 70°C or greater (the central portion of the conduit being defined as the portion midway between the first and second ends of the conduit). This central portion temperature is believed to be technically significant because it may represent the degree of heating provided to all condensate by the interior surface, typically compared to the temperatures of end portions, e.g., nearest the heating chamber, where the condensate may receive additional heating from residual heat from the heating chamber. The inventors believe that a temperature of at least 70°C at the interior surface central portion is often sufficient to significantly re-evaporate the condensate. However, in some cases, the device may be configured such that the interior surface central portion reaches a temperature of at least 80°C, in other cases at least 90°C, and in still other cases at least 100°C.

[0109] Referring now to FIG. 7a, FIG. 7a illustrates a device 100'''' according to yet another embodiment of the present disclosure. Similar to the devices illustrated in FIGS. 1-5d, the device 100'''' of FIG. 7a is configured to receive an article 110 containing an aerosol-generating material, and the device 100'''' is configured to generate an aerosol from the aerosol-generating material 1105 once the article 110 is received within the device 100''''. Thus, the device 100'''' includes a heating assembly for heating the aerosol-generating material 1105 during use. The heating assembly includes at least one heating element, such as the susceptor 136 illustrated in FIG. 7a.

[0110] The device of Figure 7a further includes a stopper 105. The stopper 105 prevents the distal end of the article 110 from moving distally beyond a limiting position when the article 110 is inserted into the aerosol delivery device. As can be seen, in the particular example shown in Figure 7, the stopper 105 defines a limiting position that is located distal to the distal end of the susceptor 136. In contrast, in the devices shown in Figures 1-5b, the stopper 105 defines a limiting position at the distal end of the susceptor 136.

[0111] As can be appreciated, by locating the restriction location distal to the distal end of the susceptor 136, when the article 110 is fully inserted into the device, there will be a portion of the length of the aerosol-generating material 1105 within the smoking article that does not overlap with any of the heating elements. This portion extends proximally a first distance 151 from the distal end 1101 of the aerosol-generating material 1105. The inventors believe that this portion will be heated significantly less than other portions of the aerosol-generating material 1105, and may therefore act to collect and / or absorb condensate that may otherwise accumulate within the device, for example, within the inlet or outlet conduits.

[0112] In the particular example shown in Figure 7a, the stopper 105 comprises an annular surface, but could alternatively comprise an array of circumferentially spaced projections, or any suitable structure.

[0113] In many cases, stopper 105 will align with opening 104 of device 100 through which article 110 is inserted (and also align with article-receiving chamber 101). Additionally, stopper 105 can have a minimum inner diameter that is smaller (e.g., 2 mm or more smaller) than the minimum inner diameter of opening 104, such that the article can move freely through opening 104, but its movement is prevented by stopper 105.

[0114] It may also be noted that in the particular embodiment shown in FIG. 7a, the distal end of the susceptor 136 is flared outward. In some embodiments, this flared distal end can have an extension of 2 mm or less along the length of the susceptor. The flared distal end can aid in reliable placement of the susceptor 136 during device assembly. For example, as shown in FIG. 7a, the flared distal end can engage (i.e., abut) with an abutment 1315. In the particular example shown in FIG. 7a, the abutment 1315 comprises an annular surface. However, the abutment 1315 could instead comprise an array of circumferentially spaced projections or any suitable structure.

[0115] In the particular example shown in Figure 7a, the abutment 1315 is provided by the component 1038 that defines (at least in part) the inlet conduit 103a. Thus, in the example shown in Figure 7a, the component 1038 provides both the stopper 105 and the abutment 1315. However, this is merely an illustrative configuration, and the abutment 1315 may be provided by any suitable component of the device 1.

[0116] As can be seen in Figure 7a, device 100'''' includes an article-receiving or heating chamber 1010 and an inlet conduit 103a. As can be seen, the width of inlet conduit 103a is narrower than the width of article-receiving chamber 1010, which can, for example, provide a user with a desired amount of draw, i.e., impedance to flow.

[0117] 7a, the distal portion 1015 of the article-receiving chamber 1010 extending from the distal end of the susceptor 136 (or more generally, from the distal end of the most distal heating element, if the device 100'''' has multiple heating elements) has a width that is the same as or greater than the proximally located portion of the article-receiving chamber 1010. Such a configuration can aid in the insertion of an article into the distal portion 1015 of the article-receiving chamber 1010.

[0118] 7a, the distal portion 1015 of the article-receiving chamber 1010 can be separated from the inlet conduit 103a by a stopper 105. In the particular example shown, the stopper 105 is provided at the junction of the distal portion 1015 of the article-receiving chamber 1010 and the inlet conduit 103a.

[0119] In some embodiments, the distal portion 1015 of the article-receiving chamber 1010 may be defined by a thermally insulating material. This may further assist in reducing the amount of heat applied to the distal portion of the smoking article. Suitably, the thermally insulating material may be a plastic, for example polyetheretherketone.

[0120] While susceptor 136 is used as the heating element in device 100'''' of FIG. 7a, it should be understood that this embodiment is not so limited. Indeed, it is contemplated that a variety of different types of heating elements may be utilized depending on the particular application. For example, susceptor 136 may be replaced with a resistive heating element, such as a resistive wire coil, or one or more interconnected conductive tracks (e.g., forming part of a film heating element) provided on a substrate.

[0121] Furthermore, the inventors contemplate that it may be appropriate to additionally (or alternatively) provide an unheated portion at the proximal end 1102 of the aerosol-forming material 1105 within the smoking article 110.

[0122] To illustrate the broad scope of this aspect of the present disclosure, reference is made to Figure 7b, which is a schematic diagram showing a smoking article 110 fully inserted into a device according to another embodiment of this aspect of the present disclosure. For ease of explanation, the device shown in Figure 7b includes only a single heating element 1200, which is shown schematically, although it will be appreciated that the device may include two, three or more heating elements depending on the particular application.

[0123] As can be seen, FIG. 7b shows the article 110 fully inserted into the device, with the distal end 111 of the article 110 in the limit position defined by the stopper 105.

[0124] 7b further illustrates aerosol-forming material 1105 within article 110. The length of aerosol-forming material 1105 is indicated in FIG.

[0125] As shown in Figure 7b, in some embodiments, the distal end 111 of the article 110 can be defined by the distal end 1101 of the aerosol-generating material 1105. As also shown in Figure 7b, the aerosol-generating material 1105 can be in the form of an elongated body, such as a cylindrical body. It may be further noted that in the particular example shown in Figure 7b, the article 110 includes a filter 1106 extending from the proximal end 1102 of the aerosol-generating material 1105.

[0126] As shown in FIG. 7b, when the article 110 is in the fully inserted position, there is a first portion of the length of the aerosol-generating material 1105 that extends proximally a first distance 1001 from the distal end 1101 of the aerosol-generating material 1105 and does not overlap at all with the heating element.

[0127] Also shown in Figure 7b, there is a second portion of the length of the aerosol-generating material 1105 that extends a second distance 1002 distally from the proximal end 1102 of the aerosol-generating material 1105 and similarly does not overlap at all with the heating element.

[0128] The first and second portions of the article may each act to collect and / or absorb condensate that may otherwise accumulate within the device, for example, within the inlet conduit or outlet conduit.

[0129] The first distance 1001 can be, for example, 2 mm or more and 10 mm or less. In certain cases, the first distance 1001 can be 3 mm or more and 7 mm or less. In other cases, the first distance 1001 can be approximately 5 mm. Similarly, the second distance 1002 can be, for example, 2 mm or more and 10 mm or less. In certain cases, the second distance 1002 can be 3 mm or more and 7 mm or less. In other cases, the second distance 1002 can be approximately 5 mm. In some cases, the first distance and the second distance 1001, 1002 can be substantially equal.

[0130] While Figure 7b shows a device in which neither the first portion 1001 nor the second portion 1002 of the length of the aerosol-generating material 1105 overlaps the heating element at all, it should be understood that in other embodiments, the device can be configured so that only the second portion of the length of the aerosol-generating material 1105 does not overlap the heating element at all. (Such embodiments would therefore have at least one heating element that overlaps the proximal end of the aerosol-generating material 1105.)

[0131] Referring now to Figures 8-11B, these figures illustrate various features of the structure and operation of the devices of Figures 1-3. Similar features can be used in the devices of Figures 5a-7b.

[0132] Referring first to Figure 8, device 100 can include a first end member 106 as shown, with a lid 108 that can be moved relative to the first end member 106 to close opening 104 when item 110 is not in place. In Figure 1, lid 108 is shown in an open configuration, but lid 108 can be moved to a closed configuration. For example, a user can slide lid 108 in the direction of arrow "A."

[0133] Device 100 may also include a user-operable control element 112, such as a button or switch that, when pressed, operates device 100. For example, a user may turn device 100 on by operating switch 112.

[0134] Device 100 may also include electrical components such as a socket / port 114 that can receive a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0135] 8 depicts the device 100 of FIG. 1 with the outer cover 102 removed and without the item 110 present. The device 100 defines a longitudinal axis 180.

[0136] 8, first end member 106 is disposed at one end of device 100, and second end member 116 is disposed at the opposite end of device 100. The first and second end members 106, 116 together at least partially define an end surface of device 100. For example, the bottom surface of second end member 116 at least partially defines the bottom surface of device 100. The edge of outer cover 102 can also define a portion of the end surface. In this example, lid 108 also defines a portion of the top surface of device 100.

[0137] Because the end of the device nearest opening 104 is closest to the user's mouth during use, this end of device 100 nearest opening 104 is sometimes known as the proximal end (or mouth end) of device 100. During use, a user inserts item 110 into opening 104, activates user control 112 to initiate heating of the aerosol-generating material, and puffs at the aerosol generated in the device, causing the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0138] The other end of the device furthest from opening 104 is sometimes known as the distal end of device 100, as it is the end farthest from the user's mouth during use. When a user puffs on the aerosol generated in the device, the aerosol flows away from the distal end of device 100.

[0139] Device 100 can further include a power source 118. Power source 118 can be a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include lithium batteries (e.g., lithium-ion batteries), nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power under the control of a controller (not shown) when required to heat the aerosol-generating material. In this example, the battery is connected to a central support 120 that holds battery 118 in place.

[0140] The device may further include at least one electronics module 122. The electronics module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also include one or more electrical tracks for electrically connecting together the various electronic components of the device 100. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via electrical tracks.

[0141] As mentioned above, in the exemplary device 100, the heating assembly is an induction heating assembly and includes various components for heating the aerosol-generating material 110a by an induction heating process. Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly can include an induction element, such as one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The variable current in the induction element produces a variable magnetic field. The variable magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents within the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore, the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by the variable orientation of magnetic dipoles in the magnetic material as a result of magnetic hysteresis losses in the susceptor, i.e., the alignment of magnetic dipoles with the variable magnetic field. In comparison with, for example, conduction heating, in induction heating, heat is generated inside the susceptor and therefore can be heated quickly. Furthermore, any physical contact between the induction heater and the susceptor is not required, thus facilitating freedom of construction and application.

[0142] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil and the second inductor coil 124, 126 are made of a conductive material. In this example, the first inductor coil and the second inductor coil 124, 126 are made of litz wire / cable that is helically wound to provide the helical inductor coils 124, 126. Litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce the skin effect loss of the conductor. In the exemplary device 100, the first inductor coil and the second inductor coil 124, 126 are made of copper litz wire having a rectangular cross-section. In other examples, the litz wire can have other cross-sections, such as a circle.

[0143] The first inductor coil 124 is configured to generate a first variable magnetic field for heating the first section 134 of the susceptor 132, and the second inductor coil 126 is configured to generate a second variable magnetic field for heating the second section 136 of the susceptor 132. Thus, as discussed above with reference to FIG. 2 , the first inductor coil 124 and the first section 134 of the susceptor 132 can be considered part of a first heating unit 161, with the first section 134 of the susceptor 132 acting as a heating element for generating heat that is transferred to the aerosol-generating material. Meanwhile, the second inductor coil 126 and the second section 136 of the susceptor 132 can be considered part of a second heating unit 162, with the second section 136 of the susceptor 132 acting as a heating element for generating heat that is transferred to the aerosol-generating material.

[0144] 8, the first inductor coil 124 is side-by-side with the second inductor coil 126 in a direction along the longitudinal axis 180 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap). The susceptor structure 132 can comprise a single susceptor or two or more individual susceptors. Ends 130 of the first and second inductor coils 124, 126 can be connected to the PCB 122.

[0145] It will be appreciated that the first and second inductor coils 124, 126 can have at least one characteristic that differs from one another in some examples. For example, the first inductor coil 124 can have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 can have a different inductance value than the second inductor coil 126. In FIG. 10 , the first and second inductor coils 124, 126 are different lengths such that the first inductor coil 124 is wound across a shorter section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 can have a different number of turns than the second inductor coil 126 (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 can be constructed of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0146] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are driven at different times. For example, the first inductor coil 124 can be operated first to heat a first section / portion of the article 110, and the second inductor coil 126 can be operated at a later time to heat a second section / portion of the article 110. Winding the coils in opposite directions can help reduce the current induced in the undriven coil when used with certain types of control circuitry. In FIG. 8 , the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124, 126 can be wound in the same direction, or the first inductor coil 124 can be a left-handed spiral and the second inductor coil 126 can be a right-handed spiral.

[0147] The susceptor 132 in this example is hollow, thus defining a heated chamber 101 in which the aerosol-generating material is received. For example, the item 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular and has a circular cross section.

[0148] The susceptor 132 may be made of one or more materials. In one example, the susceptor 132 comprises carbon steel with a coating of nickel or cobalt.

[0149] In some examples, the susceptor 132 can include at least two materials, which can be heated at two different frequencies for their selective aerosolization. For example, a first section of the susceptor 132 (heated by the first inductor coil 124) can include a first material, and a second section of the susceptor 132 (heated by the second inductor coil 126) can include a second, different material. In another example, the first section can include a first material and a second material, which can be heated differently based on the operation of the first inductor coil 124. The first material and the second material can be adjacent along an axis defined by the susceptor 132, or different layers can be formed within the susceptor 132. Similarly, the second section can include a third material and a fourth material, which can be heated differently based on the operation of the second inductor coil 126. The third material and the fourth material can be side by side along an axis defined by the susceptor 132, or different layers can be formed within the susceptor 132. For example, the third material can be the same as the first material, and the fourth material can be the same as the second material. Alternatively, each of these materials can be different. The susceptor can include, for example, carbon steel or aluminum.

[0150] 8 further includes an insulating member 128 that may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 may facilitate insulating the various components of the device 100 from heat generated within the susceptor 132.

[0151] The insulating member 128 can also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 8 , the first and second inductor coils 124, 126 are disposed around the insulating member 128 and are in contact with the radially outward facing surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, a small gap may exist between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0152] In a particular example, the susceptor 132 , the insulating member 128 and the first and second inductor coils 124 , 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0153] 9 shows a side view, partially in cross section, of device 100, in this example with outer cover 102 present. The rectangular cross-sectional shapes of first and second inductor coils 124, 126 can be seen more clearly.

[0154] The device 100 further includes an inlet conduit support 131 which, in the particular example shown, engages one end of the susceptor tube 132 to hold the susceptor tube 132 in place. The inlet conduit support 131 is connected to the second end member 116.

[0155] The device may also include a second printed circuit board 138 associated with the control element 112 .

[0156] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward the distal end of the device 100. The spring 142 allows the second lid 140 to be opened to provide access to the susceptor tube 132. A user can open the second lid 140 to clean the interior surface of the susceptor tube 132 and / or the inlet conduit 103a.

[0157] The device 100 further includes an extension chamber 144 extending away from the proximal end of the susceptor 132 toward the opening 104 of the device. As mentioned above, the extension chamber 144 forms part of the outlet conduit 103b in the exemplary device 1 shown in Figures 1 and 2. A retaining clip 146 is at least partially disposed within the extension chamber 144 and abuts and holds the article 110 when it is received within the device 100. The extension chamber 144 is connected to the end member 106.

[0158] FIG. 10 is an exploded view of the device 100 of FIG. 1, with the outer cover 102 omitted.

[0159] FIG. 11A depicts a cross-section of a portion of the device 100 of FIG. 8. FIG. 11B depicts a detail of an area of ​​FIG. 11A. FIGS. 11A and 11B show the article 110 received within the susceptor 132, with the article 110 sized so that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures that heating is most effective. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 can also include other components, such as a filter, wrapping material, and / or cooling structure.

[0160] 11B shows that the outer surface of the susceptor 132 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 mm to 3.5 mm, or about 3.25 mm.

[0161] 11B further shows that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm such that the inductor coils 124, 126 are in abutting contact with the insulating member 128.

[0162] In one example, the susceptor 132 has a wall thickness 154 of about 0.025 mm to 1 mm, or about 0.05 mm.

[0163] In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

[0164] In one example, the insulating member 128 has a wall thickness 156 of about 0.25 mm to 2 mm, 0.25 mm to 1 mm, or about 0.5 mm.

[0165] 1-11B include a heating element for the aerosol-forming material surrounding the heating chamber, it should be understood that other devices embodying various aspects disclosed herein can also include at least one heating element (e.g., in the form of a pin, rod, or blade) that protrudes into the heating chamber to heat the aerosol-forming material from the inside out. The at least one heating element can be aligned, for example, with the longitudinal axis of the heating chamber.

[0166] As used herein, a "period of use" refers to a single cycle of use of the aerosol delivery device by a user. A period of use begins when power is first applied to at least one heating unit present in the heating assembly. The device can be used any time after a certain period of time has elapsed since the beginning of the period of use. A period of use ends when power is no longer applied to any of the heating elements in the aerosol delivery device. The end of the period of use may coincide with the point at which the smoking article is emptied (the point at which the total mg of particulate matter produced per puff is deemed unacceptably low by the user). The period will have a duration of multiple puffs. The period may have a duration of less than 7 minutes, less than 6 minutes, less than 5 minutes, less than 4 minutes 30 seconds, less than 4 minutes, or less than 3 minutes 30 seconds. In some embodiments, a period of use may have a duration of 2 to 5 minutes, 3 to 4.5 minutes, 3.5 to 4.5 minutes, or suitably 4 minutes. The period may begin when the user activates a button or switch on the device, causing the temperature of at least one heating element to begin to increase.

[0167] As used herein, a "heating chamber" may refer to a space that is heated, for example, by at least one heating element of at least one heating unit. In some examples, the heating chamber may have two open ends (e.g., an open proximal end and an open distal end), and there may be an abrupt change in cross-sectional area, for example, at one or both of these open ends. In some examples, the proximal end of the inlet conduit may open into the distal end of the heating chamber or may be directly connected to the distal end of the heating chamber. Thus, there may be an abrupt change in cross-sectional area between the proximal end of the inlet conduit and the distal end of the heating chamber. Thus (or otherwise), the cross-sectional area of ​​the proximal end of the inlet conduit may be narrower than the cross-sectional area of ​​the distal end of the heating chamber.

[0168] The above-described embodiments should be understood as illustrative examples of the present invention. Other embodiments of the present invention are contemplated. It should be understood that any feature described in connection with any one embodiment can be used alone or in combination with other features described, and also in combination with one or more features of any other embodiment, or in any combination with any other embodiment. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the present invention, as defined in the appended claims.

Claims

1. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heated chamber for receiving the aerosol-forming material; an induction heating unit for heating the aerosol-forming material during use; a conduit having an interior surface fluidly connecting the heating chamber with an exterior of the aerosol delivery device; wherein the aerosol delivery device is configured such that during use, at least a portion of the interior surface of the conduit is heated, thereby substantially preventing accumulation of condensate within the conduit.

2. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heated chamber for receiving the aerosol-forming material; an induction heating unit for heating the aerosol-forming material when the aerosol-forming material is located within the heating chamber during use; a conduit having an interior surface fluidly connecting the heating chamber with an exterior of the aerosol delivery device; wherein the aerosol delivery device is configured such that during use, the interior surface of the conduit is heated and at least a portion of the interior surface reaches a temperature of 85° C. or greater.

3. 3. The aerosol delivery device of claim 1, wherein at least a portion of the interior surface is formed from a thermally conductive material having a thermal conductivity greater than 1 W / m / K.

4. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heated chamber for receiving the aerosol-forming material; a heating unit for heating the aerosol-forming material during use; and a conduit having an interior surface fluidly connecting the heating chamber with an exterior of the aerosol delivery device; wherein at least a portion of the interior surface is formed from a thermally conductive material having a thermal conductivity greater than 1 W / m / K.

5. The aerosol delivery device of claim 4 , wherein the heating unit is an induction heating unit.

6. 6. The aerosol delivery device of claim 3, wherein the thermally conductive material has a thermal conductivity greater than 10 W / m / K, optionally greater than 20 W / m / K, and further optionally greater than 50 W / m / K.

7. the conduit having a first end and a second end, the first end being closer to the heating chamber than the second end; the at least a portion of the interior surface formed of a thermally conductive material has a first end and a second end, the first end being closer to the heating chamber than the second end; the second end of the at least a portion of the interior surface formed of a thermally conductive material is closer to the heating chamber than the second end of the conduit, and / or the first end of the at least a portion of the interior surface formed of a thermally conductive material is disposed at the first end of the conduit. The aerosol delivery device according to any one of claims 3 to 6.

8. 8. The aerosol delivery device of claim 3, further comprising a conduit support having an interior surface defining a passageway, wherein at least a portion of the interior surface of the conduit formed of a thermally conductive material is formed by a layer of thermally conductive material on the interior surface of the conduit support.

9. further comprising a tubular component constructed of a thermally conductive material, wherein said at least a portion of said interior surface formed of a thermally conductive material is formed by said tubular component; Optionally, said tubular component forms the entire interior surface of said conduit; The aerosol delivery device according to any one of claims 3 to 7.

10. 10. The aerosol delivery device of any one of claims 3 to 9, wherein the heat-conducting material is a ceramic material such as alumina or zirconia, or a metallic material such as aluminium, brass or stainless steel.

11. The device according to any one of claims 3 to 10, wherein the thermally conductive material is an electrically conductive material.

12. The aerosol delivery device of any one of claims 3 to 11, wherein the thermally conductive material is a ferromagnetic material and / or a ferrimagnetic material.

13. 13. The aerosol delivery device of any one of claims 1 to 12, wherein heating of the inner surface of the conduit during use is at least partly due to conduction of heat generated by the heating unit.

14. 14. The aerosol delivery device of any one of claims 1 to 13, wherein the aerosol delivery device is configured such that, during use, the conduit is heated so that at least a portion of the interior surface reaches a temperature of 85°C or greater, optionally 90°C or greater, further optionally 95°C or greater, and further optionally 100°C or greater.

15. 15. The aerosol delivery device of any one of claims 1 to 14, wherein the aerosol delivery device is configured such that during use, the inner surface of the conduit is heated so that at least a central portion of the inner surface intermediate the first and second ends of the conduit reaches a temperature of 70°C or more, optionally 80°C, further optionally 90°C, and further optionally 100°C or more.

16. 16. The aerosol delivery device of any one of claims 1 to 15, wherein heating the interior surface of the conduit heats the air within the conduit to a temperature of 120°C or greater, optionally 150°C or greater, further optionally 170°C or greater, and further optionally 200°C or greater.

17. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heated chamber for receiving the aerosol-forming material; a heating unit for heating the aerosol-forming material during use; and a conduit fluidly connecting the heating chamber with the exterior of the aerosol delivery device; an air heating unit for heating air within the conduit to thereby substantially prevent accumulation of condensate within the conduit; An aerosol delivery device comprising:

18. 18. The aerosol delivery device of claim 17, wherein the air heating unit comprises one or more heating elements.

19. 19. The aerosol delivery device of claim 17 or 18, wherein each of the one or more heating elements of the air heating unit is spaced apart from the exterior of the device.

20. 20. The aerosol delivery device of any one of claims 17 to 19, wherein at least some, and optionally all, of the one or more heating elements are resistive heating elements.

21. at least one aerosol-forming material sensor adapted to sense whether an aerosol-forming material is present in the heating chamber; the device is configured such that the air heating unit is controlled based on an output signal from the at least one aerosol-forming material sensor. The aerosol delivery device according to any one of claims 17 to 20.

22. 22. The aerosol delivery device of claim 21, wherein the air heating unit is configured to heat the air in the conduit to a temperature greater than a threshold temperature in response to an output signal from the at least one aerosol-forming material sensor indicating that aerosol-forming material has been removed from the heating chamber.

23. and at least one inhalation sensor adapted to sense whether a user is inhaling an aerosol produced by the device; the device is configured such that the air heating unit is controlled based on an output signal from the at least one inhalation sensor.

23. The aerosol delivery device of any one of claims 17 to 22.

24. 24. The aerosol delivery device of claim 23, wherein the air heating unit is configured to heat the air in the conduit to a temperature higher than a threshold temperature in response to an output signal from the at least one inhalation sensor indicating that a user has inhaled an aerosol generated by the device.

25. 25. The aerosol delivery device of claim 22 or 24, wherein the threshold temperature is 120°C or higher, optionally 150°C or higher, further optionally 170°C or higher, and further optionally 200°C or higher.

26. 24. The aerosol delivery device of any one of claims 17 to 19, 21 and 23, wherein the air heating unit is configured to heat the air in the conduit to a temperature above a threshold temperature of 120°C or more, optionally 150°C or more, further optionally 170°C or more, and further optionally 200°C or more.

27. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heating assembly comprising an inductor; a heating chamber for receiving the aerosol-forming material, the aerosol-forming material being capable of being heated within the heating chamber by the heating assembly; a conduit fluidly connecting the heating chamber and an exterior opening of the aerosol delivery device, the conduit being at least partially defined by a component comprising a first susceptor; wherein the device is configured to heat the first susceptor with the inductor to heat the conduit, thereby substantially preventing accumulation of condensate in the conduit.

28. 28. The aerosol delivery device of claim 27, wherein the first susceptor surrounds at least a portion of the conduit.

29. 29. The aerosol delivery device of claim 27 or 28, wherein the heating assembly is configured to allow the inductor to heat the aerosol-forming material when the aerosol-forming material is present in the heating chamber.

30. 30. The aerosol delivery device of claim 29, wherein the heating assembly comprises a second susceptor heatable by the inductor to heat the heating chamber.

31. 31. The aerosol delivery device of claim 30, wherein the second susceptor surrounds at least a portion of the heating chamber.

32. 32. The aerosol delivery device of claim 30 or 31, wherein the first susceptor abuts the second susceptor, such that the first susceptor can be heated by heat conduction from the second susceptor.

33. 33. The aerosol delivery device of any one of claims 27 to 32, wherein the conduit has a width that is wider or narrower than the heating chamber.

34. The aerosol delivery device of any one of claims 27 to 33, wherein the inductor comprises a coil, and at least a portion of the inductor coil surrounds at least a portion of the first susceptor.

35. 35. The aerosol delivery device of claim 27, further comprising a support comprising a thermally insulating material and having a first end and a second end, the first end being closer to the heating chamber than the second end, a passage extending between the first and second ends, and at least a portion of the first susceptor being disposed within the passage.

36. 36. The aerosol delivery device of claim 35, wherein the first susceptor is spaced from the second end of the support and therefore from the opening.

37. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heating assembly comprising a heating element capable of being heated by said heating assembly; a heating chamber for receiving the aerosol-forming material, the aerosol-forming material being capable of being heated within the heating chamber by the heating element; a conduit fluidly connecting the heating chamber and an exterior opening of the aerosol delivery device, the conduit being at least partially defined by a component comprising a thermally conductive material; and wherein the thermally conductive material of the component abuts the heating element and can therefore be heated by thermal conduction from the heating element to heat the conduit, thereby substantially preventing accumulation of condensate within the conduit.

38. 38. The aerosol delivery device of claim 37, wherein the thermally conductive material surrounds at least a portion of the conduit.

39. 39. The aerosol delivery device of claim 37 or 38, wherein the proximal end of the component circumferentially surrounds the distal end of the heating element.

40. 40. The aerosol delivery device of any one of claims 37 to 39, wherein the heating assembly comprises an induction heating unit and the heating element is a susceptor.

41. The aerosol delivery device of any one of claims 37 to 40, wherein the heating element surrounds at least a portion of the heating chamber.

42. 42. The aerosol delivery device of any one of claims 37 to 41, wherein the conduit has a width that is wider or narrower than the heating chamber.

43. 43. The aerosol delivery device of any one of claims 37 to 42, further comprising a support comprising a thermally insulating material and having a first end and a second end, the first end being closer to the heating chamber than the second end, a passage extending between the first and second ends, and at least a portion of the component being disposed within the passage.

44. 44. The aerosol delivery device of claim 43, wherein the component is spaced apart from the second end of the support and therefore from the opening.

45. The aerosol delivery device of any one of claims 1 to 44, wherein the conduit is an inlet conduit.

46. The aerosol delivery device of any one of claims 1 to 44, wherein the conduit is an outlet conduit.

47. 1. An aerosol delivery device for receiving an article including an aerosol-forming material and generating an aerosol from the aerosol-forming material, comprising: a stopper that prevents a distal end of the article from moving distally beyond a limit position when the article is inserted into the aerosol delivery device; a heating assembly for heating the aerosol-forming material during use, the heating assembly including a heating element, wherein heat is generated within the heating element during use of the heating assembly; and when the article is fully inserted into the device and the distal end of the article is in the restricted position, there is a first portion of the length of the aerosol-generating material that does not overlap with any heating element that can be heated to heat the article, and the first portion extends over either a first distance proximally from the distal end of the aerosol-generating material or a first distance distally from the proximal end of the aerosol-generating material.

48. 48. The aerosol delivery device of claim 47, wherein the heating unit is an induction heating unit and the heating element is a susceptor.

49. 49. The aerosol delivery device of claim 47 or 48, wherein the heating element has an outwardly flared distal end.

50. 50. The aerosol delivery device of any one of claims 47 to 49, further comprising a heating chamber, the heating element surrounding a portion of the heating chamber.

51. 51. The aerosol delivery device of claim 50, further comprising an inlet conduit fluidly connecting the heating chamber with an opening on the exterior of the aerosol delivery device, the heating chamber having a width greater than the width of the inlet conduit.

52. 52. The aerosol delivery device of claim 50 or 51, wherein the heating chamber has a distal portion extending from the distal end of the heating element to the stopper, the distal portion having a width equal to or greater than the width of a portion of the heating chamber located proximal to the distal portion.

53. 53. The aerosol delivery device of claim 52, wherein the distal portion of the heating chamber is defined by a thermally insulating material.

54. 54. The aerosol delivery device of claim 53, wherein the thermally insulating material is a plastic, optionally a polyetheretherketone.

55. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a heating assembly; One or more components, a heating chamber for receiving the aerosol-forming material, the aerosol-forming material being capable of being heated within the heating chamber by the heating assembly; a conduit fluidly connecting the heating chamber with the exterior of the aerosol delivery device; and one or more components defining wherein the one or more components form an airtight seal where the heated chamber and the conduit meet.

56. 56. The aerosol delivery device of claim 55, wherein the one or more components comprise at least one conduit-defining component that defines the conduit and at least one heating chamber-defining component that defines the heating chamber, and the at least one conduit-defining component is sealingly coupled to the at least one heating chamber-defining component.

57. 57. The aerosol delivery device of claim 56, wherein the at least one conduit-defining component is sealingly coupled to the at least one heating chamber-defining component by welding or brazing.

58. 58. The aerosol delivery device of claim 57, wherein the welding or brazing is around the exterior of the at least one conduit-defining component and the heating chamber-defining component.

59. 59. The aerosol delivery device of any one of claims 56 to 58, wherein at least one of the at least one conduit-defining components comprises a thermally conductive material.

60. 56. The aerosol delivery device of claim 55, wherein the one or more components comprise a single, integrally formed component.

61. the heating assembly is an induction heating assembly and comprises at least one inductor; the one or more components are heatable by the at least one inductor to form a first susceptor that heats the aerosol-generating material and generates the aerosol; 61. The aerosol delivery device of any one of claims 55 to 60.

62. 62. The aerosol delivery device of any one of claims 56-59 and 61, wherein the at least one heating chamber-defining component comprises the first susceptor.

63. 63. The aerosol delivery device of claim 62, wherein the at least one conduit-defining component comprises a second susceptor heatable by the at least one inductor.

64. the at least one inductor comprises a first inductor and a second inductor; the first inductor can heat the first susceptor; The second inductor can heat the second susceptor.

64. The aerosol delivery device of claim 63.

65. the at least one inductor comprises a first inductor and a second inductor; the first inductor is operable to inductively heat a first portion of the integrally formed component, the first portion defining the heating chamber and forming the first susceptor; the second inductor is operable to inductively heat a second portion of the integrally formed component, the second portion defining the conduit; 62. The aerosol delivery device of claim 60 or 61.

66. the conduit fluidly connects a first end of the heating chamber to a first opening on the exterior of the aerosol delivery device; the one or more components further define an additional conduit fluidly connecting a second opposite end of the heating chamber and a second opening on the exterior of the aerosol delivery device; the one or more components form an additional airtight seal where the heating chamber and the additional conduit meet; 66. The aerosol delivery device of any one of claims 55 to 65.

67. 67. The aerosol delivery device of claim 66, wherein the conduit fluidly connecting the first end of the heating chamber and the first opening has an internal width that is narrower than the heating chamber.

68. 68. The aerosol delivery device of claim 66 or 67, wherein the additional conduit has a wider internal width than the heating chamber.

69. 69. A method of generating an aerosol, comprising using an aerosol delivery device according to any one of claims 1 to 68 to heat an aerosol-forming material to generate the aerosol.

70. an aerosol delivery device according to any one of claims 1 to 68; Aerosol-generating materials and An aerosol generating system comprising:

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