Apparatus for heating aerosolisable material and method of arranging apparatus

Abstract

To provide an apparatus 1 for heating an aerosolisable material to volatilize at least one component of the aerosolisable material to form an aerosol for inhalation by a user.SOLUTION: The apparatus 1 comprises: a heating arrangement 23 comprising an elongate heating zone 29 for receiving and heating an aerosolisable material; a power zone for installing a power source 27 for providing heating power to heat the heating zone 29; and control circuitry 25 for controlling the heating power; where the power zone and the control circuitry 25 are arranged in sequence in a direction substantially parallel with a longitudinal axis of the apparatus 1; and where the elongate heating zone 29 is arranged adjacent to and substantially in parallel with the power zone and the control circuitry 25.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and a method for configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products include so-called "heat-not-burn" products, or tobacco heating devices or products, which release compounds by heating a material rather than burning it. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] A first aspect of the present invention provides a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, the device comprising a heating arrangement including an elongated heating zone for receiving and heating the aerosolizable material, a power supply zone for locating a power source for providing heating power to heat the heating zone, and control circuitry for controlling the heating power, the power supply zone and control circuitry being sequentially arranged in a direction substantially parallel to a longitudinal axis of the device, and the elongated heating zone being arranged adjacent to and substantially parallel to the power supply zone and control circuitry.

[0004] In an exemplary embodiment, the longitudinal axis of the device is the main axis of the device. In an exemplary embodiment, the longitudinal axis of the device is parallel to the longitudinal axis of the elongated heating zone.

[0005] In an exemplary embodiment, the longitudinal axis of the elongated heating zone is disposed parallel to the longitudinal axis of each of the power supply zone and the control circuit.

[0006] In an exemplary embodiment, an elongated heating zone is disposed on one side of the power supply and on one side of the power circuit.

[0007] In an exemplary embodiment, the elongated heating zone is disposed within the power supply and control circuitry in a direction substantially parallel to the longitudinal axis of the elongated heating zone.

[0008] In an exemplary embodiment, one end of the power source is located closer to the proximal end of the device than one end of the elongated heating zone is to the proximal end of the device.

[0009] In an exemplary embodiment, one end of the control circuit is connected to one end of the elongated heating zone of the device.

[0010] In an exemplary embodiment, the device includes an opening for receiving the aerosolizable material, and the power zone is located closer to the opening than the control circuitry is located at the opening.

[0011] In an exemplary embodiment, the control circuitry includes a plurality of printed circuit boards (PCBs) arranged substantially parallel to a longitudinal axis of the device. In an exemplary embodiment, each PCB has a depth parallel to the depth of the device. In an exemplary embodiment, each of the plurality of PCBs is electrically connected. In an exemplary embodiment, the plurality of PCBs is provided as a split PCB. In an exemplary embodiment, one of the plurality of PCBs includes an electrical connection port for electrical connection between the device and an external power source. In an exemplary embodiment, the electrical connection port is located at an end opposite the opening for receiving the aerosolizable material, and the electrical connection port faces outward in a direction substantially perpendicular to the longitudinal axis of the device. In an exemplary embodiment, the direction substantially perpendicular to the longitudinal axis of the device is a lateral direction.

[0012] In an exemplary embodiment, the power supply zone is positioned alongside the heating zone and along only a portion of the length of the heating zone.

[0013] In an exemplary embodiment, the control circuitry is positioned alongside the heating zone and along only a portion of the length of the heating zone.

[0014] In an exemplary embodiment, the power supply zone is disposed along a first portion of the length of the heating zone, and the control circuitry is disposed along a second portion of the length of the heating zone, the size of the first portion being greater than the size of the second portion.

[0015] In an exemplary embodiment, each PCB has substantially the same length.

[0016] In an exemplary embodiment, each PCB is substantially planar.

[0017] In an exemplary embodiment, each PCB has a length that is less than the length of the power zone. In an exemplary embodiment, the length of each PCB is greater than half the length of the power zone.

[0018] In an exemplary embodiment, each PCB has a length of 30 mm to 40 mm. In an exemplary embodiment, the length is 35 mm to 38 mm. In an exemplary embodiment, the length is 36 mm to 37 mm. In an exemplary embodiment, the length is approximately 36.6 mm.

[0019] In an exemplary embodiment, the depth of at least one of the PCBs is between 1 mm and 2 mm. In an exemplary embodiment, the depth is between 1 mm and 1.5 mm. In an exemplary embodiment, the depth is approximately 1.2 mm.

[0020] In an exemplary embodiment, the apparatus includes a first chassis for independently supporting the power supply zones and a second chassis for independently supporting the heating elements and the control circuitry.

[0021] In an exemplary embodiment, the power supply zone has a volume that is greater than the volume of the control circuitry and the volume of the elongated heating zone. In an exemplary embodiment, the volume of the elongated heating zone is greater than the volume of the control circuitry.

[0022] In an exemplary embodiment, the depth of the power supply zone is greater than the depth of the control circuitry and the depth of the elongated heating zone. In an exemplary embodiment, the width of the power supply zone is greater than the depth of the elongated heating zone.

[0023] In exemplary embodiments, the aerosolizable material comprises tobacco and / or is reconstituted and / or is in the form of a gel and / or comprises an amorphous solid.

[0024] A second aspect of the present invention provides a method for configuring a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, the method comprising the steps of providing a heating arrangement having an elongated heating zone for receiving and heating the aerosolizable material, and sequentially arranging a power supply zone and control circuitry in a direction substantially parallel to a longitudinal axis of the device, the power supply zone for accommodating a power source that provides heating power for heating the heating zone, the elongated heating zone being disposed adjacent to and substantially parallel to the power supply zone and control circuitry.

[0025] In an exemplary embodiment, the arranging step includes sequentially arranging the power supplies and control circuits of the power supply zone in a direction substantially parallel to the longitudinal axis of the device.

[0026] In an exemplary embodiment, the method includes installing a power source in a power zone.

[0027] In exemplary embodiments, the aerosolizable material comprises tobacco, and / or is reconstituted, and / or is in gel form, and / or comprises an amorphous material.

[0028] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, made with reference to the accompanying drawings, in which:

[0029] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 1 is a schematic perspective view of an example of an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the apparatus being shown with a consumable containing the aerosolizable material inserted therein. [Figure 2] 2 is a schematic front view of the exemplary device of FIG. 1 with a consumable inserted. [Figure 3] FIG. 2 is a schematic right side view of the exemplary device of FIG. 1 with a consumable inserted. [Figure 4] FIG. 2 is a schematic left side view of the exemplary device of FIG. 1 with a consumable inserted. [Figure 5] 5 is a schematic cross-sectional front view of the exemplary device of FIG. 1 with a consumable inserted, taken along line AA shown in FIG. 4. [Figure 6] 2 is a schematic cross-sectional front view of the exemplary device of FIG. 1 without a consumable inserted. [Figure 7] 1 is a flow diagram illustrating an example method of configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. DETAILED DESCRIPTION OF THE INVENTION

[0031] As used herein, the term "aerosolizable material" includes materials that, upon heating, provide volatilized components, typically in the form of a vapor or aerosol. "Aerosolizable material" can be a non-tobacco-containing material or a tobacco-containing material. "Aerosolizable material" can include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. "Aerosolizable material" can be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, amorphous, gelled sheet, powder, or mass, etc. "Aerosolizable material" can also include other non-tobacco products and, depending on the product, may or may not contain nicotine. "Aerosolizable material" can also include one or more humectants, such as glycerol or propylene glycol. The term "aerosol-generating material" can also be used interchangeably herein with the term "aerosolizable material."

[0032] As noted above, the aerosolizable material can comprise an "amorphous material," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." An amorphous material is a solid material that can hold some fluid, such as a liquid, within it. In some cases, the aerosolizable material comprises about 50 wt%, 60 wt%, or 70 wt% amorphous material to about 90 wt%, 95 wt%, or 100 wt% amorphous material. In some cases, the aerosolizable material consists of amorphous material.

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

[0034] As used herein, the term "heating material" or "heater material" refers, in some instances, to a material that is heatable by penetration by a varying magnetic field, for example, when an aerosolizable material is heated by an induction heating arrangement.

[0035] Other forms of heating the heating material include resistive heating, which involves an electrical resistive heating element that heats up when an electric current is applied to the electrical resistive heating element, thereby transferring heat by conduction to the heating material.

[0036] Referring to Figure 1, a schematic perspective view of a device 1 according to an embodiment of the present invention is shown. Device 1 is for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user. In this embodiment, the aerosolizable material includes tobacco, and device 1 is a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device). Device 1 is a handheld device for inhalation of the aerosolizable material by a user of the handheld device.

[0037] The device 1 comprises a first end 3 and a second end 5 opposite the first end 3. The first end 3 may be referred to herein as the oral or proximal end of the device 1. The second end 5 may be referred to herein as the distal end of the device 1. The device 1 has an on / off button 7 to allow the device 1, as a whole, to be turned on and off as desired by a user of the device 1.

[0038] Generally speaking, device 1 is configured to generate an aerosol to be inhaled by a user by heating an aerosol-generating material. In use, a user inserts an article 21 into device 1 and activates (operates) device 1, for example, using button 7, causing device 1 to begin heating the aerosol-generating material. The user then inhales the aerosol generated by device 1 by sucking on mouthpiece 21b of article 21 near first end 3 of device 1. As the user inhales article 21, the generated aerosol flows through device 1 along a flow path toward proximal end 3 of device 1.

[0039] In examples, vapor is generated which then at least partially condenses to form an aerosol before exiting the device 1 to be inhaled by the user.

[0040] In this regard, it should first be noted that, in general, a vapor is a substance in the gas phase that is below its critical temperature, meaning, for example, that the vapor can be condensed into a liquid by increasing its pressure without decreasing its temperature. On the other hand, in general, an aerosol is a colloid of fine solid particles or liquid droplets in air or another gas. A "colloid" is a substance in which microscopically dispersed insoluble particles are suspended throughout another substance.

[0041] For reasons of convenience, the term aerosol, as used herein, should be taken to mean an aerosol, a vapor, or a combination of an aerosol and a vapor.

[0042] The device 1 includes a casing 9 for arranging and protecting the various internal components of the device 1. The casing 9 is thus an outer housing for containing the internal components. In the illustrated embodiment, the casing 9 includes a sleeve 11 that surrounds the periphery of the device 1 and is fitted with a top panel 17 at the first end 3, which generally defines the "top" of the device 1, and a bottom panel 19 at the second end 5 (see FIGS. 2-5), which generally defines the "bottom" of the device 1.

[0043] The sleeve 11 comprises a first sleeve 11a and a second sleeve 11b. The first sleeve 11a is provided on an upper portion of the device 1, shown as the upper portion of the device 1, and extends away from the first end 3. The second sleeve 11b is provided on a lower portion of the device 1, shown as the lower portion of the device 1, and extends away from the second end 5. The first sleeve 11a and the second sleeve 11b each surround the periphery of the device 1. That is, the device 1 includes a longitudinal axis in the Y-axis direction, and the first sleeve 11a and the second sleeve 11b each surround internal components in a direction radial to the longitudinal axis. The longitudinal axis is the main axis of the device 1.

[0044] In this embodiment, the first sleeve 11a and the second sleeve 11b are removably engaged with one another. In this embodiment, the first sleeve 11a is engaged with the second sleeve 11b in a snap-fit ​​arrangement comprising a groove and a recess.

[0045] In some embodiments, top panel 17 and / or bottom panel 19 may be removably secured to corresponding first and second sleeves 11 a, 11 b, respectively, to allow easy access to the interior of device 1. In some embodiments, sleeve 11 may be “permanently” secured to top panel 17 and / or bottom panel 19, for example, to prevent a user from accessing the interior of device 1. In one embodiment, panels 17 and 19 are made of a flexible material, including, for example, glass-filled nylon formed by injection molding, and sleeve 11 is made of aluminum, although other materials and manufacturing processes may be used.

[0046] The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which a consumable 21 containing an aerosolizable material is inserted into and removed from the device 1 by a user during use. In this embodiment, the consumable 21 functions as a mouthpiece for a user to place between the user's lips. In other embodiments, an external mouthpiece can be provided through which at least one volatile component of the aerosolizable material is inhaled. When the external mouthpiece is used, the aerosolizable material is not placed within the external mouthpiece.

[0047] In this embodiment, the opening 20 is opened and closed by a lid 4. In the embodiment shown, the lid 4 is movable between a closed position and an open position, and when in the open position allows for the insertion of a consumable 21 into the device 1. The lid 4 is configured to move bidirectionally along the X-axis direction.

[0048] A connection port 6 is shown at the second end 5 of the device 1. The connection port 6 is for connection to a cable and power supply 27 (shown in FIG. 6) for charging the power supply 27 of the device 1. The connection port 6 extends in the Z-axis direction from the front side of the device 1 to the rear side of the device 1. As shown in FIG. 3, the connection port 6 is accessible on the right side of the device 1 at the second end 5 of the device 1. Advantageously, the device 1 can be stood up at the second end 5 while charging or to enable a data connection through the connection port 6. In the illustrated embodiment, the connection port 6 is a Universal Serial Bus (USB) socket.

[0049] Referring to FIG. 2, the first sleeve 11a includes a tapered surface at the first end 3 of the device 1. The tapered surface has a first angle α relative to the surface of the second sleeve 11b at the second end 5. In this embodiment, the surface of the second sleeve 11b at the second end 5 is substantially parallel to the X-axis direction. Thus, as shown, the consumable 21 is insertable through the opening 20 (shown in FIG. 1) at the proximal portion of the first end 3. Where the first sleeve 11a and the second sleeve 11b meet at junction 11c, a second angle β is formed with respect to the X-axis direction. The second angle β is shown to be greater than the first angle α.

[0050] 3 and 4 show the right and left sides, respectively, of the device 1. Here, the consumable 21 is shown in a laterally centered position because the opening 20 through which the consumable 21 is inserted is located at the midpoint of the device along the Z axis and is also located off-center.

[0051] 5 and 6 show schematic cross-sectional views of the device 1 from the front along line AA of the device 1 shown in FIG. 4 with the consumable inserted and withdrawn, respectively.

[0052] As shown in FIG. 6 , a heater arrangement 23, a control circuit 25, and a power supply 27 are disposed or fixed within the casing 9. In this embodiment, the control circuit 25 is part of the electronics compartment and comprises two printed circuit boards (PCBs) 25 a, 25 b. The control circuit 25 therefore includes electrical components for controlling the heating of the heating arrangement 23. In this embodiment, the control circuit 25 and the power supply 27 are laterally adjacent to the heater arrangement 23 (i.e., adjacent when viewed from the end), and the control circuit 25 is located below the power supply 27. This advantageously allows the device 1 to be compact in the lateral direction corresponding to the X-axis direction.

[0053] In this embodiment, control circuitry 25 includes a controller, such as a microprocessor arrangement, constructed and arranged to control the heating of aerosolizable material within consumable 21, as described further below.

[0054] In this embodiment, power source 27 is a rechargeable battery. In other embodiments, a non-rechargeable battery, a capacitor, or a battery-capacitor hybrid may be used, or a connection to an electrical mains supply may be used. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and / or the like. Battery 27 is electrically connected to heater arrangement 23 to provide power when needed and, under the control of control circuitry 25, to heat the aerosolizable material in the consumable (as described above, to volatilize the aerosolizable material without burning it).

[0055] An advantage of locating the power supply 27 laterally adjacent to the heater arrangement 23 is that a physically larger power supply 27 can be used without the device 1 as a whole becoming too long. As will be appreciated, a physically larger power supply 27 will have a higher capacity (i.e., total electrical energy that can be supplied, often measured in ampere-hours or the like) and therefore the battery life of the device 1 may be longer.

[0056] In one embodiment, the heater element 23 is generally in the form of a hollow cylindrical tube having a hollow inner heating chamber 29 into which the consumable 21, including the aerosolizable material, is inserted for heating during use. Generally speaking, the heating chamber 29 is a heating zone for receiving the consumable 21. Different configurations for the heater element 23 are possible. In some embodiments, the heater element 23 may comprise a single heating element or may be formed of multiple heating elements aligned along the longitudinal axis of the heater element 23. The or each heating element may be annular or tubular around its periphery, or at least partially annular or partially tubular. In one embodiment, the or each heating element may be a thin-film heater. In another embodiment, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina, aluminum nitride, and silicon nitride ceramics, which may be layered and sintered. Other heater components are also possible, including induction heating, infrared heater elements that heat by radiating infrared light, or resistive heating elements formed, for example, by resistive electrical windings.

[0057] In this embodiment, heater structure 23 is supported by stainless steel support tube 75 and comprises heater 71. In one embodiment, heater 71 comprises a substrate on which at least one conductive element is formed. The substrate may take the form of a sheet and may comprise, for example, a flexible layer. In a preferred embodiment, this layer is a polyimide layer. The conductive element(s) may be printed onto the substrate layer or may be separately applied. The conductive element(s) may be encapsulated within or coated by the substrate.

[0058] The support tube 75 is a heating element that transfers heat to the consumable 21. Therefore, the support tube 75 is made of a heating material. In this embodiment, the heater material is stainless steel. In other embodiments, other metallic materials may be used as the heating material. For example, the heating material may include a metal or a metal alloy. The heating material may include one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, ferritic stainless steel, molybdenum, copper, and bronze.

[0059] The heater arrangement 23 is dimensioned so that when the consumable 21 is inserted into the device 1, substantially the entire aerosolizable material is heated in use.

[0060] In some embodiments, the or each heating element may be arranged so that selected zones of aerosolizable material are heated independently, e.g., sequentially (over time), or together (simultaneously), as desired.

[0061] In this embodiment, the heater element 23 is surrounded by a vacuum region 31 along at least a portion of its length. The vacuum region 31 helps reduce heat transfer from the heater element 23 to the outside of the device 1, thereby helping to keep the power requirements of the heater element 23 low because it reduces heat loss overall. The vacuum region 31 also helps keep the outside of the device 1 cool during operation of the heater element 23. In some embodiments, the vacuum region 31 may be surrounded by a double-walled sleeve, with the region between the two walls of the sleeve evacuated to provide a low-pressure region to minimize heat transfer by conduction and / or convection. In other embodiments, a different insulating element may be used in addition to or instead of the vacuum region, e.g., using a thermal insulating material, including, e.g., a suitable foam-type material.

[0062] The casing 9, also referred to as the housing, may further comprise an internal support structure 37 (best seen in FIG. 6) for supporting all internal components and the heater assembly 23.

[0063] The device 1 further comprises a collar 33 that extends around the opening 20 and protrudes from the opening 20 into the interior of the housing 9, and an expansion element 35 located between the collar 33 and one end of the vacuum region 31. The expansion element 35 is funnel-shaped and forms an expansion chamber 40 at the mouth end 3 of the device 1. The collar 33 is a retainer for holding the consumable 21 (best seen in FIG. 5). In this embodiment, the retainer is removably removable from the device 1.

[0064] One end of the expansion element 35 connects to and is supported by the first sleeve 11a, and the other end of the expansion element 35 connects to and is supported by one end of the cassette 51. A first sealing element 55, shown as an O-ring, is disposed between the expansion element 35 and the first sleeve 11a, and a second sealing element 57, also shown as an O-ring, is disposed between the expansion element 35 and the cassette 51. Each O-ring is made of silicone, although other elastomeric materials may be used to provide a seal. The first and second sealing elements 55, 57 prevent gas migration into surrounding components of the device 1. A sealing element is also provided at the distal end to prevent fluid ingress and egress at the distal end.

[0065] As best seen in FIG. 6, the collar 33, extension element 35 and vacuum region 31 / heater assembly 23 are coaxially arranged such that when the consumable 21 is inserted into the device 1, the consumable extends through the collar 33 and extension element 35 into the heating chamber 29, as best seen in FIG. 5.

[0066] As noted above, in this embodiment, heater assembly 23 is generally in the form of a hollow cylindrical tube. This tube defines a heating chamber 29 that is in fluid communication with opening 20 at mouth end 3 of device 1 via expansion chamber 40.

[0067] In this embodiment, the expansion element 35 comprises a tubular body having a first open end adjacent the opening 20 and a second open end adjacent the heating chamber 29. The tubular body comprises a first section extending approximately halfway along the tubular body from the first open end and a second section extending approximately halfway along the tubular body to the second open end. The first section comprises a flared portion that widens away from the second section. Thus, the first section has an inner diameter that narrows outward toward the open first end. The second section has a substantially constant inner diameter.

[0068] As best seen in FIG. 6 , in this embodiment, the extension element 35 is positioned within the housing 9 between the collar 33 and the vacuum region 31 / heater assembly 23. More specifically, at the second open end of the extension element 35, the extension element 35 is positioned between an end portion of the support tube 75 of the heater assembly 23 and the inside of the vacuum region 31, such that the second open end engages the inside of the support tube 75 and the vacuum region 31. At the first open end, the extension element 35 receives the collar 33 such that the legs 59 of the collar 33 protrude into the expansion chamber 40. Thus, the inner diameter of the first section of the extension element 35 is larger than the outer diameter of the legs when the consumable 21 is received within the device 1 (see FIG. 5 ) and when the consumable 21 is not present.

[0069] As best seen in Figure 5, the inner diameter of the first section of the expansion element 35 is larger than the outer diameter of the consumable 21. Thus, when the consumable 21 is inserted into the device 1 over at least a portion of the length of the expansion element 35, a gap 36 exists between the expansion element 35 and the consumable 21. The gap 36 is around the entire circumference of the consumable 21 in that region.

[0070] As best seen in FIG. 6 , the collar 33 includes a plurality of legs 59. In this embodiment, there are four legs 59, with only three visible from the perspective of FIG. 6 . However, in other embodiments, there may be more or fewer than four legs 59. The legs 59 are equally spaced circumferentially on the inner surface of the collar 33 and are disposed within the expansion chamber 40 when the device 1 is assembled. In this embodiment, when installed in the device 1, the legs 59 are equally spaced circumferentially around the periphery of the opening 20. In one embodiment, there are four legs 59, while in other embodiments, there may be more or fewer than four legs 59. Each of the legs 59 extends in the Y-axis direction, parallel to the longitudinal axis of the expansion chamber 40, and protrudes into the opening 20. The legs 59 also extend radially at their tips 59 a toward the expansion element 35, such that the tips 59 a are angled away from each other. The tip 59a of each leg 59 allows for better passage of the consumable 21 to avoid damage to the consumable 21 when inserting and / or removing it from the device 1. Collectively, the legs 59 provide a gripping section that grips the consumable 21 to properly position and hold the consumable 21 within the expansion chamber 40 when the consumable 21 is in the device 1. Between them, the legs 59 lightly squeeze or clamp the consumable 21 in the area of ​​the consumable contacted by the legs 59.

[0071] The legs 59 may be made of an elastic material (or may be elastic in some other way), so that when the consumable 21 is inserted into the device 1, they slightly deform (e.g., compress) to better grip the consumable 21, but then regain their original shape when the consumable 21 is removed from the device 1, as the legs 59 are biased to the rest position shown in FIG. 6 . Thus, the legs 59 are reversibly movable from a first position, which is the rest position, to a second position, which is the deformed position shown in FIG. 5 , thereby gripping the consumable 21. In this embodiment, the legs 59 are integrally formed with the main body of the collar 33. However, in some embodiments, the legs 59 may be separate components attached to the body of the collar 33. The inner diameter of the space formed between the legs 59 in the first rest position is, for example, 4.8 mm to 5 mm, preferably 4.9 mm. The legs 59 occupy space within the opening 20 such that the open area of ​​the opening 20 with the legs 59 in place is less than the open area of ​​the opening 20 without the legs 59 .

[0072] For example, the expansion element 35 may be formed from a flexible material including, for example, polyetheretherketone (PEEK), which has a relatively high melting point compared to most other thermoplastics and is highly resistant to thermal degradation.

[0073] 6, in this embodiment, the heating chamber 29 communicates with a region 38 of reduced inner diameter toward the distal end 5. This region 38 defines a cleaning chamber 39 formed by a cleaning tube 41. The cleaning tube 41 is a hollow tube that provides an end stop for the consumables 21 (see FIG. 5) that have passed through an opening at the mouth end 3. The cleaning tube 41 is configured to support and position the heater arrangement 23.

[0074] The device 1 further includes a lid 61 at the distal end 5 of the device 1, which opens and closes an opening in the bottom panel 19 to provide access to the heating chamber 29 so that it can be cleaned. The lid 61 pivots about a hinge 63. Such access through the lid 61 allows a user to, among other things, clean the heater assembly 23 and the interior of the heating chamber 29 at the distal end 5. When the lid 61 is open, a straight through-hole is provided through the entire device 1 between the opening 20 at the mouth end 3 and an opening at one end of the cleaning chamber at the distal end 5 of the device 1. Thus, a user can easily clean substantially the entire interior of the hollow heating chamber 29. Thus, a user can access the heating chamber 29 through either end of the device 1 as preferred. A user may use one or more various cleaning devices for this purpose, including, for example, a traditional pipe cleaner or a brush or the like.

[0075] As shown in Figure 6, the top panel 17 generally forms the first end 3 of the housing 9 of the device 1. The top panel 17 supports a collar 33 that defines an insertion point in the form of an opening 20 through which a consumable 21 is removably inserted into the device 1 during use.

[0076] Collar 33 extends around opening 20 and projects therefrom into the interior of housing 9. In this embodiment, collar 33 is a separate element from top panel 17 and is attached to top panel 17 via a fastener such as a bayonet locking mechanism. In other embodiments, adhesive or screws may be used to join collar 33 to top panel 17. In other embodiments, collar 33 may be integral with top panel 17 of housing 9, such that collar 33 and top panel 17 form a single piece.

[0077] 5 and 6, the open space defined by adjacent pairs of legs 59 of the consumable 21 and collar 33 forms air passages 20a around the outside of the consumable 21. Such air passages 20a allow hot steam escaping from the consumable 21 to escape from the device 1 and also allow cool air to flow into the device 1 around the consumable 21. In this embodiment, four air passages 20a are located around the periphery of the consumable 21, which provides ventilation for the device 1. In other embodiments, more or fewer such air passages 20a may be provided.

[0078] Referring again specifically to FIG. 5 , in this embodiment, the consumable 21 is in the form of a cylindrical rod that has or contains aerosolizable material 21a at its rear end within the section of the consumable 21 that resides within heater assembly 23 when the consumable 21 is inserted into device 1. The front end of the consumable 21 extends from device 1 and functions as mouthpiece 21b, an assembly that includes one or more of a filter for filtering the aerosol and / or a cooling element 21c for cooling the aerosol. Filter / cooling element 21c is spaced from the aerosolizable material 21a by space 21d and also from the tip of mouthpiece assembly 21b by additional space 21e. The consumable 21 is circumferentially coated with an outer layer (not shown). In this embodiment, the outer layer of consumable 21 is permeable to allow some heated volatile components from aerosolizable material 21a to escape from the consumable 21.

[0079] During operation, heater arrangement 23 heats consumable 21 to volatilize at least one component of aerosolizable material 21a.

[0080] The primary flow path for heated volatile components from aerosolizable material 21a is axially through consumable 21, through space 21d, filter / cooling element 21c, and further space 21e, before entering the user's mouth through the open end of mouthpiece assembly 21b. However, some of the volatile components may leak from consumable 21 through its permeable outer coating into space 36 surrounding consumable 21 within expansion chamber 40.

[0081] It is undesirable for the user to inhale volatile components that flow from the consumable 21 into the expansion chamber 40 because these components have not passed through the filter / cooling element 21c and are therefore not filtered or cooled.

[0082] Advantageously, the volume of air surrounding the consumable 21 within the expansion chamber 40 cools at least a portion of the volatile components that escape from the consumable 21 through its outer layer, causing them to condense on the interior walls of the expansion chamber 40, preventing them from being inhaled by the user.

[0083] This cooling effect may be facilitated by cooling air that can enter the space 36 surrounding the consumable 21 within the expansion chamber 40 from outside the device 1 via the ventilation passages 20a, which allow fluid to flow into and out of the device. A first ventilation passage is defined between a pair of adjacent legs 59 of the collar 33 to provide ventilation around the exterior of the consumable 21 at the insertion point. A second ventilation passage is provided between a second pair of adjacent legs 59 to allow at least one heated volatile component to flow from the consumable 21 at a second location. Thus, ventilation is provided around the exterior of the consumable 21 at the insertion point by the first and second ventilation passages. Furthermore, heated volatile components that escape from the consumable 21 through its outer coating can safely flow out of the device 1 via the ventilation passages 20a without condensing on the interior walls of the expansion chamber 40 and being inhaled by the user. Both the expansion chamber 40 and the vent help reduce the temperature and content of the water vapor composition released into the heated volatile components from the aerosolizable material.

[0084] The device 1 is fitted with a thermal liner 13 towards the first end 3 of the device 1. As shown in FIG. 6, the thermal liner 13 is bonded to the first sleeve 11a. The thermal liner 13 is a heat diffuser that helps manage heat distribution and helps protect the first sleeve 11a from thermal stress by distributing the internal heat generated by use of the device 1 over a larger area. The thermal liner 13 is made from a metallic material, such as aluminum, for lightweight and to dissipate heat well around the proximal end 3. This helps avoid localized hot spots and increases the lifespan of the first sleeve 11a. The liner 13 distributes heat by conduction. The liner 13 is not configured to insulate or reflect heat by radiation.

[0085] As shown in FIG. 6 , the support tube 75 is coated on the outside with a heater 71. In this example, the heater 71 is a thin-film heater comprising polyimide and a conductive element. The heater 71 can include multiple independently controlled heating zones and / or multiple simultaneously controlled heating zones. In this example, the heater 71 is formed as a single heater. However, in other embodiments, the heater 71 may be formed with multiple heaters aligned along the longitudinal axis of the heating chamber 29. In some embodiments, multiple temperature sensors may be used to detect the temperature of the heater 71 and / or the support tube. In this embodiment, the support tube 75 is made of stainless steel to conduct heat from the heater 71 to the consumable 21 when the consumable 21 is inserted into the heating zone (the heating zone is defined by the heat conduction area of ​​the support tube 75). In other embodiments, the support tube 75 may be made of a different material, as long as the support tube 75 is thermally conductive. Other heating elements 75 may be used in other embodiments. For example, the heating element may be an inductively heatable susceptor. In this embodiment, the support tube 75 acts as an elongated support for supporting the article 21 containing the aerosolizable material, in use.

[0086] In this embodiment, heater 71 is disposed outside support tube 75. However, in other embodiments, heater 71 may be disposed inside support tube 75. In this embodiment, heater 71 passes outside support tube 75 and includes a portion referred to herein as heater tail 73. Heater tail 73 extends beyond heating chamber 29 and is configured for electrical connection to control circuit 25. In the illustrated embodiment, heater tail 73 physically connects to one PCB 25a. Electrical current may be provided to heater 71 by power supply 27 via control circuit 25 and heater tail 73.

[0087] Because a connection is required between the heating chamber 29 and the control circuitry 25, it can be difficult to prevent airflow (or any other fluid flow) between the heating chamber 29 and the electronics compartment. In this embodiment, a gasket 15 is used to prevent such fluid flow, as shown in FIG. 6 . The gasket 15 includes a first seal 15a and a second seal 15b. The gasket 15 surrounds the heater tail 73 and is clamped together by the base 53 and the cassette 51. In the illustrated embodiment, four fasteners 43 are used to provide sufficient force to clamp the base 53 and the cassette 51 together, sealing access to and from the chamber 29 at this point. The fasteners 43 are screws that are tightened to a predetermined torque. In other embodiments, different fasteners 43, such as bolts, may be used.

[0088] 6, the heating arrangement 23 of the apparatus 1 is disposed in a first volume of the apparatus 1. The heating zone 29 is located in the first volume. In the illustrated embodiment, the heating zone 29 is elongated to receive an elongated article containing an aerosolizable material through the opening 20. Thus, the elongated heating zone 29 is for receiving and heating the aerosolizable material.

[0089] The power supply zone is located laterally adjacent to the heating zone 29 of the heating device 23 in the X-axis direction. That is, the power supply zone is oriented substantially parallel to the longitudinal axis BB (shown by the dashed-dotted line) of the elongated heating zone. In this embodiment, the longitudinal axis BB of the elongated heating zone 29 is parallel to the longitudinal axis of the device 1. In the illustrated embodiment, the power supply zone is located to the right of the heating zone 29.

[0090] The power supply zone is a second space for installing the power supply 27. That is, the power supply 27 occupies the second space. Thus, the power supply 27 can be installed in a compartment of the device, and the compartment defines the second space.

[0091] In the embodiment shown in Figure 6, the device 1 includes a chassis that is an internal support structure 37 of the device 1. The power supply 27 is combinable with and attached to the chassis to independently support the power supply 27. The chassis defines a power supply zone as a second space. The chassis defines the aforementioned compartment. The power supply 27 provides heating power to heat the heating zone 29 so that the aerosolizable material can be heated when the aerosolizable material is within the heating zone 29.

[0092] The control circuit 25 is disposed laterally adjacent to the heating zone 29 of the heating device 23 in the X-axis direction. That is, the control circuit 25 is disposed in a direction substantially parallel to the longitudinal axis BB of the elongated heating zone. Furthermore, the control circuit 25 is longitudinally adjacent to the power source 27 and the power supply zone (Y-axis direction). That is, the power supply zone and the control circuit are disposed in sequence in the longitudinal direction of the elongated heating zone 29. In the provided embodiment, the control circuit 25 is disposed below the power supply zone, and the control circuit 25 is disposed closer to the distal end 5 of the device 1 than the power supply zone. As previously mentioned, the control circuit 25 is for controlling the power for heating.

[0093] Both the control circuit 25 and the heating arrangement 23 are mounted on a separate chassis shown as the bottom panel 19. The bottom panel defines a space for housing the control circuit 25. The bottom panel 19 supports the heating arrangement 23 and the control circuit 25 independently.

[0094] As shown in FIG. 6 , the elongated heating zone 29 of the heating device 23 is disposed transversely relative to both the power supply zone and the control circuit 25. In the longitudinal direction (Y-axis direction), the elongated heating zone 29 overlaps with a portion of the power supply zone and a portion of the control circuit 25. FIG. 6 shows the elongated heating zone 29 with its longitudinal axis BB extending in the Y-axis direction. Thus, the power supply zone and the control circuit 25 are disposed sequentially in a direction substantially parallel to the longitudinal axis BB of the elongated heating zone 29. That is, the power supply zone and the control circuit 25 are disposed consecutively (sequentially) in the Y-axis direction, with the power supply zone being above the control circuit 25 and closer to the proximal end 3 of the device 1 than the control circuit 25.

[0095] The power supply zone is positioned closer to the opening 20 of the device 1 than the control circuitry is positioned at the opening 20 of the device. When the consumable 21 is inserted into the heating zone 29, the proximal end of the consumable 21 passes longitudinally along the power supply zone before passing longitudinally along the control circuitry 25. When fully inserted, the consumable 21 is proximate to both the power supply zone and the control circuitry 25, as shown in FIG. 5. In the illustrated embodiment, when the consumable 21 is fully inserted, the majority of the length of the consumable 21 is adjacent to the power supply zone and a short portion is adjacent to the control circuitry 25. That is, one end of the heating zone 29 is positioned to the side of the control circuitry 25 rather than the power supply zone, as the power supply zone is positioned longitudinally above one end of the heating zone 29.

[0096] As shown in FIGS. 5 and 6 , the two PCBs 25a and 25b of the device 1 are arranged sequentially in the horizontal direction (X-axis direction). The two PCBs 25a and 25b are shown as split PCBs in that they are electrically connected. The first PCB 25a is positioned farther away from the heating zone 29 than the second PCB 25b is positioned relative to the heating zone 29. In the illustrated embodiment, the first PCB 25a is electrically connected to the power source 27, and the second PCB 25b is electrically connected to the heater 71, particularly the heater tail 73. In other embodiments, the electrical connections to the PCBs 25a and 25b may be reversed. The first PCB 25a is electrically connected to a connection port 6, such as a USB port, for electrically connecting the device 1 to an external power source (not shown). The connection port 6 is located at the opposite end of the opening 20 for receiving the aerosolizable material. The electrical connection port 6 faces outwards in the lateral direction (X-axis direction) of the device 1 .

[0097] 5 and 6, each printed circuit board 25a, 25b has the same length in the Y-axis direction, which allows the control circuit 25 to be compact and shorten the overall length of the device 1. The power supply zone is longer than the control circuit 25 but shorter than the heating device 23.

[0098] The length (Y direction) of each PCB 25a, 25b is 36.6 mm. In some embodiments, the length of each PCB 25a, 25b may be 36 mm to 37 mm. The depth (X direction) of each PCB 25a, 25b is 1.2 mm. Therefore, the depth may also be referred to as the thickness. In some embodiments, the depth of each PCB 25a, 25b is 1 mm to 1.5 mm. A gap is shown between each PCB 25a, 25b. In this embodiment, the gap is approximately twice the depth of the PCBs 25a, 25b.

[0099] Referring to Figure 7, a flow diagram is shown illustrating an example method 100 of configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. The method is suitable for the apparatus 1 shown in Figures 1-6.

[0100] The method 100 includes the steps of providing a heating device 101 having an elongated heating zone for receiving and heating an aerosolizable material, and step 102 of sequentially arranging a power supply zone and control circuitry in a direction substantially parallel to a longitudinal axis of the device, the power supply zone being for locating a power source for providing heating power to heat the heating zone, the elongated heating zone being arranged adjacent to and substantially parallel to the power supply zone and control circuitry, i.e., the power supply zone and control circuitry being stacked on top of each other. When arranged, the elongated heating zone is transverse to the power supply zone and control circuitry.

[0101] In some embodiments, the arranging step 102 includes sequentially arranging the power source and control circuitry in the power source zone in a direction substantially parallel to the longitudinal axis of the device. In some embodiments, the method 100 includes installing a power source in the power source zone.

[0102] In some embodiments, the aerosolizable material includes tobacco. However, in other embodiments, the aerosolizable material may consist of tobacco, consist substantially entirely of tobacco, include tobacco and aerosolizable materials other than tobacco, include aerosolizable materials other than tobacco, or may not include tobacco. In some embodiments, the aerosolizable material may include a vapor, or an aerosol-forming agent, or a humectant such as glycerol, propylene glycol, triacetin, or diethylene glycol.

[0103] In some embodiments, the aerosolizable material is a non-flowable aerosolizable material and the device is for heating the non-flowable aerosolizable material to volatilize at least one component of the aerosolizable material.

[0104] Once all, or substantially all, of the one or more volatile components of the aerosolizable material in consumable item 21 have been consumed, the user may remove item 21 from device 1 and discard item 21. The user may subsequently reuse device 1 with another item 21. However, in other embodiments, the item may be non-consumable, and once the one or more volatile components of the aerosolizable material have been consumed, the device and item may be discarded together.

[0105] In the embodiment described herein, consumable 21 includes mouthpiece assembly 21b. However, it should be understood that in other embodiments, exemplary devices as described herein may include a mouthpiece. For example, device 1 may include a mouthpiece that is integral with the device, or in other embodiments, the device may include a mouthpiece that is removably attached to device 1. In an example, device 1 may be configured to receive an aerosolizable material to be heated. The aerosolizable material may be included in a consumable that does not include a mouthpiece portion. A user can suck on the mouthpiece of device 1 to inhale the aerosol generated by the device by heating the aerosolizable material.

[0106] In some embodiments, article 21 is sold, supplied, or provided separately from the device 1 in which article 21 can be used. However, in some embodiments, device 1 and one or more of articles 21 may be provided together as a system, such as a kit or assembly, possibly with additional components such as cleaning implements.

[0107] To address various problems and advance the art, this entire disclosure illustrates, by way of illustrations and examples, various embodiments in which the claimed invention may be practiced and which provide a novel heating element for use with an apparatus for heating an aerosolizable material, a method for forming a heating element for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and a system comprising an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and a heating element heatable by such an apparatus. The advantages and features of the present disclosure are merely of a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. They are presented solely to aid in understanding and to teach the claimed and otherwise disclosed features. It is understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limitations on the disclosure as defined by the claims or on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. The present disclosure may include other presently unclaimed inventions that may be claimed in the future.

Claims

1. 1. An apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, comprising: a heating arrangement comprising an elongated heating zone for receiving and heating the aerosolizable material; a power supply zone for installing a power supply that supplies heating power for heating the heating zone; a control circuit for controlling the power for heating; Equipped with the power supply zones and the control circuitry are arranged in sequence in a direction substantially parallel to a longitudinal axis of the device; The apparatus, wherein the elongated heating zone is disposed adjacent to and substantially parallel with the power supply zone and the control circuitry.

2. an opening for receiving the aerosolizable material; The apparatus of claim 1 , wherein the power supply zone is located closer to the opening than the control circuit is located at the opening.

3. 3. The device of claim 1 or 2, wherein the control circuitry comprises a plurality of printed circuit boards (PCBs) arranged substantially parallel in a direction substantially perpendicular to a longitudinal axis of the device.

4. The device of claim 3 , wherein one of the PCBs comprises an electrical connection port for electrical connection between the device and an external power source.

5. 5. The device of claim 4, wherein the electrical connection port is located at the end opposite the opening for receiving the aerosolizable material, and the electrical connection port faces outward in a direction substantially perpendicular to the longitudinal axis of the device.

6. An apparatus according to any preceding claim, wherein the power supply zone is arranged alongside the heating zone and along only a portion of the length of the heating zone.

7. An apparatus according to any preceding claim, wherein the control circuitry is positioned alongside the heating zone and along only part of the length of the heating zone.

8. 8. The apparatus of claim 1, wherein the power supply zone is disposed along a first portion of the length of the heating zone and the control circuitry is disposed along a second portion of the length of the heating zone, the first portion being larger in size than the second portion.

9. The apparatus of any one of claims 1 to 8, wherein each of the PCBs has substantially the same length.

10. The apparatus of any one of claims 1 to 9, wherein each of the PCBs has a length that is shorter than a length of the power supply zone.

11. The apparatus of claim 10 , wherein the length of each of the PCBs is greater than half the length of the power zone.

12. 12. The apparatus of any one of claims 1 to 11, comprising a first chassis for independently supporting the power supply zones, and a second chassis for independently supporting the heating arrangement and the control circuitry.

13. 1. A method for configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, comprising: providing a heating arrangement comprising an elongated heating zone for receiving and heating the aerosolizable material; sequentially arranging power zones and control circuits in a direction substantially parallel to a longitudinal axis of the device; Including, the power supply zone is for installing a power supply that supplies heating power for heating the heating zone; The method wherein the elongated heating zone is positioned adjacent to and substantially parallel to the power supply zone and the control circuitry.

14. 14. The method of claim 13, wherein the arranging step comprises sequentially arranging the power sources and the control circuits of the power supply zone in a direction substantially parallel to a longitudinal axis of the device.

15. 15. The method of claim 13 or 14, comprising the step of locating the power source in the power source zone.

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