Aerosol-generating device with visual feedback device

Abstract

To provide an aerosol-generating device comprising a segmented visual feedback device, the device having particular application as a device for use in an electrically operated smoking system.SOLUTION: An aerosol-generating device (10) comprises: an electrical power supply (40); a cavity (14) for receiving at least part of an aerosol-generating article (50, 60); at least one electrical heater (22) positioned within the cavity (14); a controller (42) configured to control supply of electrical power from the electrical power supply (40) to the at least one electrical heater (22) to activate the at least one electrical heater (22); and a segmented visual feedback device (32) having a plurality of segments (34) each configured to provide visual feedback.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an aerosol generating device with a segmented visual feedback device, and has particular application as a device for use in electrically operated smoking systems. [Background technology]

[0002] One type of aerosol-generating system is an electrically operated smoking system. Known handheld, electrically operated smoking systems generally include an aerosol-generating device that includes a battery, control electronics, and an electric heater for heating an aerosol-generating article specifically designed for use with the aerosol-generating device. In some examples, the aerosol-generating article includes an aerosol-generating substrate such as a tobacco rod or tobacco plug, and a heater housed within the aerosol-generating device is inserted into or around the aerosol-generating substrate when the aerosol-generating article is inserted into the aerosol-generating device. In an alternative electrically operated smoking system, the aerosol-generating article may include a capsule containing an aerosol-generating substrate, such as loose tobacco.

[0003] Some electrically operated smoking systems include simple visual feedback devices to provide basic information to the consumer, such as an indication when the device is turned on and when the heating cycle is complete.

[0004] US Patent Application No. 2011 / 265806-A1 describes an electronic smoking device that has a simple LED unit that indicates to the user when the device is nearly empty of its liquid substrate.

[0005] U.S. Patent Application No. 2014 / 261487-A1 describes an electronic smoking device that may include multiple indicators to display an estimate of the number of puffs taken or the number of puffs remaining, but such feedback is of limited use to the user because each puff may vary in flow rate and duration.

[0006] No. 5,865,185-A describes a smoking system comprising a smoking device and a replaceable tobacco flavor unit, which may comprise an indicator means for indicating when the unit has been heated, but which does not provide any feedback to the user during operation of the smoking system. Summary of the Invention [Problem to be solved by the invention]

[0007] It would be desirable to provide an aerosol generating device configured to provide improved feedback to a user during operation of the aerosol generating device.It would be desirable to provide an aerosol generating article configured to provide improved feedback to a user during use of the aerosol generating article. [Means for solving the problem]

[0008] According to a first aspect of the present invention, there is provided an aerosol generating device comprising a power supply, a cavity for receiving at least a portion of an aerosol-generating article, and at least one electric heater positioned within the cavity. The aerosol generating device further comprises a controller configured to control the supply of power from the power supply to the at least one electric heater to activate the at least one electric heater. The controller is configured to activate the at least one electric heater for a total time period when at least a portion of the aerosol-generating article is received within the cavity. The aerosol generating device also comprises a segmented visual feedback device, each of a plurality of segments corresponding to a different portion of the total time period. Each of the plurality of segments is configured to provide visual feedback when at least a portion of the aerosol-generating article is received within the cavity and when a corresponding portion of the total time period has elapsed.

[0009] The aerosol-generating device according to the present invention is configured to heat the aerosol-generating article for an entire period. That is, the aerosol-generating device is configured to heat the aerosol-generating article until one or more aerosol-forming substrates on the aerosol-generating article are consumed. The controller may be configured to activate the at least one heater continuously for the entire period, i.e., the entire period is equal to the period during which the at least one heater is continuously activated. The controller may also be configured to activate the at least one heater in a series of individual activations until the one or more aerosol-forming substrates are consumed. For example, the controller may be configured to activate the at least one heater only when a user inhales on the aerosol-generating device or when an aerosol-generating article is received in the aerosol-generating device. In such an embodiment, the entire period is equal to the sum of the periods during which the at least one heater is activated during each activation.

[0010] Advantageously, providing a segmented visual feedback device, with multiple segments each configured to provide visual feedback after a different portion of the total time period, provides a clear indication of the remaining heater activation time. That is, the segmented visual feedback device provides an accurate indication of the amount of aerosol-forming substrate consumed on the aerosol-generating article heated by the aerosol-generating device. This is in contrast to known devices that do not provide consumption feedback or that only provide an estimate based, for example, on the number of puffs.

[0011] At least some of the different portions of the total period may overlap. The different portions of the total period may be contiguous portions of the total period.

[0012] The segmented visual feedback device may include at least one segment configured to provide visual feedback at the beginning of the overall time period, i.e., the segmented visual feedback device may include at least one segment configured to provide visual feedback before any portion of the overall time period has elapsed. Preferably, the remaining segments of the segmented visual feedback device are multiple segments each configured to correspond to a different portion of the overall time period.

[0013] All of the segments of the visual feedback device may be multiple segments, each configured to correspond to a different portion of the overall time period.

[0014] The at least one electric heater may comprise a plurality of electric heaters.

[0015] The controller may be configured to activate all the electric heaters simultaneously whenever the heaters are activated for the entire period.

[0016] The controller may be configured to activate the electric heaters sequentially. The controller may be configured to activate and deactivate the electric heaters one at a time. The controller may be configured to activate the electric heaters in two or more groups, with all electric heaters in a group being activated simultaneously. The controller may be configured to activate a next heater or group of heaters after a previous heater or group of heaters has been activated but before the previous heater or group of heaters has been deactivated.

[0017] In embodiments in which the controller is configured to sequentially activate multiple electric heaters, each of the multiple subdivisions is preferably configured to provide visual feedback when the corresponding electric heater or group of electric heaters is activated for a period of time, which may be the total activation time of the heater or group of electric heaters, or the period of time may be a portion of the total activation time of the electric heater or group of electric heaters.

[0018] Preferably, each portion of the total period corresponds to the total activation time of a single electric heater, such that each of the plurality of divided sections is configured to provide visual feedback when at least a portion of the aerosol-generating article is received in the recess and when the corresponding electric heater is activated.

[0019] Preferably, the electric heater is arranged in a pattern and the segments of the segmented visual feedback device are arranged in the same pattern as the electric heater. Advantageously, providing the electric heater and the segments of the segmented visual feedback device in the same pattern may further emphasize the correlation between each of the multiple segments and consumption of the aerosol-forming substrate.

[0020] The pattern of segmented sections of the electric heater and segmented visual feedback device may include, for example, but is not limited to, a grid of linear rows and columns, a grid of linear rows and offset columns, a two-dimensional hexagonal pattern, one or more concentric circles, and combinations thereof.

[0021] Preferably, each of the plurality of segments is convertible from a first state to a second state when at least a portion of the aerosol-generating article is received in the recess and a corresponding portion of the total period has elapsed.

[0022] The first state may be the same for all of the plurality of subdivisions, or the first state of at least one of the subdivisions may be different from the first state of the remaining subdivisions.

[0023] The second state may be the same for all of the plurality of subdivisions. The second state of at least one of the subdivisions may be different from the second state of the remaining subdivisions.

[0024] The visual feedback provided by each of the plurality of segments in the second state may vary among the segments of the segmented visual feedback device, such that when at least some of the plurality of segments are converted to the second state, the segmented visual feedback device displays indicia. The indicia may comprise at least one of a graphic message and a text-based message for a user of the aerosol generating device. The indicia may include a logo, such as a brand logo. The indicia may include a brand name. When all of the plurality of segments are converted to the second state, the second state variation of at least some of the segments may provide a text-based message indicating that consumption of the aerosol-forming substrate is complete.

[0025] The segmented visual feedback device may be configured to convert the plurality of segments to the second state in a non-sequential order, whereby the segmented visual feedback device displays indicia when some of the plurality of segments are converted to the second state and some of the segments remain in the first state.

[0026] The segmented visual feedback device may include a segmented electronic display, each segment of the electronic display being individually switchable, and the controller configured to switch each of the plurality of segments from a first state to a second state when at least a portion of the aerosol-generating article is received in the recess and when a corresponding portion of the total time period has elapsed.

[0027] The segmented visual feedback device may comprise an LED array, with each segment comprising one or more LEDs.

[0028] The segmented visual feedback device may comprise an LCD display, with each segment of the segmented visual feedback device comprising one or more segments of the LCD display.

[0029] Each segment of the electronic display may be switchable between at least one of different brightness levels and different colors. The first state may comprise at least one of a first brightness level or a first color. The second state may comprise at least one of a second brightness level or a second color. One of the first brightness level and the second brightness level may be a state in which the segment is switched off.

[0030] In the first state, all of the plurality of partitions may be switched off, and each of the plurality of partitions may be transformed to the second state by switching the partition on when a corresponding portion of the total time period has elapsed.

[0031] In the first state, all of the plurality of segments may be switched on. At least one segment of the electronic display may be converted to the second state by switching the segment off when a corresponding portion of the total time has elapsed. All of the plurality of segments may be converted to the second state by switching each segment off when a corresponding portion of the total time has elapsed.

[0032] At least one segment of the electronic display may be converted to the second state by changing the color of the segment when a corresponding portion of the total time has elapsed, and all of the plurality of segments may be converted to the second state by changing the color of each segment when a corresponding portion of the total time has elapsed.

[0033] When at least a portion of the aerosol-generating article is received in the cavity and the entire period has elapsed, the controller may be configured to switch at least some of the plurality of segments to a third state, the third state being different from the first state and the second state. Advantageously, switching at least some of the plurality of segments to the third state may provide a clear indication to a user that consumption of the aerosol-forming substrate has been completed. In embodiments in which each of the plurality of segments is switched off when converted to the second state, converting at least some of the segments to the third state may include switching on at least some of the segments. In embodiments in which each of the segments is switched on when converted to the second state, converting at least some of the segments to the third state may include switching off at least some of the segments. Converting at least some of the plurality of segments to the third state may include changing the color of at least some of the segments. Converting at least some of the segments to the third state may include at least two of switching on at least one segment, switching off at least one segment, and changing the color of at least one segment.

[0034] For example, all of the segments may be switched on and illuminated in a first color when in a first state. Each segment may be switched off when converted to a second state. After a total period has elapsed, at least one of the segments may be switched on when converted to a third state. In the third state, at least one of the segments may be illuminated in a second color different from the first color.

[0035] The controller is preferably configured to reset each segment of the electronic display to the first state when a new aerosol-generating article is received in the cavity.

[0036] As described herein, the at least one electric heater may comprise a plurality of electric heaters, and each segment of the segmented visual feedback device may provide visual feedback when a corresponding electric heater is activated. Each segment of the segmented visual feedback device may overlie a corresponding electric heater, such that when the aerosol-generating article is received in the cavity, the aerosol-generating article is positioned between the plurality of electric heaters and the segmented visual feedback device. Advantageously, this may further emphasize the correlation between each segment of the visual feedback device and consumption of the aerosol-forming substrate.

[0037] Each of the plurality of segments may include a lens positioned such that a portion of the aerosol-generating article is visible through the lens when the aerosol-generating article is received in the recess. Each lens may be convertible between a first state and a second state, the shape of the lens in the second state being different from the shape of the lens in the first state. Changing the shape of the lens may change the visual appearance of the underlying portion of the aerosol-generating article when viewed through the lens, which may provide visual feedback to a user indicating activation of the corresponding electric heater.

[0038] Each lens may be electronically actuated. Each lens may include a piezoelectric actuator configured to change the shape of the lens when power is supplied to the piezoelectric actuator. The controller may be configured to electronically actuate each lens to transform the lens from a first state to a second state when a corresponding electric heater is activated.

[0039] Each lens may include a thermomechanical material configured to exhibit a change in shape when heated. Each lens may be configured such that heat from a corresponding electric heater affects a change in shape of the lens to transform the lens to a second state when the electric heater is activated. Examples of suitable thermomechanical materials include thermoresponsive polymers, including structurally modified polyvinyl alcohols. Suitable structurally modified polyvinyl alcohols include polyvinyl alcohols that have been at least one of partially acetalized and ionized. Each lens may be formed from a thermomechanical material, such as a thermoresponsive polymer. Each lens may be formed from a conventional optical material, such as glass, and a thermoresponsive polymer coating may be provided on the conventional optical material.

[0040] In embodiments in which each of the plurality of segments overlies a corresponding electric heater, each of the plurality of segments may be configured to exhibit a change in the segment's physical appearance when the segment is heated by the corresponding electric heater, advantageously providing a direct correlation between activation of each electric heater and transformation of the corresponding segment of the segmented visual feedback device to the second state.

[0041] At least one of the plurality of segments may include a thermochromic material configured to exhibit a color change when heated by a corresponding electric heater. Each of the plurality of segments may include a thermochromic material, and each segment may be configured to change from a first color to a second color. One of the first color and the second color may be colorless. The second color may be the same for all segments. The second color may be the same for all segments. The second color of at least one of the segments may be different from the second color of the remaining segments. The second color of two or more of the segments may be different from the second color of the remaining segments. Providing segments configured to exhibit different color changes can facilitate the segmented visual feedback device displaying indicia when at least some of the plurality of segments are heated. The indicia may include at least one of a graphic, text, a logo, and a brand name. Suitable thermochromic materials include leuco dyes.

[0042] At least one of the plurality of segments may include a thermomechanical material configured to exhibit a change in shape when heated by a corresponding electric heater, and each segment including the thermomechanical material may be a lens as described herein.

[0043] At least one of the segments may include a material configured to exhibit a change in at least one of its transparency and polarizing effect when heated by a corresponding electric heater. Altering the transparency and polarizing effect of a segment of the segmented visual feedback device may alter the visual appearance of the underlying portion of the aerosol-generating article when viewed through the segment. Suitable materials include spirobenzopyrans, doped oxides such as Gd(2)O(2)S:YbEr, and transparent materials including embedded microcrystalline silver halide.

[0044] Each electric heater may include an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, and iron-, manganese-, and aluminum-based alloys. In composite materials, the electrically resistive material may optionally be embedded, encapsulated, or coated with insulating material, or vice versa, depending on the required energy transfer kinetics and external physicochemical properties.

[0045] Each electric heater may comprise an infrared heating element, a photon source, or an induction heating element.

[0046] Each electric heater may comprise a semiconductor heater. Each semiconductor heater may comprise a substrate layer and a heating layer provided on the substrate layer. Each heating layer may be provided on a separate substrate layer. Preferably, the multiple semiconductor heaters comprise a common substrate layer and multiple heating layers spaced apart from one another and each provided on the common substrate layer, each heating layer forming a semiconductor heater. Advantageously, using a common substrate layer may simplify the manufacture of the multiple semiconductor heaters and the aerosol generating device. A suitable material for forming the substrate layer is silicon. The substrate layer may be a silicon wafer.

[0047] Each heating layer may comprise polycrystalline silicon. Each heating layer may include one or more dopants to provide the polycrystalline silicon with a desired electrical resistivity. A suitable dopant is phosphorus. Each heating layer may be a substantially continuous layer. Each heating layer may be patterned on the substrate layer. Advantageously, providing a patterned heating layer on the substrate layer may provide a desired temperature distribution across the semiconductor heater during operation.

[0048] The power supply may comprise a direct current (DC) supply. In a preferred embodiment, the power supply comprises a battery. The power supply may include a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery (e.g., a lithium-cobalt battery, a lithium-iron-phosphate battery, or a lithium polymer battery).

[0049] According to a second aspect of the present invention, there is provided an aerosol generating device comprising a power supply, a cavity for receiving an aerosol-generating article, and a plurality of electric heaters positioned within the cavity. The aerosol generating device further comprises a controller configured to control the supply of power from the power supply to each of the electric heaters to sequentially activate the plurality of electric heaters. The aerosol generating device also comprises a segmented visual feedback device, each segment of the segmented visual feedback device corresponding to one of the electric heaters. Each segment of the segmented visual feedback device is configured to provide visual feedback when an aerosol-generating article is received in the cavity and when the corresponding electric heater is activated.

[0050] An aerosol-generating device according to a second aspect of the present invention includes a segmented visual feedback device and a plurality of electric heaters, with a direct correlation between each segment of the visual feedback device and one of the electric heaters. Advantageously, this direct correlation provides a clear visual indication of the consumption of aerosol-forming substrate on the aerosol-generating article heated by the aerosol-generating device.

[0051] An aerosol-generating device according to a second aspect of the present invention comprises a plurality of sequentially activated electric heaters. Advantageously, the use of a plurality of sequentially activated electric heaters to heat an aerosol-forming substrate on an aerosol-generating article may facilitate a more accurate estimation or determination of the consumption of the aerosol-forming substrate.

[0052] The controller is configured to activate and deactivate the plurality of electric heaters sequentially. The controller may be configured to activate and deactivate the plurality of electric heaters one at a time. The controller may be configured to activate the plurality of electric heaters in two or more groups, with all electric heaters in a group being activated simultaneously. The controller may be configured to activate a next heater or group of heaters after a previous heater or group of heaters has been activated but before the previous heater or group of heaters has been deactivated.

[0053] Any of the optional or preferred features described herein in relation to the first aspect of the invention may be applied to the aerosol generating device according to the second aspect of the invention.

[0054] According to a third aspect of the present invention, there is provided an aerosol-generating article comprising a base layer, at least one aerosol-forming substrate positioned on the base layer, a cover layer overlying the at least one aerosol-forming substrate, and a segmented visual feedback device positioned on the cover layer, wherein each segment of the segmented visual feedback device overlies a portion of the at least one aerosol-forming substrate, and each segment of the segmented visual feedback device is configured to provide visual feedback when a corresponding portion of the at least one aerosol-forming substrate is heated.

[0055] The aerosol-generating article according to the present invention comprises a segmented visual feedback device having a direct correlation between each segment of the segmented visual feedback device and a portion of the at least one aerosol-forming substrate. Advantageously, the direct correlation provides a clear and accurate visual indication of the consumption of the at least one aerosol-forming substrate. This is in contrast to known articles that comprise an indicating means for indicating only when the entire article has been heated.

[0056] The at least one aerosol-forming substrate may be a single aerosol-forming substrate, with each segment of the segmented visual feedback device being on a portion of the single aerosol-forming substrate.

[0057] The at least one aerosol-forming substrate may comprise a plurality of individual aerosol-forming substrates, with each segment of the segmented visual feedback device being on one of the individual aerosol-forming substrates. Each of the plurality of individual aerosol-forming substrates may be substantially identical. At least one of the individual aerosol-forming substrates may be different from another one of the individual aerosol-forming substrates.

[0058] Each segment of the segmented visual feedback device may be configured to exhibit a change in the physical appearance of the segment when the segment and corresponding portion of the at least one aerosol-forming substrate are heated.

[0059] At least one segment of the segmented visual feedback device may include a thermochromic material configured to exhibit a color change when the segment and corresponding portion of at least one aerosol-forming substrate are heated. Each segment may include a thermochromic material, and each segment may be configured to change from a first color to a second color. One of the first color and the second color may be colorless. The second color may be the same for all segments. The second color of at least one segment may be different from the second color of the remaining segments. The second color of multiple segments may be different from the second color of the remaining segments. Providing segments configured to exhibit different color changes can facilitate the segmented visual feedback device displaying indicia when at least some of the segments are heated. The indicia may include at least one of a graphic, text, a logo, and a brand name. Suitable thermochromic materials include leuco dyes.

[0060] At least one segment of the segmented visual feedback device may comprise a thermomechanical material configured to change shape when the segment and corresponding portion of the at least one aerosol-forming substrate are heated. Each segment comprising the thermomechanical material may be a lens arranged so that the underlying portion of the at least one aerosol-forming substrate is visible through the lens. Preferably, each segment is configured so that the shape of the lens changes when the segment and corresponding portion of the at least one aerosol-forming substrate are heated. Changing the shape of the lens may change the visual appearance of the underlying portion of the at least one aerosol-forming substrate when viewed through the lens. Examples of suitable thermomechanical materials include thermoresponsive polymers, including structurally modified polyvinyl alcohols. Suitable structurally modified polyvinyl alcohols include polyvinyl alcohols that have been subjected to at least one of partial acetalization and ionization. Each lens may be formed from a thermomechanical material, such as a thermoresponsive polymer. Each lens may be formed from a conventional optical material, such as glass, or a thermoresponsive polymer coating may be provided on the conventional optical material.

[0061] At least one segment of the segmented visual feedback device may comprise a material configured to exhibit a change in at least one of the material's transparency and the material's polarizing effect when the segment and the corresponding portion of the at least one aerosol-forming substrate are heated. Altering at least one of the transparency and the polarizing effect of the segment of the segmented visual feedback device may change the visual appearance of the underlying portion of the at least one aerosol-forming substrate when viewed through the segment. Suitable materials include transparent materials including spirobenzopyrans, doped oxides such as Gd(2)O(2)S:YbEr, and embedded microcrystalline silver halide.

[0062] The at least one aerosol-forming substrate may comprise a tobacco-containing material provided on a base layer. The at least one aerosol-forming substrate may comprise a solid aerosol-forming substrate. The at least one aerosol-forming substrate may comprise at least one of herb leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0063] In embodiments in which at least one aerosol-forming substrate comprises homogenized tobacco material, the homogenized tobacco material may be formed by agglomerating particulate tobacco. The homogenized tobacco material may be in the form of a sheet. The aerosol former content of the homogenized tobacco material may be greater than 5 percent on a dry weight basis. The aerosol former content of the homogenized tobacco material may be between 5 percent and 30 percent on a dry weight basis. The homogenized tobacco material sheet may be formed by agglomerating particulate tobacco obtained by grinding or otherwise comminuted one or both of tobacco lamina and tobacco stems. The homogenized tobacco material sheet may include one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed, for example, during tobacco processing, handling, or transportation. The homogenized tobacco material sheet may include one or more inherent binders, such as tobacco intrinsic binders, one or more extrinsic binders (i.e., tobacco extrinsic binders), or a combination thereof, to assist in agglomerating the particulate tobacco. The homogenized tobacco material sheet may contain other additives, including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof. The homogenized tobacco material sheet is preferably formed by a casting process of a type that generally involves casting a slurry containing particulate tobacco and one or more binders onto a conveyor belt or other support surface, drying the cast slurry to form a homogenized tobacco material sheet, and removing the homogenized tobacco material sheet from the support surface.

[0064] The at least one aerosol-forming substrate may comprise at least one aerosol former. Suitable aerosol formers include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate).

[0065] Preferred aerosol formers are polyhydric alcohols or mixtures thereof such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin.

[0066] The at least one aerosol-forming substrate may comprise a single aerosol former. The at least one aerosol-forming substrate may comprise a combination of two or more aerosol formers.

[0067] In embodiments in which the at least one aerosol-forming substrate comprises a plurality of individual aerosol-forming substrates, at least one of the individual aerosol-forming substrates may comprise a porous carrier material and a liquid nicotine source sorbed onto the porous carrier material.

[0068] The porous carrier material preferably has a density of from about 0.1 grams per cubic centimeter to about 0.3 grams per cubic centimeter.

[0069] Preferably, the porous support material has a porosity of from about 15 percent to about 55 percent.

[0070] The porous carrier material may include one or more of glass, cellulose, ceramic, stainless steel, aluminum, polyethylene (PE), polypropylene, polyethylene terephthalate (PET), poly(cyclohexanedimethylene terephthalate) (PCT), polybutylene terephthalate (PBT), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), and BAREX®.

[0071] The porous carrier material is preferably chemically inert with respect to the liquid aerosol-forming substrate.

[0072] The liquid nicotine source preferably comprises one or more of nicotine, nicotine base, a nicotine salt (such as nicotine-HCl, nicotine tartrate, or nicotine bitartrate), or a nicotine derivative.

[0073] The nicotine source may include natural or synthetic nicotine.

[0074] The nicotine source may include pure nicotine, a solution of nicotine in an aqueous or non-aqueous solvent, or a liquid tobacco extract.

[0075] The nicotine source may include an electrolyte-forming compound, which may be selected from the group consisting of alkali metal hydroxides, alkali metal oxides, alkali metal salts, alkaline earth metal oxides, alkaline earth metal hydroxides, and combinations thereof.

[0076] The nicotine source may include an electrolyte-forming compound selected from the group consisting of potassium hydroxide, sodium hydroxide, lithium oxide, barium oxide, potassium chloride, sodium chloride, sodium carbonate, sodium citrate, ammonium sulfate, and combinations thereof.

[0077] The nicotine source may comprise an aqueous solution of nicotine, nicotine base, nicotine salt, or nicotine derivative, and an electrolyte-forming compound.

[0078] The nicotine source may contain other components, including, but not limited to, natural flavors, artificial flavors, antioxidants, and the like.

[0079] At least one of the individual aerosol-forming substrates may comprise a porous carrier material and a nicotine donor source sorbed onto the porous carrier material, and at least one of the individual aerosol-forming substrates may comprise a porous carrier material and an acid donor source sorbed onto the porous carrier material. In use, volatile compounds from the nicotine donor and acid donor sources may react in the gas phase to form an aerosol comprising nicotine salt particles.

[0080] The acid source may comprise an organic acid or an inorganic acid. Preferably, the acid source comprises an organic acid, more preferably a carboxylic acid, and most preferably an α-keto acid or a 2-oxo acid or lactic acid.

[0081] Preferably, the acid comprises an acid selected from the group consisting of 3-methyl-2-oxopentanoic acid, pyruvic acid, 2-oxopentanoic acid, 4-methyl-2-oxopentanoic acid, 3-methyl-2-oxobutanoic acid, 2-oxooctanoic acid, lactic acid, and combinations thereof. Advantageously, the acid comprises pyruvic acid or lactic acid. More advantageously, the acid comprises lactic acid. The invention will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief explanation of the drawings]

[0082] [Figure 1] FIG. 1 is a cross-sectional view of an aerosol generating device according to an embodiment of the present invention. [Figure 2] FIG. 2 is a top view of multiple electric heaters of the aerosol generating device of FIG. [Figure 3] FIG. 3 is a top view of the segmented visual feedback device of the aerosol generating device of FIG. [Figure 4]FIG. 4 is a perspective view of a first embodiment of an aerosol-generating article for use in the aerosol-generating device of FIG. [Figure 5] FIG. 5 is a perspective view of a second embodiment of an aerosol-generating article for use in the aerosol-generating device of FIG. [Figure 6] 6 is a cross-sectional view of the aerosol-generating article of FIG. 5 in combination with the aerosol-generating device of FIG. 1 to form an aerosol-generating system. [Figure 7] FIG. 7 is a perspective exploded view of an aerosol-generating article according to an embodiment of the present invention. [Figure 8] FIG. 8 is a cross-sectional view of an aerosol generating device used in the aerosol-generating article of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0083] 1 shows a cross-sectional view of an aerosol generating device 10 according to an embodiment of the present invention. The aerosol generating device 10 comprises a housing 12 defining a cavity 14 for receiving an aerosol-generating article. An air inlet 16 is provided at the upstream end of the cavity 14, and a mouthpiece 18 is provided at the downstream end of the housing 12. An air outlet 20 is provided in the mouthpiece 18 in fluid communication with the cavity 14, thereby defining an airflow path through the cavity 14 between the air inlet 16 and the air outlet 20. During use, a user draws on the mouthpiece 18, drawing air into the cavity 14 through the air inlet 16 and out of the cavity 14 through the air outlet 20.

[0084] The aerosol generating device 10 further comprises a plurality of electric heaters 22 provided on a flat wall 24 of the cavity 14. Each of the electric heaters 22 comprises a heater element 26 provided on a common support layer 28. The plurality of electric heaters 22 form a heater array 30, which is more clearly shown in FIG.

[0085] The aerosol generating device also includes a segmented visual feedback device 32, which is more clearly shown in Figure 3. The segmented visual feedback device 32 includes a plurality of segments 34 arranged in an array having the same pattern as the heater array 30. In the embodiment shown in Figures 1-3, each segment 34 includes a blue LED, a red LED, and a green LED so that each segment 34 can be illuminated in a variety of different colors.

[0086] The aerosol generating device 10 further includes a power supply 40 and a controller 42 positioned within the housing 12. When an aerosol-generating article is received in the cavity 14, the controller 42 controls the supply of current from the power supply 40 to each electric heater 22 to activate the electric heater 22. The controller 42 is configured to activate the electric heaters 22 in groups, with each group being activated and deactivated sequentially. The controller 42 is also configured to switch each of the segments 34 of the segmented visual feedback device 32 from a first state 36 to a second state 38 when a corresponding electric heater 22 in the heater array 30 is activated. In the first state 36, each segment 34 is switched off, and in the second state 38, each segment 34 is switched on and illuminated in a first color. When all of the electric heaters 22 are activated, the controller 42 is configured to switch all of the segments 34 of the segmented visual feedback device 32 to a third state. In the third state, all of the segments 34 are switched on and illuminated in a second color different from the first color. When the aerosol-generating article is removed from the cavity 14 and a new aerosol-generating article is inserted into the cavity 14, the controller 42 resets all of the segments 34 to the first state.

[0087] Figure 4 shows a first aerosol-generating article 50 for use in the aerosol-generating device 10 of Figures 1-3. The aerosol-generating article 50 comprises a base layer 52 and an aerosol-forming substrate 54 provided on the base layer 52. The aerosol-forming substrate 54 comprises a substantially continuous layer of solid tobacco-containing material. A removable cover layer 56 is secured to the base layer 52 to seal the aerosol-forming substrate 54 between the base layer 52 and the removable cover layer 56. The removable cover layer is formed from a non-porous polymeric film.

[0088] During use, the removable cover layer 56 is removed from the base layer 52, and the aerosol-generating article 50 is inserted into the cavity 14 of the aerosol-generating device 10 shown in FIG. 1 to form an aerosol-generating system. The controller 42 then sequentially activates and deactivates the groups of electric heaters 22 to sequentially heat individual portions of the aerosol-forming substrate 54. Each time an electric heater 22 is activated, the controller 42 switches the corresponding segment 34 of the segmented visual feedback device 32 to a second state to indicate that the corresponding portion of the aerosol-forming substrate 54 has been consumed. In this way, the segmented visual feedback device 32 provides a clear indication of the amount of aerosol-forming substrate 54 consumed.

[0089] Figure 5 shows a second aerosol-generating article 60 for use in the aerosol-generating device 10 of Figures 1-3. The aerosol-generating article 60 comprises a base layer 52 and a cover layer 56 identical to the base layer 52 and cover layer 56 of the aerosol-generating article 50 shown in Figure 4. However, the aerosol-generating article 60 comprises a plurality of individual aerosol-forming substrates 64 positioned on the base layer 52 and sealed between the base layer 52 and the cover layer 56. Each of the aerosol-forming substrates 64 comprises a porous substrate material and a liquid aerosol-forming substrate sorbed on the porous substrate material.

[0090] The plurality of aerosol-forming substrates 64 are divided into three groups: a plurality of first aerosol-forming substrates 68 each comprising a liquid nicotine solution, a plurality of second aerosol-forming substrates 70 each comprising a volatile acid, and a plurality of third aerosol-forming substrates 72 each comprising a flavorant.

[0091] In use, the removable cover layer 56 is removed from the base layer 52, and as shown in Figure 6, the aerosol-generating articles 60 are inserted into the recesses 14 of the aerosol-generating device 10 shown in Figure 1 to form an aerosol-generating system 80. The aerosol-forming substrates 64 are arranged such that when the aerosol-generating articles 60 are received in the recesses 14, each aerosol-forming substrate 64 is above an electric heater 22.

[0092] The controller 42 then sequentially activates and deactivates the groups of electric heaters 22 to sequentially heat the individual aerosol-forming substrates 64. At each sequential activation stage, the controller 42 activates the appropriate electric heaters 22 to simultaneously heat one of the first aerosol-forming substrates 68, one of the second aerosol-forming substrates 70, and one of the third aerosol-forming substrates 72. The nicotine vapor emitted from the heated first aerosol-forming substrate 68 and the acid vapor emitted from the heated second aerosol-forming substrate 70 react in the gas phase to form an aerosol containing nicotine salt particles for delivery to the user through the air outlet 20. The flavorant emitted from the heated third aerosol-forming substrate 72 imparts flavor to the aerosol delivered to the user.

[0093] Each time the electric heater 22 is activated, the controller 42 switches the corresponding segment 34 of the segmented visual feedback device 32 to the second state to indicate that the corresponding individual aerosol-forming substrate 64 has been consumed. In this manner, the segmented visual feedback device 32 provides a clear indication of the consumption of the plurality of individual aerosol-forming substrates 64.

[0094] Figure 7 shows an exploded view of an aerosol-generating article 90 according to one embodiment of the present invention. The aerosol-generating article 90 comprises a base layer 52 and a plurality of individual aerosol-forming substrates 64 that are identical to the base layer 52 and aerosol-forming substrates 64 of the aerosol-generating article 60 shown in Figure 5. Accordingly, like reference numerals are used to designate like parts.

[0095] The aerosol-generating article 90 comprises a cover layer 92 attached to the base layer 52 and overlying a plurality of individual aerosol-forming substrates 64. A segmented visual feedback device 94 is positioned on the cover layer 92, the segmented visual feedback device 94 comprising a plurality of segmented sections 96. The pattern formed by the plurality of segmented sections 96 is identical to the pattern formed by the plurality of individual aerosol-forming substrates 64, such that each segmented section 96 overlies an individual aerosol-forming substrate 64.

[0096] Each of the segments 96 of the segmented visual feedback device 94 includes a material that exhibits a change in the appearance of the material when heated. For example, each segment 96 may include at least one of a thermomechanical material, a thermochromic material, a material configured to exhibit a change in transparency when heated, and a material configured to exhibit a change in the polarizing effect of the material when heated.

[0097] FIG. 8 shows a cross-sectional view of an aerosol-generating device 100 for use with the aerosol-generating article 90 of FIG. 7. The structure and operation of the aerosol-generating article 100 are substantially identical to the aerosol-generating article 10 of FIGS. 1-3, and like reference numerals designate like parts. The aerosol-generating article 100 includes a transparent window 102 instead of a segmented visual feedback device. The transparent window 102 is positioned so as to overlie the segmented visual feedback device 94 of the aerosol-generating article 90 when the aerosol-generating article 90 is received in the recess 14. When the aerosol-generating article 90 is received in the recess 14, the controller 42 sequentially activates the electric heaters 22 to sequentially heat the plurality of individual aerosol-forming substrates 64, as described with reference to FIG. 6. As each individual aerosol-forming substrate 64 is heated, the material of the corresponding segment 96 of the segmented visual feedback device 94 undergoes a change in appearance due to the heat. The change in appearance of each divided section 96 can be observed through the transparent window 102, and in this way the divided visual feedback device 94 provides a clear indication of the consumption of the multiple individual aerosol-forming substrates 64.

[0098] 1. An aerosol generating device comprising: a power supply source; a recess for receiving at least a portion of the aerosol-generating article; at least one electric heater positioned within the cavity; a controller configured to control the supply of power from the power supply to the at least one electric heater to activate the at least one electric heater, the controller being configured to activate the at least one electric heater for an entire period when at least a portion of an aerosol-generating article is received in the cavity; and an aerosol generating device comprising: a segmented visual feedback device, wherein each of a plurality of segments of the segmented visual feedback device corresponds to a different portion of the total period, and wherein each of the plurality of segments is configured to provide visual feedback when at least a portion of an aerosol-generating article is received in the recess and when the corresponding portion of the total period has elapsed. 2. The aerosol generating device described in 1, wherein the at least one electric heater comprises a plurality of electric heaters. 3. The aerosol generating device described in 2, wherein the controller is configured to activate the multiple electric heaters sequentially. 4. An aerosol generating device as described in 3, wherein each portion of the total period corresponds to the total activation time of a single electric heater, and each of the plurality of divided sections is configured to provide visual feedback when at least a portion of an aerosol-generating article is received in the recess and when the corresponding electric heater is activated. 5. An aerosol generating device as described in 4, wherein the electric heater is arranged in a certain pattern and the divided sections of the divided visual feedback device are arranged in the same pattern as the electric heater. 6. An aerosol generating device described in any one of 1 to 5, wherein each of the plurality of divided sections is convertible from a first state to a second state when at least a portion of an aerosol-generating article is received in the recess and when the corresponding portion of the total period has elapsed. 7. An aerosol generating device as described in 6, wherein the visual feedback provided by each of the plurality of divided sections in the second state differs between the divided sections of the divided visual feedback device, thereby causing the divided visual feedback device to display an indicia when at least some of the plurality of divided sections are switched to the second state. 8. An aerosol generating device as described in 6 or 7, wherein the segmented visual feedback device is configured to convert the plurality of divided sections to the second state in a non-sequential order, whereby the segmented visual feedback device displays an indication when some of the plurality of divided sections are converted to the second state and some of the divided sections remain in the first state. 9. An aerosol generating device as described in 6, 7, or 8, wherein the segmented visual feedback device comprises a segmented electronic display, each segment of the electronic display being individually switchable, and wherein the controller is configured to switch each of the plurality of segments from the first state to the second state when at least a portion of an aerosol-generating article is received in the recess and when the corresponding portion of the total period has elapsed. 10. An aerosol generating device as described in 9, wherein each of the divided sections of the electronic display is switchable between at least one of different levels of brightness and different colors. 11. An aerosol generating device as described in 9 or 10, wherein when at least a portion of an aerosol-generating article is received in the recess and when the total period has elapsed, the controller is configured to switch at least some of the divided sections of the electronic display to a third state, the third state being different from the first state and the second state. 12. An aerosol generating device as described in 9, 10, or 11, wherein the controller is configured to reset each of the plurality of divided sections to the first state when at least a portion of a new aerosol-generating article is received in the recess. 13. An aerosol-generating article, The base layer and at least one aerosol-forming substrate positioned on the base layer; a cover layer overlying the at least one aerosol-forming substrate; an aerosol-generating article comprising: a segmented visual feedback device positioned on the cover layer, wherein each segment of the segmented visual feedback device is located on a portion of the at least one aerosol-forming substrate and is configured to provide visual feedback when the corresponding portion of the at least one aerosol-forming substrate is heated. 14. The aerosol-generating article described in 13, wherein each divided section of the divided visual feedback device is configured to exhibit a change in the physical appearance of the divided section when the divided section and the corresponding portion of the at least one aerosol-forming substrate are heated. 15. An aerosol-generating article as described in 13 or 14, wherein each divided section of the divided visual feedback device comprises at least one of a thermomechanical material, a thermochromic material, a material configured to exhibit a change in transparency when heated, and a material configured to exhibit a change in the polarization effect of the material when heated.

Claims

1. An aerosol generating device, comprising: a power supply source; a recess for receiving at least a portion of the aerosol-generating article; a plurality of electric heaters positioned within the recess; a controller configured to control the supply of power from the power supply source to the plurality of electric heaters to activate the plurality of electric heaters, the controller being configured to activate the plurality of electric heaters for a full period when at least a portion of an aerosol-generating article is received in the cavity; and a segmented visual feedback device, wherein each of a plurality of segments of the segmented visual feedback device corresponds to a different portion of the total time period, and wherein each of the plurality of segments is configured to provide visual feedback when at least a portion of an aerosol-generating article is received in the recess and when a corresponding portion of the total time period has elapsed; the plurality of heaters are arranged in a pattern, and the divided sections of the divided visual feedback device are arranged in the same pattern as the plurality of electric heaters; each of the plurality of segments is convertible from a first state to a second state when at least a portion of an aerosol-generating article is received in the recess and when the corresponding portion of the total period has elapsed; a first state of each of the plurality of segments including at least one of a level of brightness and a color; The first state for at least one of the partitions is different from the first states for the remaining partitions. Aerosol generator.

2. 2. The aerosol generating device of claim 1, wherein the controller is configured to activate the plurality of electric heaters sequentially.

3. 3. The aerosol generating device of claim 2, wherein each portion of the total period corresponds to the total activation time of a single electric heater, and wherein each of the plurality of divided sections is configured to provide visual feedback when at least a portion of an aerosol-generating article is received in the recess and when the corresponding electric heater is activated.

4. 4. The aerosol generating device of claim 3, wherein the visual feedback provided by each of the plurality of divided sections in the second state differs between the divided sections of the divided visual feedback device, thereby causing the divided visual feedback device to display an indicia when at least some of the plurality of divided sections are switched to the second state.

5. 5. The aerosol generating device of claim 3 or 4, wherein the segmented visual feedback device is configured to convert the plurality of divided sections to the second state in a non-sequential order, whereby the segmented visual feedback device displays an indicia when some of the plurality of divided sections are converted to the second state and some of the divided sections remain in the first state.

6. 6. The aerosol generating device of claim 3, 4, or 5, wherein the segmented visual feedback device comprises a segmented electronic display, each segment of the electronic display being individually switchable, and wherein the controller is configured to switch each of the plurality of segments from the first state to the second state when at least a portion of an aerosol-generating article is received in the recess and when the corresponding portion of the total period has elapsed.

7. 7. The aerosol generating device of claim 6, wherein each of the segments of the electronic display is switchable between at least one of different levels of brightness and different colors.

8. 8. The aerosol generating device of claim 6 or 7, wherein when at least a portion of an aerosol-generating article is received in the recess and when the total period has elapsed, the controller is configured to switch at least some of the divided sections of the electronic display to a third state, the third state being different from the first state and the second state.

9. 9. The aerosol generating device of claim 6, 7, or 8, wherein the controller is configured to reset each of the plurality of divided sections to the first state when at least a portion of a new aerosol-generating article is received in the recess.

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