Apparatus for heating aerosolizable material

Abstract

To provide a novel apparatus arranged to heat aerosolizable material to volatilize at least one component of the aerosolizable material.SOLUTION: The apparatus comprises a conductive wire arranged to generate heat for transfer to the aerosolizable material in response to application of an electric current. The conductive wire has a resistivity between 0.9 Ω mm2 / m and 1.6 Ω mm2 / m.SELECTED DRAWING: Figure 6a

Description

[Technical Field]

[0001] The present invention relates to an apparatus configured to heat an aerosolizable material. [Background technology]

[0002] Articles such as cigarettes, cigars, and the like burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion. Examples of such products are so-called non-combustion heating products, also known as tobacco heating products or tobacco heating devices, which release compounds by heating a material without burning it. The material may be, for example, tobacco, another non-tobacco product, or a combination, such as a blended mixture, which may or may not contain nicotine. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided an apparatus configured to heat an aerosolizable material to vaporize at least one component of the aerosolizable material, the apparatus comprising an electrically conductive wire configured to generate heat for transfer to the aerosolizable material in response to application of an electric current, the electrically conductive wire having a resistance of 0.9 ohms mm 2 / m~1.6 ohm mm 2 / m.

[0004] In one exemplary embodiment, the device further comprises a receiving portion configured to receive a consumable containing an aerosolizable material, the conductive wire being disposed about the receiving portion.

[0005] In one exemplary embodiment, the receiving portion is a tube configured to receive a cylindrical consumable containing an aerosolizable material.

[0006] In one exemplary embodiment, the conductive wire is helically disposed around the receiving portion.

[0007] In one exemplary embodiment, the conductive wire comprises one or more zones including a first zone and a second zone, the first zone extending from a distal end to an intermediate portion and the second zone extending from the intermediate portion to a proximal end.

[0008] The device is a consumable product that includes a backing sheet, a conductive wire attached to the backing sheet, and an aerosolizable material disposed on the conductive wire.

[0009] In one exemplary embodiment, the conductive wire includes a current inlet, a central portion, and a current outlet.

[0010] In one exemplary embodiment, the aerosolizable material is provided in the central portion.

[0011] In one exemplary embodiment, the backing sheet is formed from card or paper.

[0012] In one exemplary embodiment, the central portion is disc-shaped and the aerosolizable material is disc-shaped.

[0013] In one exemplary embodiment, the conductive wire includes a current inlet, a receiving portion, and a current outlet.

[0014] In one exemplary embodiment, the receiving portion is adapted to receive a consumable product that includes an aerosolizable material.

[0015] In one exemplary embodiment, the receiving portion is disc-shaped.

[0016] In one exemplary embodiment, the conductive wire is formed from at least one of Fecralloy®, Nichrome, Alkrothal®, Kanthal®, and Nikrothal®.

[0017] 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]

[0018] [Figure 1] 1 is a schematic cross-sectional view of an example of an apparatus for heating an aerosolizable material to vaporize at least one component of the aerosolizable material. [Figure 2a] 1 is a schematic cross-sectional view of an example of a conductive wire. [Figure 2b] 1 is a schematic cross-sectional view of an example of a conductive wire. [Figure 3] 1 is a schematic cross-sectional view of an example of an apparatus for heating an aerosolizable material to vaporize at least one component of the aerosolizable material. [Figure 4] 1 is a schematic cross-sectional view of an example of an apparatus for heating an aerosolizable material to vaporize at least one component of the aerosolizable material. [Figure 5] 1 is a schematic diagram illustrating an example of an apparatus according to an embodiment of the present invention. [Figure 6a] 1A and 1B show an example of a single turn configuration of conductive wire. [Figure 6b] 1A and 1B are diagrams illustrating an example shape of a conductive wire. [Figure 7] FIG. 1 illustrates an example external support for use with the present invention. [Figure 8a] FIG. 10 is a diagram showing an example of a two-turn configuration of a conductive wire. [Figure 8b] FIG. 10 is a diagram showing an example of a three-turn configuration of a conductive wire. [Figure 9] FIG. 1 illustrates an example electrical trace. [Figure 10] FIG. 10 illustrates an example receiving portion. [Figure 11] FIG. 10 illustrates another example receiving portion. [Figure 12] 1 shows an example of a consumable to be used in a tobacco heating device. [Figure 13] 1 shows an example of a removable consumable and trace within a tobacco heating device. DETAILED DESCRIPTION OF THE INVENTION

[0019] Devices are known that heat aerosolizable material without burning or combusting the aerosolizable material to vaporize at least one component of the aerosolizable material, typically thereby forming an inhalable aerosol. Such devices are sometimes referred to as "non-combustion heating" devices, or "tobacco heating products," or "tobacco heating devices," or similar terms. Similarly, so-called e-cigarette devices exist that typically vaporize aerosolizable material in liquid form, which may or may not contain nicotine. Generally, the aerosolizable material can take the form of or be provided as part of a rod, cartridge, or cassette that can be inserted into the device. The heating material for heating and vaporizing the aerosolizable material may be provided as a "permanent" part of the device or as part of a consumable that is discarded and replaced after use. A "consumable" in this context is a device or article, or other component, that includes or contains the aerosolizable material during use, which is heated during use to vaporize the aerosolizable material.

[0020] As used herein, the term "aerosolizable material" includes materials that, upon heating, provide evaporative components, typically in the form of a vapor or aerosol. "Aerosolizable material" may be a non-tobacco-containing material or a tobacco-containing material. "Aerosolizable material" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. Aerosolizable material may take the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, gelled sheet, powder, or agglomerate. "Aerosolizable material" may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. "Aerosolizable material" may also include one or more humectants, such as glycerol or propylene glycol.

[0021] 1, there is shown a schematic cross-sectional view of an example of an apparatus 100 according to one embodiment of the present invention. The apparatus 100 is for heating an aerosolizable material to vaporize at least one component of the aerosolizable material.

[0022] The device 100 comprises a device housing 102, hereafter referred to as the body 102. The body 102 comprises a receiving portion 104 for receiving at least a portion of a consumable containing an aerosolizable material to be heated.

[0023] The device 100 has an outlet 106 that allows vaporized components of the aerosolizable material to exit the receiving portion 104 and out of the device 100 when the consumable is heated during use.

[0024] The device 100 has an air inlet 108 that fluidly connects the receiving portion 104 to the exterior of the device 100. A user may be able to inhale the vaporized component(s) of the aerosolizable material by drawing on the vaporized component(s) from the consumable. As the vaporized component(s) are removed from the consumable, air may be drawn into the receiving portion 104 through the air inlet 108 of the device 100.

[0025] In this embodiment, the receiving portion 104 is cylindrical (i.e., circular in cross section) and forms a recess or cavity for receiving at least a portion of the consumable. The receiving portion 104 can have a diameter in the range of 5-10 mm. In this embodiment, the receiving portion 104 includes a flared opening 124.

[0026] The receiving portion 104 may be made from a metallic material, such as aluminum, copper, manganin, steel, constantan, nichrome, stainless steel, nickel, or Fecralloy®. In this embodiment, the receiving portion 104 is a tubular structure configured to receive a consumable having a cylindrical configuration. However, in other embodiments, the receiving portion 104 may be configured to receive consumables having other configurations (i.e., non-cylindrical) and therefore may have other geometries configured to receive such consumables. For example, the receiving portion 104 may have a rectangular cross-section. In other embodiments, the receiving portion 104 may be something other than a recess, such as a ledge, surface, or protrusion, that cooperates with or requires mechanical interlocking with the consumable to receive it. In this embodiment, the receiving portion 104 is elongated and sized and shaped to accommodate a portion of the consumable, such that another portion of the consumable protrudes from the body 102. In other embodiments, the receiving portion 104 may be dimensioned to receive the entire consumable. Typically, receiving portion 104 has a wall thickness in the range of 0.05 to 0.15 mm. For example, receiving portion 104 may be a tube having a wall thickness of about 0.1 mm.

[0027] Surrounding the receiving portion 104 is an electrically conductive wire 110 configured to generate heat by resistive heating in response to the application of an electric current. The electrically conductive wire 110 can take any suitable form. In this embodiment, the electrically conductive wire 110 is a coil of electrically conductive wire wrapped around the receiving portion 104 in a helical configuration. The coil extends along a longitudinal axis that is substantially aligned with the longitudinal axis of the receiving portion 104.

[0028] Each turn of the coil is electrically isolated from adjacent turns. In this embodiment, each turn of the coil is separated from adjacent turns by an air gap. In some embodiments, the coil may be surrounded by a dielectric material. Electrically isolating the turns of the coil from adjacent turns prevents short circuits between the turns of the coil, which would otherwise affect the resistance of the coil and change the heating characteristics of the conductive wire 110.

[0029] FIG. 2a shows a schematic cross-sectional view of wire 200 from which conductive wire 110 can be formed to cooperate with receiving portion 104. In this embodiment, wire 200 can be drawn or otherwise formed to have a substantially rectangular cross-section. As will be understood, so long as the substantially rectangular cross-section of the wire contacts receiving portion 104, the substantially rectangular cross-section may include other artifacts, such as those present from manufacturing. For example, the wire may have a C-shaped or L-shaped cross-section, or alternatively, may have any of the cross-sections seen in FIG. 2b, such as a flat hem, an open hem, a teardrop hem, or a rope hem. Such artifacts may be present on both sides. In particular, wire 200 has width 202 and thickness 204. In some embodiments, wire width 202 ranges from 2.75 mm ±30% to 5.95 mm ±30%. In some embodiments, wire thickness ranges from 0.05 mm ±30% to 0.1 mm ±30%. Additionally, the wire may be thinner, ranging from 0.01 mm ±30% to 0.1 mm ±30%. In other embodiments, such as the single-turn embodiment shown in FIGS. 6a and 6b (discussed further below), the wire may be wider, such as up to 20 mm ±30%, so that a single turn can cover the entire receiving portion 104. For wires having a non-rectangular cross-section (e.g., wires having a circular cross-section), the wire 200 provides an increased contact area with the receiving portion 104, resulting in improved thermal transfer between the wire 200 and the receiving portion 104. The increased contact area between the wire 200 and the receiving portion 104, and the resulting improved thermal contact between the wire 200 and the receiving portion 104, provides improved heat transfer between the wire 200 and the receiving portion 104, thus improving the heating efficiency of the device 100. Thus, a wire having the dimensions of wire 200 described with reference to FIG. 2a can reduce (ie, improve) the time it takes for conductive wire 110 to reach a desired temperature.

[0030] When placed within the device (i.e., wrapped around the receiving portion 104), the substantially rectangular configuration of the wire can be deformed such that its rectangular cross-section conforms to the outer surface of the receiving portion 104. For example, the lower surface 206 can conform to the radius of the outer surface of the receiving portion 104, and thus the outer surface 208 can be deformed to correspond to a radius defined by the radius of the receiving portion 104. In embodiments in which the conductive wire 200 forms a helix, the conductive wire 200 can be deformed to form a compound curve, i.e., a curve that conforms to a curve on an axis parallel to the longitudinal axis of the receiving portion 104 and a curve that conforms to a curve on an axis perpendicular to the longitudinal axis of the receiving portion 104.

[0031] In this embodiment, the conductive wire 110 extends along substantially the entire length of the receiving portion 104. However, in other embodiments, the conductive wire 110 may extend along only a portion of the receiving portion 104 (i.e., not along the entire length of the receiving portion 104).

[0032] The outer surface of the receiving portion 104 includes an insulating layer 112 that provides electrical isolation between the conductive wire 110 and the receiving portion 104. The insulating layer 112 may include, for example, a dielectric material. In some embodiments, the insulating layer 112 may be adhered to the outer surface of the receiving portion 104. For example, the insulating layer 112 may be a layer of polyimide film adhered to the outer surface of the receiving portion 104. In other embodiments, the insulating layer 112 may be an oxide layer formed on the outer surface of the receiving portion 104. For example, the receiving portion 104 may be formed of a metallic material and the insulating layer 112 may be formed of an oxide of that metal. In one example, the receiving portion 104 may be formed of aluminum and the insulating layer 112 may be an anodized layer formed of aluminum oxide. In some examples, the anodized layer may be formed by so-called hard anodizing.

[0033] In this embodiment, the conductive wire 110 is wrapped around an insulating layer 112 supported by the receiving portion 104. Resilience provided by the material from which the conductive wire 110 is made may provide a compressive force that holds the conductive wire 110 in contact with the insulating layer 112 on the surface of the receiving portion 104, thus improving thermal contact between the conductive wire 110 and the receiving portion 104. Alternatively, or additionally, another component, such as an additional tube or one or more resilient members, such as a spring clip, may be disposed around the conductive wire 110 to hold the conductive wire 110 in place in the receiving portion 104. For example, a sleeve, such as a heat shrink sleeve, may be provided around the conductive wire 110 to physically hold the conductive wire 110 in contact with the receiving portion 104, thereby improving thermal contact between the conductive wire 110 and the receiving portion 104. One such material may be PEEK heat shrink. Additionally or alternatively, other systems may be utilized to maintain tension on the conductive wire wrap to ensure good contact between the conductive wire 110 and the receiving portion 104. For example, a friction-based tensioning system may be used.

[0034] In other embodiments, the conductive wires 110 may comprise electrical traces formed between layers of dielectric material, for example, the electrical traces may be etched traces formed between sheets of polyimide.

[0035] In some embodiments, the receiving portion 104 may be defined by the conductive wire 110 itself. That is, there may not be a separate receiving portion 104 between the conductive wire 110 and the space that is to receive the consumable. For example, the outwardly facing surface of the conductive wire 110 (e.g., a coil) may be supported and / or mounted on the inner surface of a support structure, such that the conductive wire 110 and the support structure form a heating chamber without the need for a separate, thermally conductive internal support. Such an embodiment may improve the transfer of thermal energy from the conductive wire 110 to the aerosolizable material within the received consumable. In some embodiments, the support structure may be made of a plastic material that can withstand the temperatures required to vaporize one or more components of the aerosolizable material. For example, the support structure may include polyetheretherketone (PEEK).

[0036] Although the conductive wire 110 is arranged in a coil in the embodiment shown in FIG. 1, in other embodiments, the conductive wire 110 may have other configurations, for example, the conductive wire 110 may be configured in a “zigzag” pattern extending along the longitudinal axis of the receiving portion 104.

[0037] The conductive wire 110 may be formed of any suitable material. In some embodiments, the conductive wire 110 is formed of a metallic material, for example, the conductive wire 110 may include one or more of aluminum, copper, manganin, steel, constantan, nichrome, stainless steel, nickel, and Fecralloy®, an alloy of iron, chromium, and aluminum that has a relatively high resistivity for a conductor and can ramp up to a target temperature relatively quickly. In other embodiments, the conductive wire 110 may be formed of a ceramic material.

[0038] The device 100 also includes a power supply 114 for applying an electric current to the conductive wire 110 during use. In response to the application of the electric current, the temperature of the conductive wire 110 increases due to resistive heating of the conductive wire 110. In this embodiment, the power supply 114 is a rechargeable battery. In other embodiments, the power supply 114 may be something other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a combination battery and capacitor, or a connection to an external power source such as a mains or USB-powered power source.

[0039] A first terminal 114a of the power source 114 is electrically connected to the first end 110a of the conductive wire 110. A second terminal 114b of the power source 114 is electrically connected to the second end 110b of the conductive wire 110. In this embodiment, an electrical connection is also made between the second terminal 114b of the power source 114 and a midpoint 110c of the conductive wire 110 between the first end 110a and the second end 110b. This configuration of electrical connections allows power to be applied to different zones of the conductive wire 110. In particular, in this embodiment, a first zone 116 (referred to herein as Zone 1) is defined between the first end 110a and a midpoint 110c between the first end 110a and the second end 110b, and a second zone 118 (referred to herein as Zone 2) is defined between the second end 110b and a midpoint 110c between the first end 110a and the second end 110b. In other embodiments, the conductive wire 110 may be electrically connected to the power source 114 to define a single zone, or may be electrically connected to the power source 114 to define three or more zones. The zones may be of substantially equal length or may be of different lengths to provide different heating characteristics to different heating zones. In some embodiments, Zone 1 116 extends along the conductive wire 110 (and thus the receiving portion 104) for a length in the range of 10-20 mm, and Zone 2 118 extends along the conductive wire 110 (and thus the receiving portion 104) for a length in the range of 25-30 mm. In the embodiment shown in FIG. 1, Zone 1 116 extends along the conductive wire 110 (and thus the receiving portion 104) for a length in the range of 14-16 mm, and Zone 2 118 extends along the conductive wire 110 (and thus the receiving portion 104) for a length in the range of 27-28 mm. In addition to the above, it is desirable for the conductive wire 110 to be connected to the power source 114 so that each of the one or more zones can be independently operable. For example, in the embodiment of FIG. 1, only Zone 1 116 may be heated, only Zone 2 118 may be heated, or both zones may be heated, as desired.This is equally applicable to zones of any length and / or receiving portions 104 of any length, or any number of zones.

[0040] Figure 3 is a schematic diagram showing a perspective view of device 100 with conductive wire 110 wrapped around receiving portion 104. In particular, Figure 3 shows a first wire 302 (connected to a power source) connected to first end 110a of conductive wire 110, a second wire 304 (connected to a power source) connected to second end 110b of conductive wire 110 (thereby defining zone 1 116), and a third wire 306 (connected to a power source) coupled to midpoint 110c of conductive wire 110 (thereby defining zone 2 118).

[0041] The rate at which the temperature of the conductive wire 110 increases depends on the power applied to the conductive wire 110 and the resistance of the conductive wire 110. In embodiments in which the power source 114 is a rechargeable battery, the voltage provided by the battery is typically at least about 2.7 volts but can be as high as 4.2 volts and can deliver a current of up to about 8.6 amps. Thus, the maximum power that can be supplied by such a rechargeable battery is typically about 23 watts. Thus, the target resistance of the conductive wire 112 when powered by such a rechargeable battery may be about 0.32 ohms (0.35 ohms ±5%). The target resistance may be in the range of 0.31 ohms ±5% to 1 ohm ±5%. Such resistance allows the temperature of the conductive wire 110 to be increased from room temperature (i.e., about 23°C) to a target temperature of about 280°C in about 3 seconds (the "ramp-up" time), i.e., at a rate of about 90°C per second, which is comparable to the heating rate of an induction wire configured to heat consumables containing aerosolizable materials.

[0042] The resistance of the conductive wire 110 depends on the resistivity of the material. A material with a lower density has a lower mass and therefore requires less energy and / or heating time. Similarly, a material with a lower specific heat requires less energy and / or heating time. However, since density is inversely proportional to specific heat, one cannot choose to have both low; a compromise must be found.

[0043] With respect to the resistivity of a material, a trade-off must be made between the energy and / or time required to heat it and the coverage of the surface to be heated: a material with a higher resistivity requires less material and therefore has less mass (and therefore requires less energy and / or time to heat) but will cover less of the surface to be heated, while a material with a lower resistivity requires more material and therefore has more mass (and therefore requires more energy and / or time to heat) but will cover more of the surface to be heated.

[0044] If the target temperature rise is about 257°C and the maximum available power is about 23 watts, (s / mm 3 The time t required to reach the desired temperature for a given volume of material (having units of v can be calculated for a variety of materials using this formula.

[0045] t v = (temperature rise x specific heat x density) / power The controller 120 is also electrically connected to the power supply 114. The controller 120 is for controlling the supply of power from the power supply 114 to the conductive heater 110. The controller 120 may comprise an integrated circuit (IC), for example, an IC on a printed circuit board (PCB).

[0046] The controller 120 is operated by user manipulation of a user interface 122. The user interface 122 is located external to the body 102. The user interface 122 may include, for example, push buttons, toggle switches, dials, a touch screen, etc. In other embodiments, the user interface 122 may be remote and may be wirelessly connected to the rest of the device, such as via Bluetooth.

[0047] A user operates the user interface 122, which enables the controller 120 to cause the power supply 114 to apply current to the conductive heater 110, which then generates heat by resistive heating.

[0048] In some examples, during use, the apparatus 100 is configured such that the conductive wire 110 heats the first zone 116 to a first zone target temperature and the second zone 118 to a second zone target temperature. The target temperature of the first zone 116 may be in a range of between about 240°C and about 300°C, such as between about 250°C and about 280°C. Similarly, the target temperature of the second zone 118 may be in a range of between about 240°C and about 300°C, such as between about 250°C and about 280°C. In some examples, the apparatus 100 is configured such that the conductive wire 110 first heats the first zone 116 to the first zone target temperature and then subsequently heats the second zone 118 to the second zone target temperature (or vice versa).

[0049] In some examples, in use, the apparatus 100 is configured such that the conductive wire 110 heats the first zone 116 to a target temperature for the first zone in a ramp-up time of between 2 and 10 seconds, such as between 2 and 5 seconds, or between 2 and 40 seconds. Similarly, in use, the apparatus 100 is configured such that the conductive wire 110 heats the second zone 118 to a target temperature for the second zone in a ramp-up time of between 2 and 10 seconds, such as between 2 and 5 seconds, or between 2 and 40 seconds.

[0050] 4 shows the device 100, as described above with reference to FIG. 1, in use with a consumable 400 inserted into the receiving portion 104. As described above, the consumable 400 is inserted into the device 100 and heated, thereby releasing (i.e., vaporizing) components present in the aerosolizable material present in the consumable 400. The end 402 of the consumable 400, in some embodiments, can function as a mouthpiece through which vaporized components from the aerosolizable material can be inhaled.

[0051] When a consumable is present in the receiving portion 104 and the control device 120 controls the power source 114 to pass current through the conductive wire 110, the heat from the conductive wire 110 heats the aerosolizable material, causing the components of the aerosolizable material to evaporate.

[0052] Figure 5 is a perspective view of another example of an apparatus 500 according to one embodiment of the present invention. The apparatus shown in Figure 5 is similar to the apparatus shown in Figure 3, but includes multiple coils, in this example a first coil 502 and a second coil 504, that define different heating zones.

[0053] The first coil 502 has a first end 502a and a second end 502b, which are electrically connected (e.g., by a crimp or solder joint) to a first power supply wire 506a and a second power supply wire 506b, respectively. Similarly, the second coil 504 has a first end 504a and a second end 504b, which are electrically connected (e.g., by a crimp or solder joint) to a first power supply wire 506c and a second power supply wire 506d, respectively. Each of the first coil 502 and the second coil 504 is wound around the receiving portion 104 in a helical configuration. Each of the power supply wires 506a-506d can include a conductive core covered with an electrically insulating sheath. In some examples, the insulating sheath can be formed from polyetheretherketone (PEEK).

[0054] In use, the first coil 502 is configured to heat a first heating zone of the receiving portion 104, and the second coil 504 is configured to heat a second zone of the receiving portion 104. The first heating zone can extend along the receiving portion 104 from a distal end of the receiving portion 104 to a boundary point, and the second heating zone can extend from the boundary point to a proximal end of the receiving portion 104. In some examples, the first heating zone extends a length in a range of 10-15 mm. In some examples, the second heating zone extends a length in a range of 20-30 mm.

[0055] In this example, the second coil 504 is wider than the first coil 502, which can facilitate a different heating profile for the second coil 504. For example, it may be desirable for the second coil to have a faster or slower heating profile than the first coil. A wider coil can heat up more slowly.

[0056] The ends of the first and second coils include tabs that provide space for making electrical connections (e.g., by crimp or solder joints) to a power source via power supply wires 506a-506d.

[0057] The conductive wire may be provided with any number of turns to achieve its function. For example, as can be seen in FIG. 6a, the conductive wire forms a single turn around the receiving portion to provide a cylindrical element. In this manner, the conductive wire 610 may be formed from a single sheet configured to wrap around a receiving portion, such as receiving portion 104 described above. Thus, as can be seen in FIG. 6b, the conductive wire 610 may be given a simple shape, such as a rectangle or square, with a given thickness that can be bent, wrapped, or otherwise placed around the receiving portion. The conductive wire 610 may be given dimensions x and y so that it can be wrapped around a desired amount of the receiving portion without forming a complete cylinder, thus providing a gap 620 between the ends of the conductive wire 610. Such gap 620 prevents an electrical connection / short circuit between the ends of the conductive wire 610.

[0058] Alternatively, such a single-turn conductive wire 610 may define the receiving portion itself, without the need for a separate receiving portion disposed between the conductive wire and the space to receive the consumable. Again, such an embodiment may improve the transfer of thermal energy from the conductive wire 110 to the aerosolizable material within the received consumable. Omission of a separate receiving portion may advantageously reduce the overall thermal mass of the device, thereby allowing the consumable, including the aerosolizable material to be heated, to heat more quickly.

[0059] In such cases, as can be seen in FIG. 7 , the single-turn conductive wire may be provided with an external support structure 730. In this manner, the outwardly facing surface of the conductive wire 610 may be supported and / or mounted to the inner surface of the support structure 7300, such that the conductive wire 610 and support structure 730 form a heating chamber without the need for a separate, thermally conductive internal support. One such means of holding the conductive wire 610 in place within the opening 740 of the support structure 730 is to rely on the inherent resilience of the conductive wire 610, which biases the wire inside the opening 740 of the support structure 730. Additionally, to maintain the gap 620 provided by the single-turn conductive wire 610 when bent in place, the support structure may be provided with protrusions 750, which form a physical barrier between the ends of the conductive wire 610. Advantageously, such protrusions may also serve as support for positioning the received consumable. In this manner, consumables introduced through the opening 740 into the receiving portion defined by the conductive wire 610 can be kept out of direct contact with the conductive wire 610 .

[0060] In some embodiments, the support structure 730 may be made of a material that can withstand the temperatures required to vaporize one or more components of the aerosolizable material. For example, the support structure may be made of a plastic material and may include PEEK. Additionally or alternatively, the support structure may include a ceramic material.

[0061] Alternatively, the conductive wire may include more than two turns, such as two turns as seen in conductive wire 810 in FIG. 8a, three turns as seen in conductive wire 811 in FIG. 8b, or more turns as seen in FIGS. 1-5. When more than two turns are provided, each turn of the coil is electrically isolated from adjacent turns. In such embodiments, each turn of the coil is separated from adjacent turns by an air gap. In some embodiments, the coil may be surrounded by a dielectric material.

[0062] Conductive wires such as those discussed herein need not necessarily be provided as substantially cylindrical heaters, and it will be appreciated that such conductive wires may be used as flat, planar heaters configured to heat a desired planar area.

[0063] The conductive wire can be sized to provide desired heating characteristics when an electric current is passed through it. Essentially, the heating rate of the conductive wire is governed by the resistance of the conductive wire, which can be calculated using the following formula: R=ρl / A Equation 1

[0064] where R is the resistance of the conductive wire, ρ is the resistivity of the conductive wire material, l is the length of the wire, and A is the cross-sectional area of ​​the wire. For a conductive wire of substantially rectangular cross section, the cross-sectional area is given by the thickness of the wire multiplied by the width of the wire.

[0065] Using Equation 1, for a known material with a known resistivity, it is possible to modify the shape and thickness of the conductive wire to provide the desired resistance, and modify the coverage of the conductive wire in the associated area to be heated. For example, it may be desired that the resistance of the conductive wire be approximately 0.3 Ω to provide a desired heating rate while still being operable by the device's power supply. From this, it is possible to design the configuration of the conductive wire.

[0066] As will be appreciated, providing a thinner conductive wire allows for the conductive wire to have a smaller thermal mass and therefore heats up faster, resulting in the fastest heating of a consumable placed within the conductive wire, however, a thicker conductive wire may be easier to manufacture and more robust.

[0067] Based on these parameters, a conductive wire can be designed to provide its desired properties. For example, a single-turn conductive wire 610 can be given a desired width and length (a and b) as seen in FIG. 6b, and a desired thickness to provide a given resistance while covering a desired area. A two-turn or three-turn conductive wire can be designed to cover a desired area using conductive wires 810, 811 with widths c or d and corresponding thicknesses.

[0068] One such means of providing the desired resistivity from a thicker material may be to utilize one or more traces 910 as seen in Figure 9. Such trace(s) may be designed to provide a suitable heated area (or areas), i.e., the area of ​​the trace, by rearranging Equation 1. For example, a thickness of about 100 mm 2 It may be desired to heat an area of, for which different dimensions e, f and g can be calculated. Such conductive wire may be used in a planar heater or may be wrapped around a consumable as described above.

[0069] As mentioned above, the conductive wires 110, 610, 810, 811, 911 may be formed of a metallic material. For example, the conductive wires may include one or more of aluminum, copper, manganin, steel, constantan, nichrome, stainless steel, nickel, and fecralloy®. In other embodiments, the conductive wires 110, 610, 810, 811, 911 may be formed of a ceramic material. However, it has been found that it may be beneficial to provide the conductive wires with a material having a relatively high resistivity. This allows the geometry of the conductive wire to be reduced to provide the desired resistance, thus allowing for a shorter and thinner heater compared to wires made of a material with a lower resistivity. For example, a desired minimum resistivity may be 0.9 ohms mm 2 / m. This is particularly beneficial in the field of tobacco heating products, as it allows for the use of smaller consumables. Similarly, it may be desirable for the resistivity not to be too high, as this makes it more difficult to power effectively using a power source. Thus, a desired maximum resistivity is 1.6 or 1.5 ohm mm. 2 / m. A non-exhaustive list of materials falling within this desired range is provided below in Table 1. [Table 1]

[0070] It is also desirable for the thermal coefficient of resistance to be as low as possible, meaning that the resistivity of the material does not change with temperature. For example, fecralloy® may be particularly desirable because its thermal coefficient of resistance is on the order of 0.0001 Ω / K.

[0071] As will be appreciated, all of the conductive wires described above may also be found in configurations similar to that of Figure 5, where multiple heating zones are provided by multiple coils. Taking the example of Figure 5, the first coil 502 and / or the second coil 504 may be provided by single-turn configurations, such as the conductive wire 610 of Figure 6, connected in the same manner as discussed above with respect to Figure 5. Similarly, the first coil 502 and the second coil 504 may be formed by conductive wires of different lengths, number of turns, widths, and thicknesses depending on the desired heating profile of each of those heating zones.

[0072] When multiple heating zones are provided, it may be beneficial to provide the receiving portion 1004, 1005 with several different corresponding thermally independent zones HZ1 and HZ2 to prevent heat from flowing between the individual zones. For example, the first coil 502 may be disposed around HZ1, and the second coil 504 may be disposed around HZ2. The length x of HZ1 and the length v of HZ2 may be different to correspond to the respective lengths of the first coil 502 and the second coil 504.

[0073] As can be seen in FIG. 10 , HZ1 and HZ2 of receiving portion 1004 can be spaced apart by thermal stopper 1006. Thermal stopper 1006 can be made from a material with a significantly low thermal conductivity so that heat does not flow between HZ1 and HZ2, thereby keeping these zones thermally independent. This effectively creates two separate heating zones that independently heat two sections of the consumable provided inside the receiving portion. HZ1 and HZ2 can be made from the same material or different materials. For example, HZ1 and HZ2 can be made from anodized aluminum or high-carbon steel, while thermal stopper 1006 can be made from PEEK. Thermal stopper 1006 should be as thin as possible while still providing relative thermal independence between HZ1 and HZ2. For example, thermal stopper 1006 can have a width w of 1 mm, which, combined with width u of HZ1 and width v of HZ2, forms overall length z of receiving portion 1004. HZ1, HZ2, and thermal stopper 1006 may be provided together by any suitable connection. For example, thermal stopper 1006 may be held in place by holding HZ1 and HZ2 in position so that HZ1 and HZ2 hold thermal stopper 1006 in compression therebetween. Additionally or alternatively, there may be a mechanical connection between HZ1, HZ2, and thermal stopper 1006. Such a configuration allows for the use of highly thermally conductive materials throughout receiving portion 1004 and physically blocks heat from flowing away, thereby creating completely independent heating zones.

[0074] Alternatively, as can be seen in FIG. 11 , HZ1 and HZ2 of receiving portion 1104 may not be spaced apart but may be provided together. In this embodiment, HZ1 may be provided with a material having a relatively high level of thermal conductivity, while HZ2 may be provided with a material having a relatively low level of thermal conductivity. For example, HZ1 may be made of anodized aluminum, while HZ2 may be made of mild steel or high-carbon steel. HZ1 may be provided with a width x, and HZ2 may be provided with a width y, to form a total length z capable of receiving a consumable. In such a case, HZ1 may be designed to enable the fastest time to first puff of the received consumable with minimal energy usage, while HZ2 may be designed to promote a separate zone that takes longer to reach temperature to extend life. Acceptably, because there is no thermal stop between HZ1 and HZ2 of receiving portion 1014, a limited amount of heat will flow between these portions, but this will be mitigated by the relative difference in thermal conductivity between HZ1 and HZ2. Again, HZ1 and HZ2 may be coupled in any suitable manner. For example, HZ1 and HZ2 may simply be held in compression, or alternatively, overlapping portions may be provided and then welded, e.g., HZ1 and HZ2 may be laser welded together. Such a configuration allows the entire receiving portion to be used to heat a consumable provided therein.

[0075] As shown in FIG. 12 , a consumable, generally designated 1200, may be provided for use in a tobacco heating device (not shown). The consumable 1200 may include a trace disposed on a backing sheet 1203. The trace may, for example, include a material that conducts electrical current when placed in a tobacco heating device (not shown). The trace may include a current inlet 1201, a central portion 1204, and a current outlet 1202. It is envisioned that when the consumable 1200 is placed in a tobacco heating device, the current inlet 1201 and the current outlet 1202 would connect to the tobacco heating device such that electrical current can flow through the trace and heat the consumable 1200. The central portion 1204 of the trace may include a planar aerosolizable material 1205 that is to be ingested by a user during use. For example, the aerosolizable material 1205 may be in the form of an aerosolizable gel or tightly packed powder provided in the central portion 1204 of the trace.

[0076] 12, the central portion 1204 of the trace and the aerosolizable material 1205 are disk-shaped. However, it is envisioned that any shape, such as a rectangle, square, triangle, etc., may be used for the consumable 1200. The backing sheet 1203 on which the trace and the aerosolizable material 1205 are provided is, by way of example, cardboard or paper. Of course, any other material that does not conduct electrical current may be used for the backing sheet 1203.

[0077] In the example shown in FIG. 12, one conductive trace is shown on the consumable. However, it is envisioned that there may be two or more traces that are independently operable and configured to heat portions of the aerosolizable material. In one example, there may be two or more central portions that heat two or more portions of the aerosolizable material. Additionally or alternatively, when there are two or more traces, each trace may be configured to heat a separate respective portion of the aerosolizable material. For example, there may be three disc-shaped traces that heat three corresponding disc-shaped portions of the aerosolizable material.

[0078] The trace (or traces) including the current inlet 1201, current outlet 1202, and center portion 1204 may be formed from a metallic material such as aluminum, copper, manganin, steel, constantan, nichrome, stainless steel, nickel, fecralloy®, etc. The desired minimum resistivity is 0.9 ohms mm 2 Preferably, the maximum desired resistivity may be 1.6 or 1.5 ohms mm 2 / m. A non-exhaustive list of materials falling within this desired range is presented above in Table 1.

[0079] An alternative to the consumable 1200 is shown in Figure 13. As shown in Figure 13, a trace including a current inlet 1301, a current outlet 1302, and a receiving portion 1304 is provided in a tobacco heating device (not shown). The removable consumable 1300 may include a backing sheet 1303 and a planar aerosolizable material 1305 attached to the backing sheet 1303. The receiving portion 1304 of the trace within the tobacco heating device is configured to receive the removable consumable 1300, i.e., the backing sheet 1303 and the planar aerosolizable material 1305 may be received by the receiving portion 1304 of the trace within the tobacco heating device. When the removable consumable 1300 is inserted into the tobacco heating device, an electric current may flow from the current inlet 1301 to the receiving portion 1304 to heat the aerosolizable material 1305 for ingestion.

[0080] 13, the trace receiving portion 1304 and the aerosolizable material 1305 may be disk-shaped. However, it is envisioned that any shape, such as a rectangle, square, triangle, etc., may be used for the consumable 1300 or the trace receiving portion 1304. The backing sheet 1303 on which the aerosolizable material 1305 is provided is, by way of example, cardboard or paper. Of course, any other material that does not conduct electrical current may be used for the backing sheet 1303.

[0081] In the example shown in Figure 13, one conductive trace for a tobacco heating device is shown. However, it is envisioned that there may be two or more traces that are independently operable and configured to heat portions of the aerosolizable material. In one example, there may be two or more receiving portions that heat two or more portions of the aerosolizable material. The trace (or traces) including the current inlet 1301, current outlet 1302, and receiving portion 1304 may be formed from a metallic material such as aluminum, copper, manganin, steel, constantan, nichrome, stainless steel, nickel, fecralloy®, etc. A desired minimum resistivity is 0.9 ohms mm 2 Preferably, the maximum desired resistivity may be 1.6 or 1.5 ohms mm 2 / m. A non-exhaustive list of materials falling within this desired range is presented above in Table 1.

[0082] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided as merely representative samples of embodiments and are not intended to be exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An apparatus configured to heat an aerosolizable material to vaporize at least one component of the aerosolizable material, comprising: a conductive wire configured to generate heat for transfer to the aerosolizable material in response to application of an electric current; The conductive wire has a resistance of 0.9 ohm mm ２ / m to 1.6 ohm mm ２ / m.

2. a receiving portion configured to receive a consumable product containing the aerosolizable material; The device of claim 1 , wherein the conductive wire is disposed around the receiving portion.

3. The device of claim 2 , wherein the receiving portion is a tube configured to receive a cylindrical consumable containing the aerosolizable material.

4. 4. The device of claim 2 or 3, wherein the conductive wire is helically disposed around the receiving portion.

5. 5. The device of claim 1, wherein the conductive wire comprises one or more zones including a first zone and a second zone, the first zone extending from a distal end to an intermediate portion and the second zone extending from the intermediate portion to a proximal end.

6. 10. The device of claim 1, wherein the device is a consumable product comprising a backing sheet, the conductive wires being attached to the backing sheet, and the aerosolizable material being disposed on the conductive wires.

7. The device of claim 6 , wherein the conductive wire comprises a current inlet, a central portion, and a current outlet.

8. The device of claim 7 , wherein the aerosolizable material is disposed in the central portion.

9. An apparatus according to any one of claims 6 to 8, wherein the backing sheet is formed from card or paper.

10. 10. The device of any one of claims 7 to 9, wherein the central portion is disc-shaped and the aerosolizable material is disc-shaped.

11. The device of claim 1 , wherein the conductive wire includes a current inlet, a receiving portion, and a current outlet.

12. The device of claim 11 , wherein the receiving portion is adapted to receive a consumable product containing the aerosolizable material.

13. 13. The device according to claim 11 or 12, wherein the receiving portion is disc-shaped.

14. 10. The device of claim 1, wherein the conductive wire is formed from at least one of Fecralloy®, Nichrome, Alkrothal®, Kanthal®, and Nikrothal®.

Images