Non-combustible aerosol system and pre-aerosol formulation housing

Abstract

To provide a non-combustible aerosol device.SOLUTION: A non-combustible aerosol system includes a heater 148 and a housing 115. The heater is configured to supply heat to a heating chamber in an aerosol forming device. The housing is configured to be inserted into the heating chamber, defines an internal volume for containing a solid substrate, and includes a plurality of internal structures 220. The internal structures extend from a first end of the housing to a second end of the housing, extend through the internal volume, and is configured to heat the solid substrate to generate aerosol by conducting the heat supplied by the heater to the internal volume.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims priority under 35 U.S.C. § 119(e) to U.S. Application No. 16 / 251,452, filed January 18, 2019, the entire contents of which are incorporated herein by reference. [Background technology]

[0002] At least one example embodiment relates generally to non-flammable aerosol devices.

[0003] A non-combustion aerosol device may be equipped with a heater that heats a solid substrate, such as tobacco, without causing the solid substrate to burn.

[0004] The non-flammable aerosol device includes a power source, such as a rechargeable battery, disposed within the device, the battery being electrically connected to a heater such that the heater heats the solid substrate. Summary of the Invention

[0005] A non-flammable aerosol system provided by some example embodiments includes a heater configured to supply heat to a heating chamber and a housing configured to be inserted into the heating chamber, the housing defining an interior volume for containing a solid substrate.

[0006] In some example embodiments, the tobacco material may include material from any member of the Nicotiana genus. Also, in some example embodiments, the tobacco material may include a blend of two or more different tobacco varieties. Examples of tobacco materials that may be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, and blends thereof. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco material such as expanded tobacco or puffed tobacco, processed tobacco stems such as cut rolls or cut puffed stems, reconstituted tobacco material, and blends thereof. In some example embodiments, the tobacco material is in the form of a substantially dried tobacco mass.

[0007] In some example embodiments, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, subcombinations thereof, and combinations thereof.

[0008] The housing includes a plurality of internal structures extending from a first end of the housing to a second end of the housing, the plurality of internal structures extending through the internal volume, and the plurality of internal structures configured to heat the solid substrate to generate an aerosol by conducting heat supplied by the heater to the internal volume.

[0009] In some example embodiments, the housing further includes a first plate defining a first end of the housing and a second plate defining a second end of the housing, the first end and the second end of the housing being located on opposite sides of the housing.

[0010] In some example embodiments, the first plate and the second plate are of a first material, the plurality of internal structures are of a second material, and the first material and the second material are different.

[0011] In some example embodiments, the first plate, the second plate, and the plurality of internal structures are the same material.

[0012] In some example embodiments, the housing further includes an outer wall defining an interior volume, the outer wall being one of solid and mesh.

[0013] In some example embodiments, the outer wall is solid and the non-flammable aerosol system includes a piercing element configured to pierce the housing and create an outlet for the aerosol.

[0014] In some example embodiments, the outer wall is a mesh and provides an aerosol exit.

[0015] In some example embodiments, the housing further includes a first plate defining a first end of the housing and a second plate defining a second end of the housing, the first and second ends of the housing being located on opposite sides of the housing, and the outer wall extending from the first plate to the second plate.

[0016] In some example embodiments, the housing is cylindrical.

[0017] In some example embodiments, the non-flammable aerosol system is configured to not supply electrical current to the enclosure.

[0018] In some example embodiments, the solid substrate comprises at least one of tobacco leaf, reconstituted tobacco, compressed tobacco rods, powdered tobacco, subcombinations thereof, and combinations thereof.

[0019] In some example embodiments, the non-flammable aerosol system further includes a first outlet on a first side of the aerosol-forming device and a second outlet on a second side of the aerosol-forming device.

[0020] In some example embodiments, the second outlet is a one-way valve.

[0021] In some example embodiments, the internal structures are of different materials.

[0022] In some example embodiments, the plurality of internal structures extend transversely to the longitudinal axis of the aerosol-forming device.

[0023] In some example embodiments, the non-flammable aerosol system further includes a first plate defining a first end of the housing and a second plate defining a second end of the housing, the first end and second end of the housing being located on opposite sides of the housing, and the plurality of internal structures extending from the first plate to the second plate.

[0024] At least one example embodiment includes a method of operating a non-combustible aerosol system, the method having an inserting step and an activating step, wherein the inserting step inserts a housing into a non-combustible aerosol device, the housing defining an interior volume for containing a solid substrate and including a plurality of interior structures extending from a first end of the housing to a second end of the housing and extending through the interior volume and configured to conduct heat provided by a heater to the interior volume to heat the solid substrate and generate an aerosol, and the activating step activates the non-combustible aerosol device. [Brief explanation of the drawings]

[0025] Various features and advantages of the non-limiting embodiments herein may become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the scope of the claims. The accompanying drawings should not be considered to be drawn to scale unless specifically noted. Various dimensions of the drawings may be exaggerated for clarity.

[0026] [Figure 1]FIG. 1 is a side view of a non-flammable aerosol system according to some example embodiments.

[0027] [Figure 2] FIG. 2 illustrates a pre-aerosol formulation housing, according to some example embodiments.

[0028] [Figure 3] FIG. 3 is a cross-sectional view of the non-flammable aerosol system of FIG.

[0029] [Figure 4] FIG. 4 illustrates a pre-aerosol formulation housing, according to some example embodiments.

[0030] [Figure 5] FIG. 5 is a side view of a non-flammable aerosol system using the pre-aerosol formulation enclosure of FIG. 4 according to some example embodiments.

[0031] [Figure 6] FIG. 6 is a cross-sectional view of the non-flammable aerosol system of FIG.

[0032] [Figure 7A] FIG. 7A illustrates several example embodiments of a pre-aerosol formulation housing. [Figure 7B] FIG. 7B illustrates some example embodiments of a pre-aerosol formulation housing. [Figure 7C] FIG. 7C illustrates some example embodiments of a pre-aerosol formulation housing.

[0033] [Figure 8] FIG. 8 is a side view of a non-flammable aerosol system according to some example embodiments.

[0034] [Figure 9] FIG. 9 is a cross-sectional view of the non-flammable aerosol device of FIG.

[0035] [Figure 10] FIG. 10 is a diagram illustrating a method of operation of a non-flammable aerosol system, according to some example embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0036] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely exemplary for purposes of describing one embodiment of the present invention. The exemplary embodiments, however, may be embodied in many alternative forms and should not be construed as limited to only the embodiments set forth herein.

[0037] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, embodiments thereof are shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed, but on the contrary, the exemplary embodiments are intended to cover all modifications, equivalents, and alternatives falling within the scope of the exemplary embodiments. Reference numerals refer to the same elements throughout the description of the figures.

[0038] When an element or layer is referred to as "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, it should be understood that it may be directly on, connected to, coupled to, attached to, adjacent to, or covering the other element or layer, and that intervening elements or layers may be present. In contrast, when an element is referred to as "directly on," or "directly connected to," or "directly coupled to," another element or layer, there are no intervening elements or layers. Reference numerals refer to the same elements throughout the specification. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0039] While terms such as first, second, third, etc. are used herein to describe various elements, components, regions, layers, and / or sections, it should be understood that these elements, components, regions, layers, and / or sections are not limited by these terms. These terms are merely used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section described below could be a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0040] Additionally, spatially relative terms (e.g., "beneath," "below," "lower," "above," "upper," etc.) are readily used herein to describe the relationship of one element or feature to another element or feature as shown in the figures. It should be understood that spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the figures. For example, if a device in the figures were turned over, elements described as "below" or "beneath" the other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" encompasses both an orientation above and below. The device may be oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0041] Additionally, the terminology used herein is for the purpose of describing various embodiments only and is not intended to limit example embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. "Includes," "including," "comprises," and / or "comprising," as used herein, are understood to specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups.

[0042] Additionally, when the terms "about" and "substantially" are used herein in connection with numerical values, unless expressly defined otherwise, the associated numerical value is intended to include a tolerance of ±10% of the stated numerical value.

[0043] Furthermore, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments belong. Terms, including words defined in commonly used dictionaries, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art. Furthermore, unless defined herein, such terms should not be interpreted in an idealized or overly formal sense.

[0044] Additionally, the hardware may be implemented using processing or control circuitry such as, but not limited to, one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field programmable gate arrays (FPGAs), one or more systems-on-chips (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application specific integrated circuits (ASICs), or other devices capable of responding to and executing instructions in a defined manner.

[0045] Aerosol, vapor, and dispersion are terms used interchangeably and are meant to encompass any substance produced or output by the claimed devices and equivalents thereof. A pre-aerosol formulation may be a pre-vapor formulation or a pre-dispersion formulation.

[0046] Figure 1 is a side view of a non-combustion aerosol system according to at least one example embodiment. As shown in Figure 1, the non-combustion aerosol system 10 includes a non-combustion aerosol device 100 and a pre-aerosol formulation housing 200. The pre-aerosol formulation housing 200 may contain a solid substrate pre-aerosol formulation (referred to as a tobacco housing in example embodiments using tobacco).

[0047] Non-combustible aerosol device 100 may include a power supply section 105 and a heating section 110. As shown in Figure 1, non-combustible aerosol device 100 includes a housing 115. In at least one example embodiment, housing 115 may have a generally square cross-section. In other example embodiments, housing 115 may have a generally triangular or circular cross-section.

[0048] As shown, the power supply unit 105 and the heating unit 110 are integral parts of the housing 115. However, it should be understood that example embodiments are not limited in this respect, and the power supply unit 105 and the heating unit 110 may have separate, removable housings. For example, the heating unit 110 may be a replaceable cartridge, and the power supply unit 105 may be a reusable battery unit. Additionally, the power supply unit 105 and the heating unit 110 may be coupled by any type of connector, such as a snap fit, a detent, a clamp, a bayonet, and / or a clasp.

[0049] The housing 115 extends longitudinally between a first end 130 and a second end 132 .

[0050] At least one air inlet 120 extends through a portion of the housing 115. In at least one example embodiment, the at least one air inlet 120 may be formed in the housing 115 to control the resistance to draw (RTD) during use. In at least one example embodiment, the air inlets 120 may be machined into the housing 115 with precision tooling so that their diameters are tightly controlled and can be replicated from one non-flammable aerosol device 100 to the next during manufacturing.

[0051] In at least one example embodiment, the air inlet 120 may be sized and configured such that the non-flammable aerosol device 100 has a desired resistance-to-draw (RTD) range of 20-150 mm of water.

[0052] The non-combustible aerosol device 100 includes a mouthpiece 125 at a first end 130 of the non-combustible aerosol device 100. As shown in Figure 1, the heating unit 110 is at a proximal end 135 of the non-combustible aerosol device 100 (opposite to the mouthpiece 125), and the power supply unit 105 is at a distal end 134 of the non-combustible aerosol device 100 (opposite to the mouthpiece 125).

[0053] At least one side of the housing 115 of the heating section 110 defines an opening 140 to the channel space within the housing 115 of the non-combustible aerosol device 100. In some example embodiments, the opening 140 may have the same shape as the pre-aerosol formulation housing 200. While the opening 140 is illustrated as being oval, example embodiments are not limited thereto. For example, the opening 140 may be circular, rectangular, triangular, or other polygonal.

[0054] The opening 140 may be configured to receive the pre-aerosol formulation housing 200 in the channel space of the non-combustible aerosol device 100 .

[0055] FIG. 2 illustrates an example embodiment of a pre-aerosol formulation housing 200. The cross-sectional shape of the pre-aerosol formulation housing 200 may have the same shape as the opening 140 and may have an outer diameter corresponding to the diameter 142 of the opening 140. As shown in FIG. 2, the pre-aerosol formulation housing 200 is an enclosed capsule and includes a first plate 205, a second plate 210, and a lateral outer wall 215. The outer wall 215, the first plate 205, and the second plate 210 form the enclosed capsule. The pre-aerosol formulation housing 200 may be cylindrical, where the first plate 205 and the second plate 210 are circular ends of the pre-aerosol formulation housing 200. The outer wall 215 extends from the first plate 205 to the second plate 210 and defines an interior volume V having a diameter corresponding to (e.g., the same as) the diameters of the first plate 205 and the second plate 210. The outer wall 215 prevents the pre-aerosol formulation from escaping from the pre-aerosol formulation housing 200 by enclosing the interior volume V between the first plate 205 and the second plate 210 .

[0056] A flexible material, such as a polymer, can be used for the first plate 205 and second plate 210 of the pre-aerosol formulation housing 200 and the opening 140 that forms a seal when the pre-aerosol formulation housing 200 is inserted into the housing 115.

[0057] A plurality of internal structures 220 extend from the first plate 205 to the second plate 210. In some example embodiments, the internal structures 220 are elongated and have a longitudinal direction that is transverse to the airflow direction when inserted into the housing 115. In the example embodiment shown in FIG. 2 , the internal structures 220 have a square cross-section. However, the internal structures 220 may have any cross-sectional shape, such as rectangular, oval, circular, etc. Additionally, each of the internal structures 220 may have a different cross-sectional shape.

[0058] Internal structure 220 is made of a material that conducts heat to heat the pre-aerosol formulation in pre-aerosol formulation housing 200 without combustion occurring. For example, heater (e.g., as shown in FIG. 3) and pre-aerosol formulation housing 200 are configured to heat the pre-aerosol formulation to a temperature in the range of 100-350°C to generate an aerosol. Internal structure 220 creates more surface area contact with the pre-aerosol formulation, improving heating efficiency of the pre-aerosol formulation.

[0059] The pre-aerosol formulation housing 200 may be made of any material capable of conducting heat. In some example embodiments, the pre-aerosol formulation housing 200 may be made of metal and may therefore be referred to as a metal housing. The internal structure 220 may be made of the same material as the first plate 205, the second plate 210, and the outer wall 215, or may be made of a different material. Furthermore, the internal structures 220 may all be made of the same material, or at least one of the internal structures 220 may be made of a different material than the remaining internal structures.

[0060] The internal structure 220 is attached to the first plate 205 and the second plate 210 by any means that allows the internal structure 220 to sufficiently conduct heat from the first plate 205 and the second plate 210, such as, for example, soldering, welding, or a male / female friction fit connection.

[0061] For example, the internal structure 220 may be made of a pure metal, an alloy, and / or a polymer.

[0062] The diameter 225 of the first plate 205 and the second plate 210 can be between 1 and 20 millimeters, and the width 227 of the pre-aerosol formulation housing 200 can be between 1 and 20 millimeters. In some example embodiments, the width 227 is transverse to the longitudinal axis of the non-flammable aerosol device 100. The width 227 can be the same as or less than the length of the chamber 144.

[0063] 2, the outer wall 215 is, in some example embodiments, but not limited to, a mesh. When the outer wall 215 is a mesh, the generated aerosol may escape from the pre-aerosol formulation housing 200 through holes in the mesh and flow to the mouthpiece 125.

[0064] The pre-aerosol formulation housing 200 may contain a pre-aerosol formulation, with the first plate 205, the second plate 210 and the outer wall 215 configured to conduct heat from the heater 148 to heat the pre-aerosol formulation.

[0065] FIG. 3 is a cross-sectional view of a non-flammable aerosol device 10 according to some example embodiments. As shown in FIG. 3, an opening 140 may be configured to receive a pre-aerosol formulation housing 200 in a channel space of the non-flammable aerosol device 100. The pre-aerosol formulation housing 200 may have the same shape as the opening 140 and may have an outer diameter corresponding to the diameter 142 of the opening 140. In some example embodiments, the pre-aerosol formulation housing 200 has an outer diameter smaller than the diameter 142 so that the pre-aerosol formulation housing 200 can be inserted into the opening 140. While the pre-aerosol formulation housing 200 is illustrated as having an oval cross-section (a cut perpendicular to the longitudinal axis of the pre-aerosol formulation housing 200), example embodiments are not limited thereto. For example, the pre-aerosol formulation housing 200 may have a cross-section that is circular, rectangular, triangular, or other polygonal.

[0066] Opening 140 provides access to chamber 144. In some example embodiments, chamber 144 has the same shape as opening 140. The diameter of chamber 144 may be the same as diameter 142. To provide a specific size and secure fit between pre-aerosol formulation housing 200 and chamber 144, a seal is formed between housing 115 and pre-aerosol formulation housing 200. The seal may also be formed by spring-loaded plates (not shown) on the front and back of chamber 144 that provide pressure on the front and back of pre-aerosol formulation housing 200 when pre-aerosol formulation housing 200 is inserted.

[0067] In some example embodiments, the end of the pre-aerosol formulation housing 200 may be exposed to ambient air when inserted into the non-flammable aerosol device 100. Alternatively, the non-flammable aerosol device 100 may include a cover that covers the opening 140 when the pre-aerosol formulation housing 200 is inserted into the non-flammable aerosol device 100. The cover may be a hinged, sliding, spring-loaded, or other type of cover.

[0068] In some example embodiments, the housing 115 may include an opening opposite the opening 140 on the side opposite the opening 140. In other example embodiments, the side opposite the opening 140 does not have an opening.

[0069] The pre-aerosol formulation housing 200 may be inserted into the channel space defined by the chamber 144 through the opening 140 such that the pre-aerosol formulation housing 200 is exposed to heat generated by the heater 148. In some example embodiments, the pre-aerosol formulation housing 200 does not contact a heat source, such as the heater 148 and / or an electrical source. Rather, the pre-aerosol formulation housing 200 is made of a material that conducts the heat generated from the heater 148 and heats the pre-aerosol formulation 202 (e.g., tobacco) within the pre-aerosol formulation housing 200; therefore, no electrical heating of the pre-aerosol formulation housing 200 occurs.

[0070] The pre-aerosol formulation housing 200 may conduct heat generated by the heater 148 to the pre-aerosol formulation 202 to an extent that the flavoring, nicotine, and / or ingredients contained in the pre-aerosol formulation 202 are at least partially extracted (e.g., aerosolized) to generate a downstream aerosol 350b (and bypass airflow 355, which may contain the aerosol) that is extracted from the pre-aerosol formulation 202. The pre-aerosol formulation housing 200 heats the pre-aerosol formulation 202 to an extent that the pre-aerosol formulation 202 and the flavoring, nicotine, and / or pre-aerosol formulation remain below combustion temperatures. That is, in some example embodiments, the pre-aerosol formulation housing 200 does not combust any materials in the pre-aerosol formulation 202, including the flavoring, nicotine, and / or pre-aerosol formulation.

[0071] As described above, the pre-aerosol formulation housing 200 includes at least an outer wall 215 and an internal structure 220 that conducts heat to heat the pre-aerosol formulation 202. Although the internal structure 220 is illustrated as being transverse to the longitudinal axis of the non-combustion aerosol device 100, example embodiments are not limited in this respect, and the internal structure 220 may be parallel to the longitudinal axis of the non-combustion aerosol device 100.

[0072] In some example embodiments, the heater 148 contacts the pre-aerosol formulation housing 200. In other example embodiments, the heater 148 is spaced a distance from the heater 148 to generate the desired temperature.

[0073] The power supply section 105 includes a power supply 152 and a circuit board 156 disposed in the non-combustible aerosol device 100. The power supply 152 and the circuit board 156 may be mounted on a common support 160. The common support 160 is configured to fit within the housing 115 to eliminate / reduce movement of the power supply 152 and the circuit board 156 when the non-combustible aerosol device 100 is in use.

[0074] The power source 152 may be a lithium-ion battery or one of its variants, such as a lithium-ion polymer battery. Alternatively, the power source 152 may be a nickel-metal hydride battery, a nickel-cadmium battery, a lithium-manganese battery, a lithium-cobalt battery, a solar cell, or a fuel cell. The non-flammable aerosol device 100 may be used until the energy in the power source 152 is depleted or, in the case of a lithium-polymer battery, until a minimum voltage cutoff level is reached.

[0075] Circuit board 156 may include at least control circuitry 162, airflow sensor 164, and memory 165. Circuit board 156 may also include other circuitry, such as communication circuitry 166 (e.g., Bluetooth™) for wirelessly communicating with an external device such as a mobile phone. Thus, non-flammable aerosol device 100 is not limited to the circuitry shown in FIG. 3. Memory 165 (e.g., a tangible storage medium) may also be, for example, read-only memory (ROM), random access memory (RAM), or flash memory (e.g., USB flash memory, memory card, memory stick, etc.). Example embodiments are not limited by these aspects of any given embodiment.

[0076] In at least one example embodiment, control circuitry 162 may include at least one processor. In this example, the processor may be any known or later developed processor configured to execute computer-readable instructions stored in memory 165. Execution of the computer-readable instructions stored in memory 165 transforms the at least one processor into a special-purpose processor for performing the functions described herein. Memory 165 may be further configured to store various types of information related to non-flammable aerosol system 10, as described above.

[0077] Although a processor and memory have been described in some instances, according to at least some example embodiments, control circuitry 162 (or control circuitry, or processing circuitry) may be (or include) hardware, firmware, hardware executing software, or any combination thereof. For example, control circuitry 162 may include one or more central processing units (CPUs), digital signal processors (DSPs), application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or other circuitry configured as special purpose machines to perform the functions of control circuitry 162.

[0078] The control circuit 162 is connected to the power supply 152 by the cathode connector 170a and the anode connector 170b. The control circuit 162 is configured to use the power provided by the power supply 152 to power the electrical components of the non-flammable aerosol device 100 (e.g., the heater 148, the airflow sensor 164, and the memory 165).

[0079] Power supply unit 105 may be separated from heating unit 110 by divider 172. Divider 172 may be a gasket (or seal) that provides a substantially tight seal with the interior surface of housing 115. Divider 172 includes a channel 174 disposed between power supply unit 105 and heating unit 110 and can apply a negative pressure within power supply unit 105 when air is drawn through air inlet 120 (e.g., when air is drawn through outlet 176 of mouthpiece 125).

[0080] Divider 172 may also include holes 178a and 178b. Holes 178a and 178b are sized to fit wires 180a and 180b. In other example embodiments, electrical contacts may be used in place of wires 180a and 180b. Holes 178a and 178b may be sized to prevent air from flowing between power supply unit 105 and heating unit 110 through holes 178a and 178b. In other example embodiments, holes 178a and 178b may have seals to prevent air from flowing between power supply unit 105 and heating unit 110.

[0081] The heater 148 may extend laterally through the interior passageway 182 between opposing walls of the housing 115. In some example embodiments, the heater 148 may extend parallel to the longitudinal axis of the interior passageway 182.

[0082] The power supply 105 may further include an end cap 151 at the second end 132. The end cap 151 may seal the second end 132. The end cap 151 may attach to the housing 115 using a known connection system, such as a threaded connector and / or a friction fit connection system. The end cap 151 may include electrical contacts 153a and 153b for charging the power supply 152.

[0083] In another example embodiment, the end cap 151 may be an integral part of the housing 115 .

[0084] In at least one example embodiment, power supply 152 is rechargeable. Power supply 105 may include circuitry configured to allow the battery to be recharged by an external charging device. To recharge non-flammable aerosol device 100, a USB charger or other suitable charger assembly may be used by connecting the external charger to electrical contacts 153a and 153b. Control circuit 162 is connected to electrical contacts 153a and 153b and controls the re-supply of power to power supply 152.

[0085] Heater 148 may be a wire coil, a planar body, a ceramic body, a single wire, a cage of resistive wire, or any other suitable form. Heater 148 may be any heater configured to heat the pre-aerosol formulation to a sufficient temperature to generate an aerosol.

[0086] In at least one example embodiment, the heater 148 may be formed of any suitable electrically resistive material. For example, the heater 148 may include at least one material selected from the group consisting of stainless steel, copper, a copper alloy, a nickel-chromium alloy, a superalloy, or any subcombination or combination thereof. In an example embodiment, the heater 148 may be formed of a nickel-chromium alloy or an iron-chromium alloy. In another example embodiment, the heater 148 may be a ceramic heater having an electrically resistive layer on its outer surface.

[0087] In at least one example embodiment, the heater 148 may heat the pre-aerosol formulation housing 200 by thermal conduction. Alternatively, heat from the heater 148 may be conducted to the pre-aerosol formulation housing 200 by a thermal conduction element, or the heater 148 may transfer heat to incoming ambient air that is drawn through the non-combustible aerosol device 100 during use, thereby heating the pre-aerosol formulation housing 200 by convection.

[0088] The pre-aerosol formulation housing 200 resides in or near an airflow path 350a defined by the non-combustible aerosol device 100. This airflow path 350a may be formed, for example, by the air inlet 120 and the outlet 176. The airflow path 350a may pass across the pre-aerosol formulation housing 200 or may pass directly through the pre-aerosol formulation housing 200. It should be understood that if the non-combustible aerosol device 100 includes a bypass airflow 355, this bypass airflow 355 may include entrained aerosol as it passes across an exposed surface of the pre-aerosol formulation housing 200, just as the downstream aerosol 350b (which has passed through the matrix pre-aerosol formulation housing 200) also includes aerosol.

[0089] In some example embodiments, the pre-aerosol formulation includes a plant material. For example, the plant material may include a tobacco material.

[0090] In some example embodiments, the tobacco material may include material from any member of the Nicotiana genus. Also, in some example embodiments, the tobacco material may include a blend of two or more different tobacco varieties. Examples of tobacco materials that may be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, and blends thereof. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco material such as expanded tobacco or puffed tobacco, processed tobacco stems such as cut rolls or cut puffed stems, reconstituted tobacco material, and blends thereof. In some example embodiments, the tobacco material is in the form of a substantially dried tobacco mass.

[0091] In some example embodiments, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, subcombinations thereof, and combinations thereof.

[0092] In example embodiments, a flavoring, flavoring, or flavor system is optionally included in the pre-aerosol formulation to release aroma and / or flavor during operation, including when heated and / or when airflow passes through the non-burning aerosol device 100. In example embodiments, the flavoring includes volatile tobacco flavor compounds. The flavoring may also include flavors other than tobacco or may be in addition to tobacco flavor. The flavoring may include at least one flavor that is a natural flavor or an artificial flavor. For example, the at least one flavor may include tobacco flavor, tobacco extract, menthol, wintergreen, peppermint, herbal flavor, fruit flavor, nut flavor, liquor flavor, roasted, mint, savory, cinnamon, clove, and any other desired flavor, as well as combinations or subcombinations thereof. In some example embodiments, the pre-aerosol formulation housing 200 containing the tobacco material is referred to as a tobacco element.

[0093] In operation, with non-combustible aerosol device 100 in an assembled configuration, negative pressure may be applied to mouthpiece 125. For example, negative pressure may be drawn to mouthpiece 125. This negative pressure creates an internal pressure drop within non-combustible aerosol device 100, causing inlet airflow to enter non-combustible aerosol device 100 through airflow inlet 120. The internal pressure drop may also create an internal pressure drop within heating section 110 as air is drawn through airflow inlet 120 (through the airflow path and through heating section 110).

[0094] The airflow sensor 164 may be exposed to the channel 174. In example embodiments, the airflow sensor 164 generates an output signal indicative of the magnitude and direction of the airflow 350a through the internal passageway 182, and the control circuit 162 receives the output signal from the airflow sensor 164 and determines whether the following internal conditions exist: (1) the direction of the airflow 350a indicates a retraction of the mouthpiece 125 (as opposed to a blowing of air through the mouthpiece 125), and / or (2) the magnitude of the airflow 350a exceeds a threshold value. In some example embodiments, only one condition may be sufficient to activate the heater 148, while in other examples, two or all of the conditions may need to be met before the heater is activated. If these internal conditions of the non-flammable aerosol device 100 are met, the control circuit 162 electrically closes an electrical circuit connecting the power source 152 to the heater 148, thereby sending current to the heater 148 and activating it. In the example embodiment, airflow sensor 164 generates a variable output signal that is at least partially correlated to the magnitude of the pressure drop sensed by sensor 106 .

[0095] Airflow sensor 164 may be a sensor such as that disclosed in U.S. Patent Application No. 14 / 793,453, filed July 7, 2015, entitled "Electronic Smoke Apparatus," or U.S. Patent No. 9,072,321, issued July 7, 2015, entitled "Electronic Smoke," each of which is incorporated herein by reference in its entirety. Other types of sensors that detect airflow may also be used.

[0096] In at least some example embodiments, the non-flammable aerosol device 100 may include a temperature sensor that monitors the temperature of the heater 148 and feeds the sensed temperature back to the control circuit 162. The control circuit 162 may use the sensed temperature and / or the sensed pressure drop to control the supply of power to the heater 148.

[0097] Wires 180a and 180b energize heater 148, passing an electric current through heater 148. The energized heater 148 then heats pre-aerosol formulation housing 200. First plate 205, second plate 210, outer wall 215, and internal structure 220 conduct heat from heater 148 to heat the flavor material within pre-aerosol formulation housing 200. Pre-aerosol formulation housing 200 conducts heat from heater 148 to a temperature sufficient to generate an aerosol without burning the flavor material (e.g., 100-300°C).

[0098] In another example embodiment, the non-flammable aerosol device 100 may include a push button for operating the non-flammable aerosol device 100 and for causing the power supply 152 and control circuitry 162 to provide power to the heater 148 .

[0099] The aerosol may dissolve nicotine and / or tobacco elements into the stream, and there may also be some thermal reaction between the aerosol and the tobacco elements.

[0100] Figure 4 illustrates a pre-aerosol formulation housing according to some example embodiments. As shown in Figure 4, the pre-aerosol formulation housing 200a includes an outer wall 215a that is a solid material.

[0101] In example embodiments including a pre-aerosol formulation housing 200a, the non-combustible aerosol device 100 includes a piercing mechanism that pierces at least one of the outer wall 215a, the first plate 205, and the second plate 210 in the pre-aerosol formulation housing 200a that is inserted into the non-combustible aerosol device 100. This piercing creates an outlet for the aerosol generated from the flavor material within the pre-aerosol formulation housing 200a when the pre-aerosol formulation housing 200 is heated to an aerosol-generating temperature (e.g., 100-350°C).

[0102] FIG. 5 is a side view of a non-flammable aerosol system using the pre-aerosol formulation enclosure of FIG. 4, according to some example embodiments.

[0103] FIG. 6 is a cross-sectional view of the non-flammable aerosol system of FIG.

[0104] As shown in FIG. 5, the non-flammable aerosol system 10a is the same as the non-flammable aerosol system 10, except that the non-flammable aerosol device 100a includes a button 605 at the first end 130 for activating the penetrating structure.

[0105] 6, button 605 actuates piercing structure 610 to pierce pre-aerosol formulation housing 200a. In an example embodiment, piercing structure 610 includes first piercing element 615 (e.g., a blade), second piercing element 620 (e.g., a blade), rods 625a-625c, first link 630, and second link 635.

[0106] Rod 625a extends along the longitudinal axis of non-combustible aerosol device 100a and connects button 605 and first piercing element 615. First link 630 connects rod 625a to first end 625b1 of rod 625b. First link 630 may be a pin that extends through rod 625a and rod 625b and allows rod 625b to rotate along the axis of first link 630. The axis of first link 630 about which rod 625b may rotate may be transverse to the longitudinal axis of non-combustible aerosol device 100a. In other example embodiments, first link 630 may maintain the positional relationship between rod 625a and rod 625b.

[0107] Rod 625b extends from first end 625b1 to second end 625b2 over chamber 144a. Chamber 144a may differ from chamber 144 in that chamber 144a includes two semicircular portions 632a and 632b. In at least a portion of chamber 144a along the longitudinal axis of chamber 144a, semicircular portions 632a and 632b define openings 635a and 635b between semicircular portions 632a and 632b.

[0108] Similar to rod 625b, rod 625c extends above chamber 144a from a first end 625c1 to a second end 625c2.

[0109] A second link 635 connects second end 625b2 of rod 625b and second end 625c2 of rod 625c. Second link 635 may be a pin (e.g., spring-loaded) that allows both rods 625b to rotate about second link 635. As shown in the example embodiment of FIG. 6, second piercing element 620 is integral with rod 625c. First end 625c1 is angled toward pre-aerosol formulation housing 200a so that second piercing element 620 faces pre-aerosol formulation housing 200a. However, it should be understood that example embodiments are not limited thereto.

[0110] When the aerosol adult consumer presses button 605 toward interior passageway 182, the force applied by the aerosol adult consumer causes rod 625a, more specifically, first piercing element 615, to move toward pre-aerosol formulation housing 200a and pierce wall 215a of pre-aerosol formulation housing 200a. Second link 635 allows rod 625b to rotate in direction 640. The force applied to pre-aerosol formulation housing 200a by first piercing element 615 causes pre-aerosol formulation housing 200a to move in the same direction as, or substantially similar to, the longitudinal axis of non-combustible aerosol device 100a. When the aerosol adult consumer applies force to button 605, pre-aerosol formulation housing 200a moves to second piercing element 620, which pierces pre-aerosol formulation housing 200a. The penetration by the first piercing element 615 and the second piercing element 620 creates an airflow path 650 through the pre-aerosol formulation housing 200 a to the outlet 176 .

[0111] 6 illustrates a button-activated piercing structure, but the example embodiment is not limited thereto. For example, a piercing structure that uses a lever and release spring may be used to pierce the housing of the pre-aerosol formulation.

[0112] FIG. 7A illustrates an example embodiment of a pre-aerosol formulation housing. As shown in FIG. 7A, pre-aerosol formulation housing 200b is the same as pre-aerosol formulation housing 200, except that first plate 205a and second plate 210 are mesh instead of solid. The mesh may be a screen-type material made of pure metal, metal alloy, or polymer. The hole size may range from 0.001 to 0.1 inches. Wall 215 is omitted in FIG. 7A for clarity.

[0113] 7B shows an example embodiment of a pre-aerosol formulation housing. As shown in FIG. 7B, pre-aerosol formulation housing 200c is the same as pre-aerosol formulation housing 200, except that internal structure 220a has a circular cross-section instead of a square cross-section. Wall 215 is omitted for clarity.

[0114] FIG. 7C illustrates an example embodiment of a pre-aerosol formulation housing. As shown in FIG. 7C, the pre-aerosol formulation housing 200d is the same as the pre-aerosol formulation housing 200, except that the first plate 205a and the second plate 210 are square instead of circular. For clarity, the walls 215 are omitted. The walls 215 extend around each of the four edges of the first plate 205c and the second plate 210c. The heights 225c of the first plate 205c and the second plate 210c may be between 1 and 20 millimeters.

[0115] Figure 8 is a side view of a non-combustible aerosol device according to at least another example embodiment. Figure 9 is a cross-sectional view of the non-combustible aerosol device of Figure 8.

[0116] As shown in FIG. 8, non-combustible aerosol device 10b is similar to non-combustible aerosol device 10, except that heating portion 110a of non-combustible aerosol device 100b includes olfactory port 305.

[0117] 9, olfactory port 305 is positioned above chamber 144 and pre-aerosol formulation housing 200 (when pre-aerosol formulation housing 200 is inserted into chamber 144). Olfactory port 305 extends at an angle from heating portion 110. This angle may be greater than 0 degrees and less than or equal to 90 degrees so that an adult aerosol consumer can smell the aerosol produced by non-flammable aerosol device 100b. Olfactory port 305 allows a portion of the air exposed to the flavorant within pre-aerosol formulation housing 200 to flow out of olfactory port 305, as shown by airflow 310.

[0118] In the example embodiment, olfactory port 305 is integral with housing 115a and is made from the same material as housing 115a.

[0119] In the example embodiment, the olfactory port 305 is a one-way valve so as not to affect the RTD. Additionally, the olfactory port 305 may be opened or closed as desired by an adult consumer. For example, a user interface, such as a needle valve or slide, may be attached to the housing 115a to allow the adult consumer to control the olfactory port 305.

[0120] 10 illustrates a method of operation of a non-flammable aerosol system according to at least one example embodiment. The non-flammable aerosol system may be included in any of the systems described in FIGS.

[0121] In S1005, an adult aerosol consumer inserts a pre-aerosol formulation housing into a non-combustible aerosol device. The pre-aerosol formulation housing defines an interior volume for containing the pre-aerosol formulation and includes a plurality of interior structures extending from a first end of the housing to a second end of the housing. The plurality of interior structures extend through the interior volume and are configured to conduct heat provided by a heater to the interior volume, thereby heating the pre-aerosol formulation to generate an aerosol. For example, an adult aerosol consumer may insert a pre-aerosol formulation housing 200 into a non-combustible aerosol device 100.

[0122] In S1010, the adult aerosol consumer activates the non-combustible aerosol device by applying negative pressure to the mouthpiece. This negative pressure causes a sensor to send a signal to the control circuit representing the pressure within the non-combustible aerosol device. Based on the signal, the control circuit activates the heater. The pre-aerosol formulation housing may conduct heat generated by the heater to the pre-aerosol formulation to an extent that at least partially extracts (e.g., aerosolizes) the flavoring, nicotine, and / or ingredients in the pre-aerosol formulation and generates a downstream aerosol extracted from the pre-aerosol formulation.

[0123] Finally, although various exemplary embodiments of the present invention have been described, it should be understood that these may be embodied in various other forms. Such embodiments and modifications do not depart from the spirit and scope of the invention, and are included in the scope of the invention described in the claims and their equivalents.

Claims

1. 1. A non-flammable aerosol system comprising: A heater and a housing are provided. the heater is configured to supply heat to a heating chamber in the aerosol forming device; The housing includes: configured to be inserted into the heating chamber; defining an interior volume for containing a solid substrate; It includes a plurality of internal structures, The plurality of internal structures include: extending from a first end of the housing to a second end of the housing; extending through the interior volume; configured to heat the solid substrate to generate an aerosol by conducting heat provided by the heater to the interior volume; Non-flammable aerosol system.

2. 2. The non-flammable aerosol system of claim 1, The housing includes: Further comprising a first plate and a second plate, The first plate is configured to define the first end of the housing; The second plate is configured to define the second end of the housing; the first end and the second end are located on opposite sides of the housing; Non-flammable aerosol system.

3. 3. The non-flammable aerosol system according to claim 2, the first plate and the second plate are of a first material; the plurality of internal structures are of a second material; the first material and the second material are different; Non-flammable aerosol system.

4. 3. The non-flammable aerosol system according to claim 2, the first plate, the second plate, and the plurality of internal structures are made of the same material; Non-flammable aerosol system.

5. 2. The non-flammable aerosol system of claim 1, The housing includes: Further comprising an outer wall; The outer wall is configured to define the interior volume; either solid or mesh, Non-flammable aerosol system.

6. 6. The non-flammable aerosol system according to claim 5, the outer wall is solid; The non-flammable aerosol system comprises: including a penetrating element; The piercing element comprises: configured to penetrate the housing to create an outlet for the aerosol; Non-flammable aerosol system.

7. 6. The non-flammable aerosol system according to claim 5, the outer wall is a mesh, and the outer wall provides an exit for the aerosol. Non-flammable aerosol system.

8. 6. The non-flammable aerosol system according to claim 5, The housing includes: Further comprising a first plate and a second plate, The first plate is configured to define the first end of the housing; The second plate is configured to define the second end of the housing; the first and second ends of the housing being on opposite sides of the housing; Non-flammable aerosol system.

9. 9. The non-flammable aerosol system of claim 8, The housing is cylindrical. Non-flammable aerosol system.

10. 2. The non-flammable aerosol system of claim 1, the non-flammable aerosol system is configured to not supply electrical current to the enclosure; Non-flammable aerosol system.

11. 2. The non-flammable aerosol system of claim 1, The solid substrate comprises at least one of tobacco leaf, reconstituted tobacco, compressed tobacco rod, powdered tobacco, subcombinations thereof, and combinations thereof; Non-flammable aerosol system.

12. 2. The non-flammable aerosol system of claim 1, Further comprising a sensor and a control unit, The sensor configured to detect airflow in the heating chamber; The control unit configured to power the heater based on the detected airflow. Non-flammable aerosol system.

13. 2. The non-flammable aerosol system of claim 1, The aerosol-forming device further includes a first outlet on a first side surface thereof and a second outlet on a second side surface thereof. Non-flammable aerosol system.

14. 14. The non-flammable aerosol system of claim 13, the second outlet is a one-way valve; Non-flammable aerosol system.

15. 2. The non-flammable aerosol system of claim 1, the plurality of internal structures are of different materials; Non-flammable aerosol system.

16. 2. The non-flammable aerosol system of claim 1, the plurality of internal structures extend in a direction transverse to the longitudinal axis of the aerosol-forming device; Non-flammable aerosol system.

17. 17. The non-flammable aerosol system of claim 16, The housing includes: Further comprising a first plate and a second plate, The first plate is configured to define the first end of the housing; The second plate is configured to define the second end of the housing; the first and second ends of the housing being on opposite sides of the housing; Non-flammable aerosol system.

18. 1. A method of operating a non-flammable aerosol system, comprising: An insertion step and an actuation step are included, In the inserting step, a housing is inserted into a non-flammable aerosol device; Here, the housing is defining an interior volume for containing a solid substrate; It includes a plurality of internal structures, The plurality of internal structures include: extending from a first end of the housing to a second end of the housing; extending through the interior volume; configured to heat the solid substrate to generate an aerosol by conducting heat provided by a heater to the interior volume; The activation step activates the non-flammable aerosol device. method.

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