Aerosol Delivery Device

Abstract

An aerosol delivery device 100 is disclosed that comprises an aerosol generator that comprises an inductor that comprises a plurality of separate ring electrodes 101 mounted on a first substrate 102 .

Description

[Technical field]

[0001] The present invention relates to components of an aerosol delivery device, an aerosol generator, an aerosol delivery device, an aerosol generation system, and a method for generating an aerosol.

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

[0003] Aerosol delivery systems are known that cover the aforementioned devices or products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. Often the medium used needs to be replaced or changed to provide a different aerosol for inhalation. It is known to use an induction heating system as a heater to generate an aerosol from a suitable medium. An induction heating system generally consists of a magnetic field generating device for generating a varying magnetic field and a susceptor or heating material that can be heated by the penetration of the varying magnetic field to heat the suitable medium.

[0004] Known magnetic field generating devices include induction coils. The induction coils may be formed to have an appropriate geometry to achieve the desired heating of the material. This may be achieved by winding a suitable material, such as LITZ (RTM) wire, into the desired coil shape. However, the geometry (e.g., pitch) of the coil may be unintentionally altered when the device is assembled, which may prevent the desired heating of the material from being achieved. Overview

[0005] According to one aspect, an aerosol delivery device is provided, the aerosol delivery device comprising: Aerosol generator comprising an inductor comprising a plurality of separate ring electrodes mounted on a first substrate Equipped with.

[0006] According to various embodiments, an inductor is provided, the inductor comprising a plurality of ring electrodes, which may be individually controlled or grouped into one or more groups of electrodes, and which may be mounted in a compact and robust manner to a substrate, such as a printed circuit board.

[0007] Optionally, the first substrate comprises a first printed circuit board ("PCB"). According to various embodiments, the first substrate may comprise multiple printed circuit boards.

[0008] Optionally, the ring electrodes are planar.

[0009] Optionally, the ring electrode comprises a conductive material.

[0010] Optionally, the ring electrodes comprise copper or other conductive metal.

[0011] Optionally, the ring electrodes have a rectangular, circular or polygonal cross-sectional profile.

[0012] Optionally, the ring electrodes are embedded in a matrix to form a housing.

[0013] Optionally, the matrix or housing comprises polyetheretherketone ("PEEK") or an equivalent high temperature plastic material.

[0014] Optionally, a portion of the ring electrode extends beyond the housing to form an electrical connector.

[0015] Optionally, the electrical connector is soldered or fixed to the first substrate.

[0016] Optionally, the first substrate comprises one or more connectors or pads for electrically connecting the first substrate to the second substrate.

[0017] Optionally, the second substrate comprises a second printed circuit board ("PCB").

[0018] Optionally, the plurality of separate ring electrodes comprises 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more than 20 electrodes.

[0019] Optionally, the multiple ring electrodes are arranged coaxially.

[0020] Optionally, the multiple ring electrodes are evenly spaced axially.

[0021] Optionally, the plurality of ring electrodes are grouped into at least a first group of ring electrodes and a second group of ring electrodes.

[0022] Other embodiments are envisioned in which the plurality of ring electrodes are grouped into a first group of ring electrodes and one or more further groups of ring electrodes.

[0023] Optionally, the first group of ring electrodes has a first axial spacing S1 and the second group of ring electrodes has a second, different axial spacing S2. According to an embodiment, the first axial spacing S1 may be <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm or >10 mm. Similarly, according to an embodiment, the second axial spacing S2 may be <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm or >10 mm.

[0024] Optionally, the first group of ring electrodes has a first cross-sectional profile and the second group of ring electrodes has a second, different cross-sectional profile.

[0025] Optionally, the aerosol delivery device further comprises a control device configured to supply a first voltage V1 to the first group of ring electrodes and a second, different voltage V2 to the second group of ring electrodes. According to various embodiments, the ratio V1 / V2 may be in the range of <0.5, 0.5-0.6, 0.6-0.7, 0.7-0.8, 0.8-0.9, 0.9-1.0, 1.0-1.1, 1.1-1.2, 1.2-1.3, 1.3-1.4, 1.4-1.5, or >1.5. The voltages V1 and V2 comprise AC (alternating current) voltages.

[0026] According to another aspect, there is provided an aerosol generation system, the aerosol generation system comprising: an aerosol delivery device as described above; Aerosol products and Equipped with.

[0027] According to another aspect, there is provided a method of generating an aerosol, the method comprising: inserting an aerosol production article into an inductor comprising a plurality of separate ring electrodes mounted on a first substrate; energizing an inductor; Includes.

[0028] According to another aspect, there is provided an aerosol delivery device, the aerosol delivery device comprising: an aerosol generator comprising a plurality of ring electrodes; a control device configured to independently apply one or more AC voltages to individual ring electrodes and / or groups of ring electrodes; Equipped with.

[0029] According to another aspect, there is provided an aerosol generation system, the aerosol generation system comprising: an aerosol delivery device as described above; Aerosol products and Equipped with.

[0030] According to another aspect, there is provided a method of generating an aerosol, the method comprising: Providing an aerosol generator comprising a plurality of ring electrodes; Inserting an aerosol production article into an aerosol generator; applying AC voltages to individual ring electrodes and / or groups of ring electrodes independently; Includes.

[0031] According to one aspect, an aerosol delivery device is provided, the aerosol delivery device comprising: an aerosol generator comprising a plurality of ring electrodes configured to form a plurality of independently controllable heating zones; a control device configured to independently energize the ring electrodes such that a heating profile is moved along at least a portion of the length of the aerosol generator during a session of use; and Equipped with.

[0032] A session of use may last <3 minutes, 3-4 minutes, 4-5 minutes, 5-6 minutes or >6 minutes.

[0033] Optionally, the control device is configured to apply the AC voltage to individual ring electrodes and / or groups of ring electrodes in sequence or according to a predetermined sequence.

[0034] Optionally, the aerosol delivery device comprises an opening for receiving the aerosol product, the first heating zone is disposed proximal to the opening and the second heating zone is disposed distal to the opening, and the control device (i) moving the heating profile from the first heating zone towards the second heating zone during a session of use; and / or (ii) shifting the heating profile from the second heating zone towards the first heating zone during a session of use; It is composed.

[0035] According to one aspect, there is provided a method of generating an aerosol, the method comprising: providing a plurality of ring electrodes, the ring electrodes configured to form a plurality of independently controllable heating zones; Inserting an aerosol product article into a heating zone; independently energizing the ring electrodes such that a heating profile is moved along at least a portion of the length of the aerosol generator during a session of use; Includes.

[0036] According to one aspect, a component of an aerosol delivery device is provided, the component comprising: an inductor element comprising a plurality of separate ring electrodes mounted on a substrate; A first module configured to receive a DC (direct current) voltage and output an AC current; a second module configured to supply an alternating current to selected ring electrodes; Equipped with.

[0037] According to another aspect, there is provided a component of an aerosol delivery device, the component comprising: an inductor element comprising a plurality of separate ring electrodes mounted on a substrate; a module configured to supply an alternating current to selected ring electrodes; Equipped with.

[0038] Optionally, the second module comprises a plurality of electronic switch elements, which may comprise a switch arrangement, for example comprising a pair of MOSFETs.

[0039] Optionally, at least one electronic switch element is connected to at least some of the ring electrodes.

[0040] Optionally, at least some of the switch elements are independently controllable so that an alternating current output from the first module can be applied to selected ring electrodes.

[0041] Optionally, at least some of the switch elements, or each of the switch elements, comprise a half-bridge circuit.

[0042] Optionally, at least some or each half-bridge circuit comprises two MOSFETs.

[0043] According to another aspect, there is provided an aerosol generator for an aerosol delivery device, the aerosol generator comprising: The components described above Equipped with.

[0044] According to another aspect, there is provided an aerosol delivery device, the aerosol delivery device comprising: The aerosol generator described above Equipped with.

[0045] Optionally, an alternating current supplied to one or more ring electrodes results in the generation of a varying magnetic field.

[0046] Optionally, the aerosol delivery device further comprises a controller, the controller configured to control the second module to control which ring electrodes are supplied with the alternating current.

[0047] Optionally, the aerosol delivery device further comprises a tubular susceptor located at least partially within a volume defined by the plurality of ring electrodes.

[0048] Optionally, the tubular susceptor includes one or more peripheral slots.

[0049] Optionally, the tubular susceptor comprises a plurality of annular susceptor portions, at least some of the annular susceptor portions being spaced apart from one another by one or more thermal barrier portions.

[0050] In alternative embodiments, the susceptor element may be provided as part of the aerosol product (ie, a consumable item) and therefore may not form part of the aerosol delivery device.

[0051] According to another aspect, there is provided an aerosol delivery system, the aerosol delivery system comprising: an aerosol delivery device as described above; Aerosol products and Equipped with.

[0052] The aerosol producing article comprises an aerosol forming material.

[0053] According to another aspect, there is provided a method of generating an aerosol, the method comprising: Providing an aerosol delivery device as described above; at least partially inserting an aerosol product article into an aerosol delivery device; activating an aerosol delivery device; Includes. [Brief description of the drawings]

[0054] [Figure 1] 1 illustrates an aerosol delivery device according to one embodiment, the aerosol delivery device comprising an inductor and a tubular susceptor element formed from a plurality of separate ring electrodes mounted to a first substrate comprising a printed circuit board. [Diagram 2] An aerosol generator according to one embodiment is illustrated, comprising an inductor element comprising a plurality of ring electrodes mounted on a first substrate comprising a printed circuit board, and a tubular susceptor element positioned within a volume defined by the ring electrodes. [Diagram 3]Illustrated is a cross-sectional view of an aerosol generator according to one embodiment, the aerosol generator comprising an inductor element comprising a plurality of ring electrodes mounted on a first substrate comprising a printed circuit board, and a tubular susceptor element positioned within a volume defined by the ring electrodes. [Figure 4] 1 illustrates a side view of an aerosol generator according to one embodiment, showing a connector portion of the ring electrode extending through the rear surface of the printed circuit board. [Diagram 5] 1 illustrates a side view of an aerosol generator according to one embodiment, illustrating a thermocouple connected to a susceptor element. [Figure 6] 1 illustrates a cross-sectional view of an aerosol generator according to one embodiment, illustrating two groups of ring electrodes embedded in a housing. [Figure 7] A first substrate is shown having a plurality of electrical connections arranged in two groups such that the ring electrodes connected to the electrical connections are grouped into a first group of ring electrodes and a second group of ring electrodes. [Figure 8] 1 illustrates in more detail the first substrate and two groups of electrical connections provided thereon. [Figure 9] A control device is shown on a second substrate connected to a first substrate, with ring electrodes connected to electrical connections on the first substrate grouped into two groups of ring electrodes. [Figure 10] A schematic of the electronic components of an aerosol delivery device is illustrated, including an inductor element comprising a plurality of separate ring electrodes, a first module for converting a DC voltage to an AC voltage, and a second module comprising a plurality of semiconductor switches (e.g., MOSFETs) configured to independently select which ring electrodes receive the AC voltage. [Figure 11] 1 illustrates a schematic of an electrical configuration of a component of an aerosol delivery device that may be used to apply an AC voltage to a group of ring electrodes. [Figure 12]1 illustrates a schematic of the electrical configuration for the components of the aerosol delivery device that may be used to apply an AC voltage to a group of five ring electrodes L1-L5. [Figure 13] 1 illustrates an aerosol generator according to one embodiment, comprising six ring electrodes mounted on a printed circuit board ("PCB") and a susceptor element positioned within a volume defined by the ring electrodes, wherein the susceptor element may have one or more peripheral slots to reduce heat flow from one section of the susceptor element to an adjacent section of the susceptor element. [Figure 14] 1 illustrates the direction of current flow and the resulting magnetic field around multiple ring electrodes according to one embodiment. Detailed Description

[0055] In this specification, aspects and features of certain examples and embodiments are discussed or described. Some aspects and features of certain examples and embodiments may be implemented in a conventional manner, and they are not discussed or described in detail for the sake of brevity. Thus, it will be understood that aspects and features of the devices and methods discussed in this specification that are not described in detail may be implemented in accordance with conventional techniques for implementing such aspects and features.

[0056] According to this disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating material component (or components thereof) of the aerosol delivery system is not burned or combusted to facilitate delivery of at least one substance to a user.

[0057] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0058] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0059] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0060] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. The solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0061] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0062] In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables are sometimes referred to as articles throughout this disclosure.

[0063] In some embodiments, a non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat source. In some embodiments, the heat source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat transfer material proximate the heat source.

[0064] In some embodiments, the non-combustible aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0065] In some embodiments, consumables for use with a non-combustion aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transport component, an aerosol generator, an aerosol generating area, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0066] An aerosol-forming material is a material that is capable of generating an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (such as a gel) form, and may or may not contain active substances and / or flavorings.

[0067] The aerosol-generating material may include a binder and an aerosol former. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-generating material may or may not be soluble. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0068] The aerosol-generating material may comprise or may be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol former, and one or more other components, such as an active agent, to form a slurry, and then heating the slurry to evaporate at least some of the solvent to form an aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such as a construction of separate pieces of film on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0069] The aerosol-generating film may comprise or be a sheet, which may optionally be chopped to form a chopped sheet.

[0070] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0071] The aerosol generator is a device configured to cause the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause the generation of an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to expose the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0072] A consumable is an article that includes or consists of an aerosol-generating material and is intended to be consumed in part or in whole by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that generates heat upon use to generate an aerosol from the aerosol-generating material. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0073] The susceptor is a heating material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, where the penetration of the varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material, where the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, where the susceptor is heatable by both heating mechanisms. In this specification, an aerosol delivery device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0074] The non-combustion aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some embodiments, the non-combustion aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may comprise an electrical power source, such as, for example, a battery or a rechargeable battery. In some embodiments, the non-combustion aerosol delivery device may also comprise an aerosol generating component. However, in other embodiments, the aerosol product article may comprise, in part or entirely, the aerosol generating component.

[0075] Induction heating is a process in which an electrically conductive object, called a susceptor, is heated by the penetration of a varying magnetic field into the object. This process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another such that the resulting varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of current, and when such eddy currents are generated in the object, their flow against the object's electrical resistance causes the object to heat up. This process is called Joule heating, Ohmic heating, or resistive heating.

[0076] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by the penetration of a varying magnetic field into the object. The magnetic material can be thought of as containing many atomic-scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align with the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field created by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the applied varying magnetic field. This reorientation of the magnetic dipoles results in the generation of heat in the magnetic material.

[0077] When an object is both conductive and magnetic, subjecting the object to a varying magnetic field can result in both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can enhance the magnetic field, which can intensify Joule heating.

[0078] Various embodiments will now be described in more detail.

[0079] 1 illustrates an aerosol delivery device 100 according to one embodiment. The aerosol delivery device 100 comprises an outer housing 130 and an inductor or induction heating element comprising a plurality of ring electrodes 101 arranged around a heating chamber housing 104. A susceptor 103 is provided within the heating chamber housing 104, and a heating chamber is formed within the susceptor 103. The susceptor 103 may be tubular. A lid or slidable cover 107 may be provided at an entrance to the heating chamber. An aerosol product article including an aerosol-generating material may be inserted into the heating chamber via the lid or slidable cover 107 and may be surrounded by at least a portion of the susceptor 103.

[0080] It will be appreciated that the susceptor 103 heats up by interacting with the magnetic field generated by the inductor or induction heating element comprising the multiple ring electrodes 101. As a result, the aerosol product located within the susceptor 103 is heated.

[0081] An inductor or induction heating element according to various embodiments comprises a plurality of ring electrodes 101 mounted on a first substrate 102. The first substrate 102 may comprise a printed circuit board ("PCB"). According to various embodiments, the inductor or induction heating element may comprise 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more than 20 ring electrodes 101.

[0082] The susceptor 103 may be located within the heater chamber housing 104 and mounted between an upper portion 105 of the heater chamber housing 104 and a sweep tube 106. According to various embodiments, the susceptor 103 may be held in compression between the upper portion 105 of the heater chamber housing 104 and the sweep tube 106. It should be understood that the reference to being held in compression relates to the location of the susceptor 103 rather than the susceptor 103 being exposed to high compressive forces.

[0083] The susceptor 103 comprises a heating material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor 103 may comprise an electrically conductive material, where the penetration of the varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material, where the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor 103 may be both electrically conductive and magnetic, where the susceptor 103 can be heated by both heating mechanisms. The susceptor 103 may comprise a ferroelectric and / or ferromagnetic material.

[0084] An aerosol product article may be inserted through an inlet into a heating chamber formed by the susceptor 103. The aerosol product article may be received within the heating chamber such that the aerosol product article is in thermal communication with the susceptor 103. Thus, when the susceptor 103 is inductively heated, the susceptor 103 transfers heat to the aerosol product article, thereby resulting in the generation of an aerosol from the aerosol-generating material that comprises the aerosol product article.

[0085] The control device 109 may be provided on a second substrate 150 (which may also include a printed circuit board) and may be connected to the first substrate 109 via one or more electrical connections. The control device 109 may be configured to apply an AC voltage to the ring electrode 101 to generate a time-varying magnetic field. The time-varying magnetic field results in heating of the heating material of the susceptor 103.

[0086] According to one embodiment, the control device 109 may be configured to apply an AC voltage independently to each of the ring electrodes 101. Alternatively, the control device 109 may be configured to apply an AC voltage to a group of the ring electrodes 101. It will be appreciated that passing an alternating current through each of the ring electrodes 101 generates an alternating magnetic field, which results in heating of a corresponding region of the susceptor 103.

[0087] 1, the control device 109 may be provided on a second substrate 150 separate from the first substrate 102 on which the ring electrodes 101 are mounted. However, other embodiments are envisioned in which all or part of the components of the control device 109 may be located on the same first substrate 102 on which the ring electrodes 101 are mounted.

[0088] According to various embodiments, the first substrate 102 and the second substrate 150 may comprise printed circuit boards (PCBs). The first substrate 102 or printed circuit board may include one or more connectors or pads on a rear side of the first substrate 102 that may be configured to electrically connect to corresponding connectors or pads provided on a front side of the second substrate 150 or printed circuit board.

[0089] An embodiment is envisaged in which the control device 109 may be located on a substrate 150 different from that of the first substrate 102 on which the ring electrode 101 is mounted, and a wireless connection may be made between the first substrate 102 and the other substrate 150.

[0090] FIG. 2 illustrates in more detail an inductor or induction heating element according to one embodiment, the inductor or induction heating element comprising a plurality of separate ring electrodes 101 mounted on a first substrate 102. According to the particular embodiment illustrated in FIG. 2, twelve ring electrodes 101 are mounted on the first substrate 102. However, it will be appreciated that according to other embodiments, a different number of ring electrodes 101 may be mounted on the first substrate 102. The inductor or induction heating element according to various embodiments comprising a plurality of separate ring electrodes 101 may allow different desired inductor geometries to be easily constructed. For example, the number of ring electrodes 101 may be varied and / or the separation distance between the ring electrodes 101 may be varied. This allows different heating profiles to be achieved. The tubular susceptor element 103 may be located within the volume inscribed by the ring electrodes 103.

[0091] According to various embodiments, the ring electrode 101 may comprise a highly rigid electrode, such that a robust inductor or induction heating element is provided when the ring electrode 101 is provided on the first substrate 102. It will thus be appreciated that, according to various embodiments, a particularly robust and robust aerosol delivery device is provided.

[0092] Each of the separate ring electrodes 101 may be provided as a discrete or separate element mounted on the first substrate 102, with each ring electrode 101 spaced apart from the others. Each ring electrode 101 may comprise a ring section or portion having an electrical connection at each end. The ends of the ring electrodes 101 may comprise an electrical connection, which may be attached or otherwise secured to the first substrate 102. Each ring electrode 101 may be electrically connected to and supported by the first substrate 102 via the electrical connection.

[0093] According to various embodiments, each ring electrode 101 may include two electrical connections that allow for appropriate electrical connection to the first substrate 102 while allowing the ring electrode 101 to be positioned on the first substrate 102 independently of the other ring electrodes 101. To allow independent control of a particular electrode(s) 102, each ring electrode 101 may have its own electrical connection to the first substrate 102 that is independent from the electrical connections of at least some of the other electrodes 101 to the first substrate 102.

[0094] The ring electrode 101 may be attached to the first substrate 102 in any suitable manner. In one embodiment, the electrical connection portion and / or the first substrate 102 may be configured and adapted for connection to one another. For example, the electrical connection portion of the ring electrode 101 and the first substrate 102 may be configured such that the electrical connection portion is inserted into a corresponding hole or slot provided in the first substrate 102. Other embodiments are envisioned in which the electrical connection portion includes a hole or slot configured for attachment to a corresponding electrode provided in the first substrate 102. Attachments such as screws may be used.

[0095] According to one embodiment, the ring electrodes 101 may be soldered to the first substrate 102. To facilitate this soldering, the electrical connections may be configured to be soldered into corresponding slots in the first substrate 102, which may comprise a printed circuit board. The electrical connections may be coated with a material (e.g., gold) that facilitates soldering connections to the first substrate 102.

[0096] According to various embodiments, insertion of the electrical connection portion into a corresponding slot in the first substrate 102 may be sufficient to secure the ring electrode 101 to the first substrate 102 and form an electrical connection between the first substrate 102 and the ring electrode 101. For example, according to various embodiments, the ring electrode 101 may be connected to the first substrate 102 by an interference fit or a snap fit.

[0097] An alternating current may be configured to pass through the ring portion of the electrode 101 via the electrical connection, thereby generating a varying magnetic field. It will be appreciated that the varying magnetic field results in heating of a susceptor 103 located radially inside the ring electrode 101. The susceptor 103 may be located within a volume defined by an inner radius of the ring portion of the ring electrode 101. One end of the susceptor 103 may be fixed to a portion of the heater chamber housing 104. Another end of the susceptor 103 may be fixed to a sweep tube 106.

[0098] The ring electrodes 101 may be arranged so as to be coaxial with each other. Each of the ring electrodes 101, or at least a ring portion thereof, may be substantially flat, i.e. planar. The ring electrodes 101 are substantially flat in a plane perpendicular to the axis of the ring electrodes 101 or the longitudinal axis of the inductor or induction heating element. The ring electrodes 101 may be aligned with each other such that the planar surfaces of the ring electrodes 101 lie in parallel planes when attached to the first substrate 102. Providing planar ring electrodes 101 may allow localized heating of a relatively small portion of the susceptor 103 by each ring electrode 101, thereby allowing precise control of the temperature distribution along the length of the susceptor 103.

[0099] Other embodiments are envisaged in which the ring electrodes 101 may not be planar, but may be, for example, helical, allowing heating of a relatively large length of the susceptor 103 with a relatively small number of electrodes. The ring electrodes 101 may be planar and have a rectangular, circular or polygonal cross-sectional profile. The ring portions may comprise a conductive material, for example copper or gold. It may also be envisaged that one or both planar faces of each ring electrode 101 may be provided with conductive wiring, or that the ring portions themselves may consist (entirely) of a conductive material (e.g. copper). The ring electrodes 101 may be constructed, for example, by being cut from a planar sheet of material, or by a long strip of material bent into the required shape. The ring electrodes 101 are shown mounted in a heater chamber housing 104 connected to a sweep tube 106.

[0100] 3 illustrates a cross-sectional view of an aerosol generator according to various embodiments. The aerosol generator comprises an inductor or induction heating element comprising a plurality of separate ring electrodes 101 mounted on a first substrate 102, which may comprise a printed circuit board. The ring electrodes 101 may be mounted around a heater chamber housing 104, or may optionally be embedded within the heater chamber housing 104. The aerosol generator further comprises a susceptor 103 located within the heater chamber housing 104.

[0101] According to one embodiment, the susceptor 103 may be mounted between an upper portion 105 of the heater chamber housing 104 and a cleaning tube 106. The heater chamber housing 104 may be located within a ring portion of the ring electrode 101, and the susceptor 103 may be located within the heater chamber housing 104.

[0102] The electrical connection portion of the ring electrode 101 may extend beyond the heater chamber housing 104 to allow connection to the first substrate 102. A number of spacers 111 formed of an electrically insulating material (e.g., a thermoplastic material such as polyetheretherketone (PEEK)) may be located between the ring electrodes 101. The spacers 111 may have a cross-sectional shape that substantially corresponds to the ring portion of the electrode 101. However, it should be understood that the spacers 111 are optional and the ring electrodes 101 may have sufficient rigidity such that any spacers 111 provided between the ring electrodes 101 are not required. According to various embodiments, a temperature sensor 113, such as a thermocouple, may be attached to the susceptor 103 to sense the temperature of the susceptor 103.

[0103] FIG. 4 illustrates a side view of the ring electrode 101 , the spacer 111 , the heater chamber housing 104 , the upper portion 105 of the heater chamber housing, the cleaning tube 106 , and the first substrate 102 attached to the electrical connection portion of the ring electrode 101 .

[0104] 5 illustrates a side view of an aerosol generator according to various embodiments. The aerosol generator comprises an inductor or induction heating element comprising a plurality of separate ring electrodes 101 mounted on a first substrate 102 (e.g., a PCB). The aerosol generator further comprises a susceptor (not shown), a heater chamber housing 104, an upper housing 105, and a sweep tube 106.

[0105] According to one embodiment, the ring electrodes 101 may be embedded in a matrix to form the heater chamber housing 104. According to one embodiment, the matrix may be injection molded around the ring electrodes 101 to form the heater chamber housing 104. The matrix or heater chamber housing 104 may comprise a thermoplastic material such as polyetheretherketone (PEEK).

[0106] The first substrate 102 (e.g., a PCB) may be connected to the ring electrode 101 before or after the heater chamber housing 104 is formed around the ring electrode 101. One end of the heater chamber housing 104 may be configured for attachment to an upper housing 105 and the other end of the heater chamber housing 104 may be configured for attachment to a cleanout tube 106. A susceptor may be located within the heater chamber housing 104 between the cleanout tube 106 and the upper housing 105.

[0107] Shielding material 117 may be provided around the outer surface of ring electrode 101 to prevent the magnetic field generated by ring electrode 101 from being emitted radially outward and thus toward the user. Shielding material 117 may include a ferrite material. A thermocouple 113 may be attached to the susceptor to measure the temperature of the susceptor.

[0108] 6 illustrates a cross-sectional view of an aerosol generator according to one embodiment. According to one embodiment, a first seal 114a may be provided between the upper housing 105 and the heater chamber housing 104. A second seal 114b may be provided between the heater chamber housing 104 and the cleanout tube 106.

[0109] The heater chamber housing 104 may be formed to have an integral or continuous upper portion instead of a separate and distinct upper housing 105. The upper housing 105 may comprise a thermoplastic material such as polyetheretherketone (PEEK). The heater chamber housing 104 may be formed to have a hole or slot into which the thermocouple 113 may be inserted. The thermocouple 113 may be configured to sense the temperature of the susceptor 103. A seal 115a may be provided to secure the thermocouple 113 within the hole or slot provided in the heater chamber housing 104. The seal 115a may abut against a surface of the first substrate 102 on which the multiple ring electrodes 101 are attached.

[0110] A shielding material 117 may be provided around the outer surface of the ring electrode 101 to attenuate the magnetic field generated by the ring electrode 101 in a radial direction toward the outer housing of the aerosol delivery device. According to various embodiments, the shielding material 117 may be provided as an adhesive wrapper. The shielding material 117 may include a magnetic material, such as ferrite.

[0111] The susceptor 103 may be secured within the heater chamber housing 104 by being attached at one end to the cleaning tube 106 and at another end to the upper housing 105 and / or the upper portion of the heater chamber housing 104. For example, when the heater chamber housing 104 comprises an integral upper portion 105, the susceptor 103 may be inserted into the heater chamber housing 104 from an end opposite the upper portion 105. The cleaning tube 106 may be configured to be attached to an end of the susceptor 103 once the susceptor 103 is inserted. According to one embodiment, the cleaning tube 106 may have a snap-fit ​​connection with the susceptor 103 to secure the susceptor 103 between the upper portion 105 and the cleaning tube 106. Other embodiments are envisioned in which the susceptor 103 is held in compression between the upper portion 105 and the cleaning tube 106.

[0112] According to one embodiment, the cleaning tube 106 may be configured for attachment to the susceptor 103, and the cleaning tube 106 may first be attached to the susceptor 103, and then both the susceptor 103 and the attached cleaning tube 106 are inserted together into the heater chamber housing 104 and secured to an upper portion of the heater chamber housing 104.

[0113] When a separate upper housing 105 is provided, the susceptor 103 may be inserted into the heater chamber housing 104 through a bottom portion of the heater chamber housing 104 in the manner discussed above. Alternatively, the susceptor 103 may be inserted through a top end of the heater chamber housing 104 and then the upper housing 105 may be secured to (or contacted with) the susceptor 103. The upper housing 105 may be configured for attachment to the heater chamber housing 104 using, for example, a compression fit.

[0114] According to various embodiments, the multiple ring electrodes 101 may be arranged in one or more groups of electrodes. For example, the aerosol generator may be configured to heat different regions of the susceptor 103 (and thus different regions of the aerosol product) to different temperatures. For example, each group of electrodes 101 may be configured to maintain a corresponding portion of the susceptor 103 at a different temperature during a session of use.

[0115] According to one embodiment illustrated in Figure 6, the ring electrodes 101 may be arranged in a first group of ring electrodes 101a and a second group of ring electrodes 101b. In the particular embodiment illustrated in Figure 6, the first group of ring electrodes 101a comprises seven ring electrodes 101 and the second group of ring electrodes 101b comprises five ring electrodes 101. However, it will be appreciated that both the first group of ring electrodes 101a and the second group of ring electrodes 101b may comprise a different number of ring electrodes 101.

[0116] It is envisioned that different regions of the susceptor 103 may be maintained at different temperatures during use. This may be achieved by applying a different voltage to the first group of ring electrodes 101a than to the second group of ring electrodes 101b. Other embodiments are envisioned in which the axial separation (pitch) between the electrodes 101 in the different groups and / or the number of electrodes 101 in the different groups of electrodes may be different. For example, the first group of ring electrodes 101a may have a first axial spacing S1 between the electrodes and the second group of ring electrodes 101b may have a second different axial spacing S2 between the electrodes. According to one embodiment, the first axial spacing S1 may be <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm or >10 mm. Similarly, according to one embodiment, the second axial spacing S2 may be <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm, or >10 mm. According to various embodiments, the susceptor may be segmented and thermal barrier portions may separate the segments such that different susceptor segments may be maintained at different temperatures.

[0117] It is envisioned that the different temperatures may additionally or otherwise be provided by an aerosol delivery device configured to supply different voltages and / or currents to different groups of electrodes 101. The aerosol delivery device may comprise a control device (shown and described above in connection with FIG. 1 and described in more detail in connection with FIG. 9) that may be configured to apply one or more AC voltages independently to groups of ring electrodes 101. This may allow different voltages to be applied independently to different groups of ring electrodes 101.

[0118] For example, the control device may be configured to simultaneously apply different non-zero voltages to different groups of ring electrodes 101, and / or may be configured to apply a voltage to one or more groups of ring electrodes 101 while applying substantially no voltage to one or more other groups of ring electrodes 101. The control device may be configured to independently apply one or more AC voltages to individual ring electrodes 101 of the same or different groups.

[0119] According to one embodiment, the control device may be configured to supply a first voltage V1 to the first group of ring electrodes 101a and a second voltage V2 to the second group of ring electrodes 101b. According to various embodiments, the ratio V1 / V2 may be in the range of <0.5, 0.5-0.6, 0.6-0.7, 0.7-0.8, 0.8-0.9, 0.9-1.0, 1.0-1.1, 1.1-1.2, 1.2-1.3, 1.3-1.4, 1.4-1.5 or >1.5. The first voltage V1 and the second voltage V2 comprise AC voltages.

[0120] According to an embodiment, the frequency f1 of the first voltage V1 and the frequency f2 of the second voltage V2 may be different. According to various embodiments, the ratio f1 / f2 may be in the range of <0.5, 0.5-0.6, 0.6-0.7, 0.7-0.8, 0.8-0.9, 0.9-1.0, 1.0-1.1, 1.1-1.2, 1.2-1.3, 1.3-1.4, 1.4-1.5 or >1.5. According to other embodiments, the aerosol generator may comprise a single group of ring electrodes 101 and the control device may be configured to apply one or more AC voltages to each of the individual ring electrodes 101 independently.

[0121] Maintaining different regions of the susceptor 103 at different temperatures may allow for selective heating of different portions of an aerosol product article inserted into the aerosol generator while not heating other specific portions of the aerosol product article. For example, the control device may be configured to apply one or more voltages to the first group 101a of the ring electrodes 101 to heat a first portion of the aerosol product article at a first time t1 while not heating a second portion of the aerosol product article at the same first time t1.

[0122] The control device may be configured to apply one or more voltages to the second group 101b of ring electrodes so as to heat a second portion of the aerosol product at a second time t2, while not heating the first portion of the aerosol product at the second time t2.

[0123] The control device may additionally or alternatively be configured to apply a particular voltage to a particular group of electrodes to heat a certain portion of the aerosol product to a certain temperature, and simultaneously apply different voltages to different groups of electrodes to heat different portions of the aerosol product to different temperatures.

[0124] The control device may comprise or consist of a circuit or circuitry. The circuit / circuitry may be programmed and configured by software. According to various embodiments, the control device may be located on the first substrate 102 on which the plurality of ring electrodes 101 are mounted, or alternatively, the control device may be located on another substrate, e.g., another printed circuit board, which may be connected to the first substrate 102.

[0125] Each of the groups of ring electrodes 101 may be axially spaced apart from each other. The ring electrodes 101 may be arranged such that the planar surfaces of the ring electrodes 101 of different groups lie in planes parallel to each other. Each group(s) of electrodes 101 may comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or more than 20 ring electrodes 101.

[0126] Embodiments are envisaged in which the ring electrodes 101 may be grouped into 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more than 10 groups of ring electrodes 101. Each of the groups may comprise the same or a different number of ring electrodes 101. Each group of ring electrodes 101 may comprise at least 2, 3, 4, 5 or more than 5 ring electrodes 101. For example, according to one embodiment, the ring electrodes 101 may be arranged in 2 to 5 groups of ring electrodes 101, each group of ring electrodes 101 comprising at least 3 ring electrodes 101. The different groups of ring electrodes 101(s) may all be mounted on the same first substrate 102, or alternatively, the different groups of electrodes 101 may be mounted on different substrates.

[0127] 7 illustrates a first substrate having a plurality of electrical connections 119 configured to contact a plurality of ring electrodes 101. The ring electrodes and associated electrical connections are shown grouped into a first group of ring electrodes 101a and associated electrical connections provided on the first substrate, and a second group of ring electrodes 101b and associated electrical connections provided on the first substrate. A portion of shielding material 117 is also shown.

[0128] 8 illustrates the first substrate 102 in more detail. The first substrate 102 may comprise a plurality of electrical connections which may be arranged in a first group of electrical connections 121 and a second group of electrical connections 122. Each electrical connection may comprise at least one slot or opening 124a, 124b, 124c, 124d, 124e for receiving an electrical connection portion of the ring electrode 101 therein. The electrical connection portion of the ring electrode 101 may be received in two adjacent slots or openings 124a, 124b, or the ring electrode 101 may be fixed to the slots or openings 124a, 124b by soldering.

[0129] The electrical connections 119a, 119b may be configured such that within each group 121, 122 of electrical connections a first electrical connection portion of a ring electrode 101 may be received in a slot 124a of one electrical connection portion 119a and a second electrical connection portion of the same ring electrode 101 may be received in a slot 124b of a different second electrical connection portion 119b. The second electrical connection portion 119b may include a second slot or opening 124c for receiving another ring electrode 101 axially adjacent to the ring electrode 101 received in the slot or opening 124a, 124b.

[0130] Thus, the first substrate 102 may be configured to electrically connect axially adjacent ring electrodes 101 such that a voltage applied to the electrical connections at both axial ends of a group of ring electrodes 101 causes each of the ring electrodes 101 in the group to pass a current in the same direction about the longitudinal axis of the ring electrodes 101. It will be appreciated that an AC voltage may be applied to selected ring electrodes 101 as desired.

[0131] However, there are other embodiments in which the coil termination configurations shown and described with reference to Figures 7-9 may be modified so that the ring electrodes may be terminated in a manner different from that shown and described with reference to Figures 7-9. An embodiment in which the currents in adjacent ring electrodes flow in opposite directions is described below with reference to Figures 10-12. In such an arrangement, instead of the end of the ring electrode provided in slot 124b being electrically connected to the end of the ring electrode provided in slot 124c, the end of the ring electrode provided in slot 124b may be electrically connected to the end of the ring electrode immediately above, i.e., the end of the ring electrode provided in slot 124d. Similarly, the end of the ring electrode provided in slot 124c may be electrically connected to the end of the ring electrode provided in slot 124e immediately above.

[0132] Other arrangements of electrical connections to provide this configuration may also be provided. The printed circuit board ("PCB") substrate 102 may be configured in this manner to allow a voltage to be applied to each group of electrodes by electrical connections at both axial ends of the group to generate a varying magnetic field.

[0133] The first substrate 102 may be configured to have different specific axial spacings (pitch) between adjacent ring electrodes 101 as desired based on which electrical connections the ring electrodes 101 are connected to. If there are vacant electrical connections between adjacent ring electrodes 101, solder may be used to connect the electrical connections between adjacent ring electrodes 101.

[0134] The first substrate 102 may be configured for a different number of groups and / or a different number of electrodes 101 within a group based on the connections between the electrical connections and the control device. One or more additional connections 125 may be provided for electrical connection to other components other than the ring electrodes 101, such as temperature sensors or other types of sensors.

[0135] 9 illustrates a control device 109 that may be connected to the first substrate 102, according to various embodiments. The control device 109 may be provided on a second PCB board 150 connected to the first substrate 102. However, other embodiments are envisioned in which all or part of the control device 109 may instead be provided on the same first substrate 102 to which the ring electrodes 101 are attached. Electrical connections may be provided between the control device 109 and the electrical connections at both axial ends of each of the groups of electrical connections 121, 122. This allows the control device 109 to apply voltages independently to the groups of electrodes 101 via the electrical connections at both axial ends of each of the groups of electrical connections 121, 122.

[0136] According to various embodiments, an AC voltage may be configured to be supplied or applied under the control of the control device 109 to a first group of electrodes connected to the first electrical connection 121 such that all electrodes of the first group of electrodes connected to the first electrical connection 121 are simultaneously supplied with the AC voltage. Similarly, an AC voltage may be configured to be supplied or applied under the control of the control device 109 to a second group of electrodes connected to the second electrical connection 122 such that all electrodes of the second group of electrodes connected to the second electrical connection 122 are simultaneously supplied with the AC voltage. In this way, an aerosol generator with two heating zones that can be independently controlled is provided.

[0137] 10 illustrates a schematic of an electronic component 126 of an aerosol generator according to various embodiments. The component may be incorporated into an aerosol delivery device. The component 126 comprises an inductor element 127 comprising a plurality of separate ring electrodes L1-L12. The component further comprises a first module 128 configured to receive a DC voltage and output an alternating current (AC current). The component 126 also comprises a second module 129 configured to supply or switch the AC current to selected ones of the ring electrodes L1-L12.

[0138] In Figure 10, each of the ring electrodes L1-L12 is shown diagrammatically as an inductor. The electrodes L1-L12 may comprise ring electrodes as described above. For example, the electrodes L1-L12 may be planar and mounted on a substrate (not shown), such as a printed circuit board ("PCB").

[0139] According to one embodiment, the ring electrodes L1-L12 may be arranged in two groups of electrodes. For example, the ring electrodes L1-L12 may be arranged to form a first group of electrodes including ring electrodes L1-L7 and a second group of electrodes including ring electrodes L8-L12. The ring electrodes in the same group may be connected in series with each other, but not with ring electrodes of other groups.

[0140] The first module 128 may be configured to generate an alternating current in any suitable manner. For example, the first module 128 may include a half-bridge driver 128a including two MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor) switches 130a, 130b and a MOSFET driver 131 connected to respective gate terminals of the MOSFET switches 130a, 130b for controlling the MOSFET switches 130a, 130b.

[0141] The first MOSFET switch 130a may be connected to a DC voltage input (e.g., 6V) and the second MOSFET switch 130b may be connected to a common / ground terminal. The MOSFET driver 131 may be configured to toggle the MOSFET switches 130a, 130b to output an AC current. The first module 128 may further comprise a power controller 132 that may be configured to provide a signal (e.g., a regular periodic signal or a clock signal) to the MOSFET driver 131 to control when the MOSFET switches 130a, 130b are toggled and thus determine the frequency of the AC current to be output. The AC current signal generated by the first module 128 may be provided to the second module 129 via an AC power rail 133. According to one embodiment, the AC voltage provided via the AC power rail 133 may have a DC offset of 3V. Therefore, the AC voltage according to various embodiments may oscillate between 0V and 6V.

[0142] The second module 129 may include a first plurality (e.g., 10) of semiconductor switches 134a and a second plurality (e.g., 12) of semiconductor switches 134b. The first plurality of semiconductor switches 134a are connected to a switch controller 136, an AC power rail 133, and first ends of at least some (e.g., 10) of the ring electrodes L3-L12. The second plurality of semiconductor switches 134b are connected to second ends of the (e.g., 12) ring electrodes L1-L12 via a capacitor 135, and to a common / ground terminal(s) 137 and the switch controller 136. According to various embodiments, the second module 129 may include the control device 109 described above with reference to FIGS. 1 and 9.

[0143] According to various embodiments, the first semiconductor switch 134a comprises a switch connected between the inductor element 127 (which includes the ring electrodes L1-L12) and the AC power rail 133, and the second conductive switch 134b is connected between the inductor element 127 (which includes the ring electrodes L1-L12) and the common / ground terminal(s) 137. The capacitor 135 is connected in series with the ring electrodes L1-L12 to form an RLC (resistor-inductor-capacitor) or LC (inductor-capacitor) circuit together with the ring electrodes forming an inductor. The capacitor 135 may be configured to set (e.g., reduce) a resonant frequency for optimal driving of the ring electrodes L1-L12. The capacitance of the capacitors 135 may be the same. Alternatively, some capacitors 135 may have different capacitances. The switch controller 136 may be configured to control the first plurality of semiconductor switches 134a and the second plurality of semiconductor switches 134b such that only certain (selected) ring electrodes L1-L12 receive power from the AC power rail 133 at a particular time. Thus, the switch controller 136 may control which ring electrodes L1-L12 receive an alternating current or voltage supply. This may be used to provide a selected heating profile.

[0144] The semiconductor switches 134a, 134b may comprise a switch arrangement, for example, a pair of MOSFETs.

[0145] As discussed in more detail below, the susceptor element may be segmented into a series of segments, for example, each segment may include a portion of the susceptor element immediately proximate to one of the ring electrodes L1-L12.

[0146] In a particular example of an embodiment including twelve ring electrodes L1-L12 illustrated in FIG. 10, the susceptor element may be configured to include twelve segments, each of which may be independently controlled. The susceptor element may be configured to include thermal barriers between the segments. According to various embodiments, during a session of use lasting, for example, 3 to 6 minutes, a first susceptor segment may be configured to be maintained at a temperature T1 in the range of 20-400° C., a second susceptor segment may be configured to be maintained at a temperature T2 in the range of 20-400° C., a third susceptor segment may be configured to be maintained at a temperature T3 in the range of 20-400° C., a fourth susceptor segment may be configured to be maintained at a temperature T4 in the range of 20-400° C., a fifth susceptor segment may be configured to be maintained at a temperature T5 in the range of 20-400° C., and a sixth susceptor segment may be configured to be maintained at a temperature T6 in the range of 20-400° C. The seventh susceptor segment may be configured to be maintained at a temperature T7 in the range of 20-400° C., the eighth susceptor segment may be configured to be maintained at a temperature T8 in the range of 20-400° C., the ninth susceptor segment may be configured to be maintained at a temperature T9 in the range of 20-400° C., the tenth susceptor segment may be configured to be maintained at a temperature T10 in the range of 20-400° C., the eleventh susceptor segment may be configured to be maintained at a temperature T11 in the range of 20-400° C., and the twelfth susceptor segment may be configured to be maintained at a temperature T12 in the range of 20-400° C. Thus, with respect to the embodiment illustrated in FIG. 10 , the controller may be configured to set the susceptor elements to a desired spatial heating profile in which at least some or all of the susceptor segments may be maintained at different temperatures at any moment in time. For example, the controller may be configured to set a heating profile such that T1 ≠ T2 ≠ T3 ≠ T4 ≠ T5 ≠ T6 ≠ T7 ≠ T8 ≠ T9 ≠ T10 ≠ T11 ≠ T12.Embodiments are contemplated in which the inductor element 127 comprises 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 or >30 ring electrodes. Similarly, embodiments are contemplated in which the susceptor element comprises 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 or >30 segments. At least some or all of the segments of the susceptor element may be separated from one another by a thermal barrier, such as a potting compound, adhesive, thermoset plastic, or epoxy.

[0147] Figure 11 illustrates a schematic of an electrical configuration 150 for components of an aerosol generator or aerosol delivery device according to various embodiments. Figure 11 shows how, in the particular example illustrated, the electrical configuration 150 may be used to toggle a DC voltage to a group of ring electrodes, such as ring electrodes L8-L12 illustrated and described above with respect to the configuration illustrated in Figure 10. However, it will be appreciated that the electrical configuration 150 is more generally suitable for applying a DC voltage that reverses direction through a plurality of ring electrodes.

[0148] With the arrangement shown and described with reference to FIG. 10, an AC voltage was selectively switched to the desired ring electrodes, for example by a switch arrangement. In contrast, the arrangement disclosed with reference to FIG. 11 shows how a DC voltage from the DC power rail 133a can be selectively switched to one or more of the ring electrodes L8-L12 by an array of half-bridge circuits 140. Each half-bridge circuit 140 comprises a first or upper MOSFET switch and a second or lower MOSFET switch. The first or upper MOSFET switch is connected to the DC power rail 133a and the second or lower MOSFET switch is connected to common / ground. A capacitor may be provided in series with each ring electrode. According to various embodiments, the capacitor may be mounted on a printed circuit board (PCB) on which the ring electrodes L8-L12 are also mounted. Each ring electrode L8-L12 and a corresponding capacitor form a resonant circuit. According to various embodiments, two half-bridge circuits 140 are switched on and off in a diagonal complementary pattern to generate magnetic flux around the ring electrodes L8-L12 or conductive loops.

[0149] The DC voltage provided to the DC power rail 133 a may be controlled by a first DC power module 170 .

[0150] Figure 12 illustrates a schematic of electrical configuration 151 for components of an aerosol generator or aerosol delivery device according to another embodiment. Figure 12 shows how electrical configuration 151 can be used to apply an AC voltage to a group of five ring electrodes L1-L5.

[0151] According to various embodiments, a DC voltage from the DC power rail 133a may be selectively switched to one or more of the ring electrodes L1-L5 by an array of six half-bridge circuits 140a-f. Each half-bridge circuit 140a-f comprises a first MOSFET switch and a second MOSFET switch. The first MOSFET switch is connected to the DC power rail 133a and the second MOSFET switch is connected to common / ground. Each ring electrode L1-L5 is connected in series with a capacitor. According to various embodiments, the capacitor may be mounted on a printed circuit board (PCB) on which the ring electrodes L1-L5 are also mounted. Each ring electrode L1-L5 and the corresponding capacitor form a resonant circuit. According to various embodiments, two half-bridge circuits 140a-f are switched on and off in a diagonal complementary pattern to generate a magnetic flux around the ring electrodes L1-L5 or conductive loops.

[0152] The DC voltage provided to DC power rail 133a may be controlled by a DC power module 170.

[0153] Selective heating of individual susceptor element segments is possible. For example, to heat the susceptor element segments corresponding to the ring electrodes L2, L3, and L4, a DC voltage from the DC power rail 133a first passes through the ring electrodes L2, L3, and L4 in a first direction, and then the second, third, fourth, and fifth half-bridge circuits 140b, 140c, 140d, and 140e are switched on and off in a diagonal complementary pattern such that the current switches direction and passes through the ring electrodes L2, L3, and L4 in a second direction opposite to the first direction. As a result, an AC voltage is applied to the ring electrodes L2, L3, and L4. According to various embodiments, the first half-bridge circuit 140a may be switched in coordination with the second half-bridge circuit 140b. Similarly, the sixth half-bridge circuit 140f may be switched in coordination with the fifth half-bridge circuit 140e. As a result, a zero voltage loop is formed which prevents current flow in, for example, the first ring electrode L1.

[0154] According to various embodiments, only two MOSFET switch elements are required per ring electrode L1-L5 (or per ring electrode L3-L12 in the embodiment shown and described with reference to FIG. 10), along with two additional MOSFETs. This is in contrast to other configurations, where for example four MOSFETs may be provided in a full H-bridge configuration to drive the current or voltage through the inductor coil. As a result, the electronic circuit according to various embodiments utilizes a reduced number of MOSFETs, which allows the electronic components to be provided on a printed circuit board with a reduced footprint. This allows a more compact aerosol delivery device to be provided. It will also be appreciated that the cost of manufacture may be reduced. According to various embodiments, the various electronic components may be provided in a driver unit, which is configured in a space-efficient manner as a single integrated circuit (IC).

[0155] It will be appreciated that selective heating of susceptor element segments according to various embodiments may be achieved by parallel connection of multiple independently controlled loop or ring electrodes. Improved system controllability may be achieved by utilizing a relatively high series capacitance / capacitor to reduce the resonant frequency of each ring electrode. For reference purposes, a 7-turn inductor coil may have an inductance of about 400 nH and may be placed in series with a 100 nF capacitor to provide an inductor element with a resonant frequency of about 1 MHz. According to various embodiments, each ring electrode may have an inductance of about 50 nH and may be placed in series with, for example, a 1 μF capacitor such that the resonant frequency of the ring electrode is about 1 MHz.

[0156] However, other embodiments are envisaged. According to other embodiments, the inductance of each ring electrode may be <1nH, 1-10nH, 10-20nH, 20-30nH, 30-40nH, 40-50nH, 50-60nH, 60-70nH, 70-80nH, 80-90nH, 90-100nH. The capacitance of the capacitor provided in series with each ring electrode may be <100nF, 100-200nF, 200-300nF, 300-400nF, 400-500nF, 500-600nF, 600-700nF, 700-800nF, 800-900nF, 900-1000nF, 1-2μF, 2-3μ ... It may be up to 4 μF, 4 to 5 μF, 5 to 6 μF, 6 to 7 μF, 7 to 8 μF, 8 to 9 μF, 9 to 10 μF, 10 to 11 μF, 11 to 12 μF, 12 to 13 μF, 13 to 14 μF, 14 to 15 μF, 15 to 16 μF, 16 to 17 μF, 17 to 18 μF, 18 to 19 μF, 19 to 20 μF, or >20 μF.

[0157] The resonant frequency of at least some of the or each ring electrode may be configured to be <10 kHz, 10-100 kHz, 100-200 kHz, 200-300 kHz, 300-400 kHz, 400-500 kHz, 500-600 kHz, 600-700 kHz, 700-800 kHz, 800-900 kHz or 900-1000 kHz. According to other embodiments, the resonant frequency of at least some of the or each ring electrode is between 1.0 and 1.1 MHz, 1.1 and 1.2 MHz, 1.2 and 1.3 MHz, 1.3 and 1.4 MHz, 1.4 and 1.5 MHz, 1.5 and 1.6 MHz, 1.6 and 1.7 MHz, 1.7 and 1.8 MHz, 1.8 and 1.9 MHz, 1.9 and 2.0 MHz, 2.0 and 2.1 MHz, 2.1 and 2.2 MHz, 2.2 and 2.3 MHz, 2.3 and 2.4 MHz, 2.4 and 2.5 MHz, 2.5 and 2.6 MHz, 2.6 and 2.7 MHz, 2.7 and 2.8 MHz, 2.8 and 2.9 MHz, 2.9 and 3.0 MHz, 3.0 and 3.1 MHz, 3.1 and 3.2 MHz, 3.2 and 3.3 MHz, 3.3 and 3.4 MHz, 3.4 and 3.5 MHz, 3.5 and 3.6 MHz, 3.7 and 3.8 MHz, 3.8 and 3.9 MHz, 3.9 and 4.0 ... Hz, 2.9 to 3.0 MHz, 3.0 to 3.1 MHz, 3.1 to 3.2 MHz, 3.2 to 3.3 MHz, 3.3 to 3.4 MHz, 3.4 to 3.5 MHz, 3.5 to 3.6 MHz, 3.6 to 3.7 MHz, 3.7 to 3.8 MHz, 3.8 to 3.9 MHz, 3.9 to 4.0 MHz, 4.0 to 4.1 MHz, 4.1 to 4.2 MHz, 4.2 to 4.3 MHz, 4.3 to 4.4 MHz, 4.4 to 4.5 MHz, 4.5 to 4.6 MHz, 4.6 to 4.7 MHz, 4.7 to 4.8 MHz, 4.8 to 4.9 MHz, or 4.9 to 5.0 MHz. According to other embodiments, the resonant frequency of at least some of the, or each, ring electrode may be configured to be between 5-10 MHz, 10-20 MHz, 20-30 MHz, 30-40 MHz, 40-50 MHz, 50-60 MHz, 60-70 MHz, 70-80 MHz, 80-90 MHz, 90-100 MHz or >100 MHz.

[0158] With respect to the coil termination configurations shown and described above with reference to Figures 7-9, it will be appreciated that when the control system described above with reference to Figures 10-12 is implemented, the coils may be terminated in other ways than as shown and described with reference to Figures 7-9. It will be appreciated that with the implementations shown and described with reference to Figures 10-12, the currents in adjacent ring electrodes flow in opposite directions. For example, in the configuration illustrated in Figure 8, the end of the ring electrode provided in slot 124b is shown as being electrically connected to the end of the ring electrode provided in slot 124c, but according to various embodiments, the end of the ring electrode provided in slot 124b may instead be electrically connected to the end of the ring electrode provided in the immediately above slot 124d. Similarly, the end of the ring electrode provided in slot 124c may be electrically connected to the end of the ring electrode provided in slot 124e.

[0159] FIG. 13 illustrates an aerosol generator 1306 according to one embodiment, comprising six ring electrodes L1-L6 or conductive loops 1302 and a tubular susceptor element 1305 located within a volume defined by the ring electrodes or conductive loops 1302. The ring electrodes or conductive loops 1302 are mounted on a printed circuit board ("PCB") 1304. A number of segments 1301 are provided between adjacent ring electrodes or conductive loops 1302. According to various embodiments, one or more peripheral slots 1303a-f may be provided in the susceptor element 1305 to reduce heat runoff. For example, if it is desired to apply an AC voltage to the first ring electrode L1, a corresponding current may be induced in a corresponding segment of the tubular susceptor element 1305 located immediately proximal to the first electrode L1. As a result, that segment of the tubular susceptor element 1305 may quickly reach a temperature T1, e.g., 250-350° C. However, it may be desirable to maintain adjacent segments of the tubular susceptor element 1305 at a lower temperature, e.g., 20-250° C. It will be appreciated that if the tubular susceptor element 1305 comprised a continuous, non-segmented tubular element, thermal energy transferred to one section of the susceptor element 1305 would be rapidly transferred to the entire tubular element by conduction. As a result, the entire tubular element would quickly exhibit substantially the same temperature.

[0160] However, according to various embodiments, one or more peripheral slots 1303a-1303f may be provided in the susceptor element 1305. The one or more peripheral slots 1303a-1303f provide a thermal barrier or partial thermal barrier that reduces the transfer of thermal energy between adjacent segments of the susceptor element 1305 by thermal conduction.

[0161] One or more of the peripheral slots 1303a-1303f may be at least partially filled with an insulating material. The insulating material may include a potting compound, an adhesive, a thermosetting plastic, or an epoxy resin. According to various embodiments, the potting compound may include an epoxy resin. For example, a two-component epoxy may be used that is comprised of a polymer resin and a hardener that when mixed together undergo a chemical reaction that crosslinks the chemical bonds in the polymer chains, resulting in a tough, rigid, and strong compound. Other embodiments are envisioned in which the potting compound includes polyurethane ("PU"), e.g., a thermosetting plastic. This may include a two-component compound that is comprised of a base resin with an isocyanate hardener. Other embodiments are envisioned in which the potting compound includes a silicone. For example, a silicone rubber may be utilized that includes a synthetic polysiloxane polymer that uses an added catalyst (such as platinum) for transition from a liquid state to a solid state.

[0162] 14 illustrates the direction of current flow 1400 and the resulting magnetic field around multiple ring electrodes 101 according to one embodiment. A tubular susceptor element 1401 is shown positioned within the ring electrode 101. The susceptor element 1401 may comprise multiple susceptor element segments with thermal barrier portions between the susceptor element segments.

[0163] According to various embodiments, an aerosol generator is disclosed that includes a plurality of ring electrodes. The ring electrodes may be configured to form a plurality of independently controllable heating zones. The control device may be configured to independently energize the ring electrodes. For example, a two-zone heating profile may be utilized. Other embodiments are envisioned in which more complex heating profiles may be utilized. For example, according to one embodiment, a heating profile may be utilized in which segmented susceptor elements are progressively energized such that, in effect, the heating profile is moved along at least a portion of the length of the aerosol generator during a session of use. For example, the control device may be configured to apply AC voltages to individual ring electrodes and / or groups of ring electrodes in sequence or according to a predetermined sequence. The aerosol delivery device may include an opening for receiving the aerosol product article, with a first heating zone disposed proximal to the opening and one or more additional heating zones disposed distal to the opening. The control device may be configured to (i) move the heating profile from the first heating zone towards one or more further heating zones during a session of use, and / or (ii) move the heating profile from the one or more heating zones towards the first heating zone during a session of use.

[0164] Embodiments are envisaged in which the aerosol generator comprises 3, 4, 5, 6, 7, 8, 9, 10 or more than 10 independently controllable heating zones, and the heating profile can be moved between or along the different heating zones.

[0165] According to various embodiments, an electronic component of an aerosol delivery device is provided that includes an inductor element that includes a plurality of separate electrodes mounted on a substrate. The electrodes may include ring electrodes or planar electrodes with a single loop. The electronic component may include a first module configured to receive a DC voltage and output an alternating current. The first module may include a DC-AC converter (or a DC-AC inverter) with, for example, a half-bridge or full H-bridge that converts DC to an AC current or voltage. According to an embodiment, the first module may include two MOSFETs combined with a MOSFET driver to form a half-bridge circuit. The electronic component may further include a second module configured to provide an alternating current to a selected electrode. The second module may include a plurality of semiconductor switches. According to an embodiment, an AC current or voltage from an AC power rail may be individually switched to a plurality of electrodes, for example ring electrodes, by a switch element. Each electrode or ring electrode may include a switch element. The switch element may include two MOSFETs. The electrodes, for example ring electrodes, may be mounted on a printed circuit board (PCB) and each electrode may be connected in series with a relatively high capacitance capacitor, for example a 1 μF capacitor. As a result, the resulting resonant frequency of each individual ring electrode may be configured to be about 1-2 MHz. According to one embodiment, the resonant frequency of each individual ring electrode may be configured to be 1.0-1.2 MHz, 1.2-1.4 MHz, 1.4-1.6 MHz, 1.6-1.8 MHz or 1.8-2.0 MHz.

[0166] Although embodiments have been described above in which the susceptor element, which may be segmented, is provided as part of an aerosol generator (the aerosol generator forming part of an overall aerosol delivery device), embodiments are also envisaged in which the susceptor element is instead provided as part of an aerosol product article, i.e., a consumable, that includes the aerosol generating material. For example, according to an embodiment, an aerosol product article may be provided that includes a susceptor element. For example, the susceptor element may include a planar stainless steel element. The planar stainless steel element may include a nickel coating. The nickel coating may have a Curie temperature of about 354° C., while the stainless steel element may include 430 stainless steel with 0% nickel. The Curie temperature of 430 stainless steel is >400° C. When the nickel coating reaches a Curie temperature of about 354° C., the nickel coating undergoes a reversible change from a ferromagnetic phase to a paramagnetic phase. The susceptor may be segmented by the thermal barrier portions discussed above that are provided between adjacent segments.

[0167] When the susceptor is heated to around 350°C (i.e., below the Curie temperature of nickel), the apparent resistance increases. This increase in resistance may be detected by measuring the DC current drawn from a DC power source that is supplied to a DC-AC converter (or DC-AC inverter). The output from the DC-AC converter (or DC-AC inverter) includes an AC voltage that is supplied to the electrodes that form the inductor elements. As will be appreciated by those skilled in the art, if the voltage supplied to the DC-AC converter (or DC-AC inverter) is kept constant (e.g., 6V) and the apparent resistance increases with increasing temperature, the DC current decreases.

[0168] It will be appreciated that the high frequency alternating magnetic field induces eddy currents in close proximity to the surface of the susceptor. This effect is known as the skin effect. The resistance in the susceptor depends in part on the depth of the skin layer available to the induced eddy currents. The nickel layer loses its magnetic properties when it reaches its Curie temperature. This results in an increase in the skin layer available to eddy currents in the nickel layer resulting in a decrease in the apparent resistance of the susceptor. As a result, a temporary increase in the sensed DC current may be observed when the nickel layer reaches its Curie temperature. Therefore, by monitoring the DC current drawn by the DC power source, a known temperature (e.g., 354°C) can be determined.

[0169] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims, or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. The various embodiments of the present 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. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. Aerosol generator comprising an inductor comprising a plurality of separate ring electrodes mounted on a first substrate An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the first substrate comprises a first printed circuit board ("PCB").

3. The aerosol delivery device of claim 1 or 2, wherein the ring electrode is planar.

4. The aerosol delivery device of any one of claims 1 to 3, wherein the ring electrodes are embedded in a matrix to form a housing.

5. The aerosol delivery device of any one of claims 1 to 4, wherein the first substrate comprises one or more connectors or pads for electrically connecting the first substrate to a second substrate.

6. The aerosol delivery device of claim 5 , wherein the second substrate comprises a second printed circuit board ("PCB").

7. 1. An aerosol delivery device comprising: an aerosol generator comprising a plurality of ring electrodes; a control device configured to apply one or more AC voltages independently to individual ring electrodes and / or groups of ring electrodes; An aerosol delivery device comprising:

8. an aerosol generator comprising a plurality of ring electrodes configured to form a plurality of independently controllable heating zones; a control device configured to independently energize the ring electrodes such that a heating profile is moved along at least a portion of the length of the aerosol generator during a session of use; and An aerosol delivery device comprising:

9. The aerosol delivery device of claim 8 , wherein the control device is configured to apply an AC voltage to individual ring electrodes and / or groups of ring electrodes in sequence or according to a predetermined sequence.

10. The aerosol delivery device includes an opening for receiving an aerosol product, a first heating zone is disposed proximal to the opening, and one or more further heating zones are disposed distal to the opening, and the control device comprises: (i) moving the heating profile from the first heating zone towards the one or more further heating zones during a session of use; and / or (ii) moving the heating profile from the one or more further heating zones towards the first heating zone during a session of use. The aerosol delivery device of claim 8 or 9,

11. A component of an aerosol delivery device, comprising: an inductor element comprising a plurality of separate ring electrodes mounted on a substrate; a first module configured to receive a DC voltage and output an AC current; a second module configured to supply the alternating current to selected ring electrodes; A component comprising:

12. The component of claim 11 , wherein the second module comprises a plurality of electronic switch elements.

13. The component of claim 12 , wherein at least one electronic switch element is connected to at least some of the ring electrodes.

14. 14. A component as claimed in claim 12 or 13, wherein at least some of the switch elements are independently controllable so that the alternating current output from the first module can be applied to selected ring electrodes.

15. 15. The component of claim 12, 13 or 14, wherein at least some of the switch elements or each of the switch elements comprises a half-bridge circuit.

16. 16. The component of claim 15, wherein at least some or each half-bridge circuit comprises two MOSFETs.

17. A component of an aerosol delivery device, comprising: an inductor element comprising a plurality of separate ring electrodes mounted on a substrate; a module configured to supply an alternating current to selected ring electrodes; A component comprising:

18. 1. An aerosol generator for an aerosol delivery device, comprising: A component according to any one of claims 11 to 17. An aerosol generator comprising:

19. The aerosol generator according to claim 18. An aerosol delivery device comprising:

20. 20. The aerosol delivery device of claim 19, wherein the alternating current supplied to one or more ring electrodes results in the generation of a varying magnetic field.

21. 21. The aerosol delivery device of claim 19 or 20, further comprising a controller, the controller configured to control the second module or the module to control which ring electrodes receive the alternating current.

22. 22. The aerosol delivery device of claim 19, 20 or 21, further comprising a tubular susceptor located at least partially within a volume defined by the plurality of ring electrodes.

23. 23. The aerosol delivery device of claim 22, wherein the tubular susceptor comprises one or more peripheral slots.

24. 24. The aerosol delivery device of claim 22 or 23, wherein the tubular susceptor comprises a plurality of annular susceptor portions, at least some of the annular susceptor portions being spaced apart from one another by one or more thermal barrier portions.

25. An aerosol delivery device according to any one of claims 1 to 10 or claims 19 to 24; Aerosol products and An aerosol delivery system comprising:

26. 1. A method for generating an aerosol, comprising: Providing an aerosol delivery device according to any one of claims 1 to 10 or claims 19 to 24; inserting an aerosol product at least partially into the aerosol delivery device; activating the aerosol delivery device; A method comprising:

Images