Aerosol delivery device with magnetic flux concentrator

Abstract

A novel aerosol delivery device is provided. [Solution] An aerosol supply device (202) is disclosed, comprising an aerosol generator (224)a having one or more magnetic field generators, and one or more magnetic field shaping elements (250) configured to shape, focus, concentrate or parallelize the varying magnetic field generated by the one or more magnetic field generators (224a).

Description

[Technical field]

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

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide an alternative to these articles by creating products that release compounds without combustion. Examples of such products include so-called "heat-not-burn" products, which release compounds by heating a material without burning it, or tobacco heating devices or products. The material 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 above mentioned devices or products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. In many cases, the medium used must 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 fluctuating magnetic field, and a susceptor or heating material that can be heated by permeating the fluctuating magnetic field to heat a suitable medium.

[0004] A conventional aerosol delivery device includes a cylindrical heating chamber into which a rod-shaped consumable is inserted.

[0005] Next generation devices are contemplated in which consumables having shapes other than cylindrical are used, such as consumables comprising a planar substrate. The planar substrate may comprise a susceptor that is heated by penetration with a varying magnetic field. For example, the planar substrate may comprise a card base layer to which an aluminum foil layer is adhered. The aluminum foil layer may function as the susceptor. The aerosol generating material (i.e., gel) may be provided on the aluminum foil layer (susceptor). The planar substrate may be inserted into the aerosol delivery device and translated or rotated relative to the heating element.

[0006] It will be appreciated that in order to provide an on-demand experience, the time to first puff should be as short as possible.

[0007] It would therefore be desirable to provide an improved aerosol delivery device. Summary of the Invention

[0008] According to one aspect, there is provided an aerosol delivery device comprising: an aerosol generator comprising one or more magnetic field generators; and one or more magnetic field shaping elements configured to shape, focus, concentrate or collimate the varying magnetic field generated by the one or more magnetic field generators.

[0009] Providing one or more magnetic field shaping elements has been found to be beneficial in that the one or more magnetic field shaping elements can focus, concentrate or collimate the fluctuating magnetic field generated by one or more magnetic field generators (which may comprise, for example, induction or inductor heating elements). As a result, the magnetic flux in the area of ​​the aerosol product article that is inserted into the aerosol delivery device during use can be substantially increased. As a result, the time to first puff can be substantially reduced, providing a puff-on-demand aerosol delivery device. Furthermore, the area of ​​the aerosol product article that is heated and consumed can be reduced, thereby allowing (i) to provide a denser aerosol-generation area per aerosol product article, and / or (ii) to provide a smaller aerosol product article that can still provide the same number of puffs.

[0010] Optionally, the aerosol generator may comprise one or more inductors, inductor elements or inductor coils.

[0011] Optionally, the one or more inductors, inductor elements or inductor coils may be substantially planar.

[0012] Optionally, the one or more magnetic field shaping elements may comprise one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials.

[0013] Optionally, the aerosol delivery device may further comprise a body portion and a removable mouthpiece, wherein one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials are configured to releasably secure the mouthpiece to the body portion.

[0014] Alternatively, the one or more magnetic field shaping elements may comprise one or more inductors, inductor elements, inductor coils, or electromagnets.

[0015] Optionally, the aerosol delivery device may further comprise a receiving area for receiving the aerosol product article.

[0016] Optionally, the one or more magnetic field shaping elements may be configured to shape, focus, concentrate or collimate the varying magnetic field generated by the one or more magnetic field generators onto a target area of ​​the aerosol product.

[0017] Optionally, the aerosol generator may be disposed on a first side of the receiving area, and the one or more magnetic field shaping elements may be disposed on a second, different side of the receiving area.

[0018] Optionally, the aerosol delivery device further comprises one or more ferrite based elements.

[0019] One or more ferrite based elements may be disposed adjacent the magnetic field generator to help improve the frequency response of the magnetic field generator.

[0020] Optionally, the one or more ferritic elements include a ceramic compound comprised of iron oxide (Fe2O3) chemically combined with one or more additional metallic elements.

[0021] Optionally, the one or more ferritic elements are disposed on a first surface of the receiving area.

[0022] Optionally, the one or more magnetic field generators have a first side and a second side, the first side of the one or more magnetic field generators being positioned adjacent to the one or more ferrite-based elements and the second side of the one or more magnetic field generators being positioned adjacent to the first side of the receiving area. According to various embodiments, there is provided an aerosol delivery device comprising: a receiving area for receiving the aerosol product; one or more aerosol generators, each comprising one or more magnetic field generators, the one or more aerosol generators being positioned adjacent to the receiving area; one or more ferrite-based elements disposed adjacent to the one or more aerosol generators; one or more magnetic field shaping elements configured to shape, focus, concentrate or collimate the varying magnetic field generated by the one or more magnetic field generators; An aerosol delivery device is provided in which one or more aerosol generators are disposed on a first side of a receiving area and one or more magnetic field shaping elements are disposed on a second, different side of the receiving area.

[0023] Optionally, the aerosol delivery device may further comprise an aerosol chamber configured to receive an aerosol generated from the aerosol product.

[0024] Optionally, the aerosol delivery device may further comprise a first device configured to move, translate or rotate the aerosol product article relative to the aerosol generator during a use session.

[0025] Optionally, the aerosol delivery device may comprise multiple magnetic field generators configured to cause generation of aerosol from different portions of the aerosol product during a use session.

[0026] Optionally, the aerosol delivery device may comprise multiple aerosol chambers, at least some or each aerosol chamber configured to receive aerosol generated from different portions of the aerosol product article during a use session.

[0027] According to another aspect, there is provided an aerosol delivery device comprising: an aerosol generator comprising one or more magnetic field generators; and one or more magnetic flux concentrating elements configured to concentrate magnetic flux generated by the one or more magnetic field generators.

[0028] It has been found that the provision of one or more magnetic flux concentrating elements serves to concentrate the magnetic flux generated by one or more magnetic field generators (which may comprise, for example, induction or inductor heating elements). As a result, the magnetic flux in the area of ​​the aerosol product article that is inserted into the aerosol delivery device during use can be substantially increased. As a result, the time to first puff can be substantially reduced, providing a puff-on-demand aerosol delivery device. Furthermore, the area of ​​the aerosol product article that is heated and consumed can be reduced, thereby allowing (i) to provide a denser aerosol-generation area per aerosol product article, and / or (ii) to provide a smaller aerosol product article that can still provide the same number of puffs.

[0029] Optionally, the aerosol generator may comprise one or more inductors, inductor elements or inductor coils.

[0030] Optionally, the one or more inductors, inductor elements or inductor coils may be substantially planar.

[0031] Optionally, the one or more flux concentrating elements may comprise one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials.

[0032] Optionally, the aerosol delivery device may further comprise a body portion and a removable mouthpiece, wherein one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials are configured to releasably secure the mouthpiece to the body portion.

[0033] Optionally, the one or more magnetic flux concentrating elements may comprise one or more inductors, inductor elements, inductor coils, or electromagnets.

[0034] Optionally, the aerosol delivery device may further comprise a receiving area for receiving the aerosol product article.

[0035] Optionally, the one or more magnetic flux concentrating elements may be configured to concentrate the varying magnetic field generated by the one or more magnetic field generators at a target region of the aerosol product article.

[0036] Optionally, the aerosol generator may be disposed on a first side of the receiving area, and the one or more magnetic flux concentrating elements may be disposed on a second, different side of the receiving area.

[0037] Optionally, the aerosol delivery device further comprises one or more ferrite based elements.

[0038] One or more ferrite based elements may be disposed adjacent the magnetic field generator to help improve the frequency response of the magnetic field generator.

[0039] Optionally, the one or more ferritic elements include a ceramic compound comprised of iron oxide (Fe2O3) chemically combined with one or more additional metallic elements.

[0040] Optionally, the one or more ferritic elements are disposed on a first surface of the receiving area.

[0041] Optionally, the one or more magnetic field generators have a first side and a second side, the first side of the one or more magnetic field generators being positioned adjacent to the one or more ferrite-based elements and the second side of the one or more magnetic field generators being positioned adjacent to the first side of the receiving area.

[0042] Optionally, the aerosol delivery device may further comprise an aerosol chamber configured to receive an aerosol generated from the aerosol product.

[0043] Optionally, the aerosol delivery device may further comprise a first device configured to move, translate or rotate the aerosol product article relative to the aerosol generator during a use session.

[0044] Optionally, the aerosol delivery device may comprise multiple magnetic field generators configured to cause generation of aerosol from different portions of the aerosol product during a use session.

[0045] Optionally, the aerosol delivery device may comprise multiple aerosol chambers, at least some or each aerosol chamber configured to receive aerosol generated from different portions of the aerosol product article during a use session.

[0046] According to another aspect, an aerosol delivery device as described above; an aerosol product article comprising an aerosol-generating material and one or more susceptors; An aerosol generating system is provided, comprising:

[0047] Optionally, the aerosol product article may include a planar aerosol product article.

[0048] For example, the susceptor may include a metal foil.

[0049] Optionally, the metal foil may include aluminum foil. According to another aspect, there is provided a method of generating an aerosol, comprising the steps of: Providing an aerosol delivery device as described above; introducing an aerosol product comprising an aerosol-generating material and one or more susceptors into an aerosol delivery device.

[0050] Optionally, the method further comprises activating an aerosol delivery device.

[0051] According to another aspect, there is provided an aerosol delivery device comprising: a receiving area for receiving the aerosol product; one or more aerosol generators comprising one or more magnetic field generators, the one or more aerosol generators being disposed on a first surface of the receiving area; An aerosol supply device is provided, comprising: one or more magnetic field shaping elements configured to shape, focus, concentrate or parallelize a varying magnetic field generated by one or more magnetic field generators, the one or more magnetic field shaping elements being positioned on a second, different surface of the receiving area.

[0052] Optionally, the one or more magnetic field shaping elements include one or more inductors, inductor elements, inductor coils, electromagnets, or ferrite-based materials.

[0053] Optionally, the aerosol delivery device further comprises one or more ferrite based elements.

[0054] Optionally, the one or more ferritic elements include a ceramic compound comprised of iron oxide (Fe2O3) chemically combined with one or more additional metallic elements.

[0055] Optionally, the one or more ferritic elements are disposed on a first surface of the receiving area.

[0056] Optionally, the one or more magnetic field generators have a first side and a second side, the first side of the one or more magnetic field generators being positioned adjacent to the one or more ferrite-based elements and the second side of the one or more magnetic field generators being positioned adjacent to the first side of the receiving area.

[0057] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0058] [Figure 1]1 is a schematic cross-sectional view of an aerosol delivery device and an aerosol product article, the aerosol delivery device including a plurality of induction coils and the aerosol product article including a plurality of portions of aerosol-generating material and corresponding susceptor portions. [Diagram 2] FIG. 1 illustrates an aerosol delivery device in combination with an aerosol product article, the aerosol product article comprising multiple portions of an aerosol generating material, the aerosol delivery device comprising a single induction heating element and a movement mechanism for rotating the aerosol product article relative to the single induction heating element. [Figure 3A] FIG. 2 is a plan view of the aerosol product. [Figure 3B] 1 is an end view of the aerosol product article showing multiple susceptors embedded in the aerosol product article. [Figure 3C] 1 is a side view of an aerosol product article showing multiple susceptors embedded in the aerosol product article. [Figure 4A] FIG. 1 is a perspective view of an aerosol delivery device having a mouthpiece in which a slidable fastener is used to secure an upper lid portion of the aerosol delivery device to a lower base portion. [Figure 4B] FIG. 13 is a perspective view of the slidable fastener removed. [Figure 4C] FIG. 2 is a perspective view of the aerosol delivery device with the lid open and an aerosol product inserted into the aerosol delivery device. [Diagram 5] A diagram showing a portion of an aerosol delivery device according to various embodiments, with the aerosol chamber and mouthpiece removed, and one or more magnets disposed in the upper lid of the aerosol delivery device, which function as one or more magnetic field shaping elements or magnetic flux concentrating elements to concentrate magnetic flux emitted by one or more inductor coils disposed in the base of the aerosol delivery device. [Figure 6]FIG. 1 illustrates an aerosol delivery device, in which an aerosol product article having a card substrate, an aluminum foil susceptor layer, and an aerosol generating material layer is positioned within a receiving area of ​​the aerosol delivery device such that the aerosol product article is positioned above an inductor coil and below one or more permanent magnets positioned on a lid portion of the aerosol delivery device, the one or more permanent magnets being configured to shape the magnetic field generated by the one or more inductor coils. [Figure 7] FIG. 13 shows how the temperature of the aluminum foil susceptor layer was determined to change during an initial 4 second calibration period. The temperature (TC) was measured directly by a thermocouple and the calculated temperature (TCalc), determined by the control system monitoring the resonant frequency of the induction heating element, is shown for comparison purposes; the results shown were obtained without placing a magnet in the vicinity of the aluminum foil susceptor to shape the magnetic field. [Figure 8] FIG. 1 shows how the temperature of the aluminum foil susceptor layer was determined to change during an initial 4 second calibration period; the temperature (TC) was measured directly by a thermocouple and the calculated temperature (TCalc), determined by the control system monitoring the resonant frequency of the induction heating element, is shown for comparison purposes; the results shown were obtained with a permanent magnet positioned above the aluminum foil susceptor layer, the magnet acting as a magnetic field shaping or flux concentrating element. [Figure 9] 1 is a table summarizing test data obtained with and without a permanent magnet placed on the aluminum foil susceptor layer, showing how the time to reach the maximum directly measured temperature (TCMax) was reduced from 1.8 seconds (when no magnet was present) to 1.2 seconds in the presence of a magnetic field shaping magnet, according to various embodiments. [Figure 10]FIG. 13 illustrates how the determined resonance of the resonant circuit (and therefore the calculated temperature of the aluminum foil susceptor layer) was determined to decrease as a function of time both when no magnet was placed above the aluminum foil susceptor layer and when a permanent magnet was placed above the aluminum foil susceptor layer to shape the magnetic field, according to various embodiments. [Figure 11] FIG. 1 shows a test aerosol product having an aluminum foil susceptor layer used in an aerosol delivery device, illustrating how blisters of different sizes were formed in the aluminum foil susceptor layer, the size of the blister depending on whether or not a magnet was positioned above the aluminum foil susceptor layer and the associated inductor heating element. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0059] Aspects and features of certain examples and embodiments are discussed or described herein. Some aspects and features of certain examples and embodiments may be implemented in a conventional manner and, for the sake of brevity, will not be discussed or described in detail. Thus, it will be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented in accordance with conventional techniques for implementing such aspects and features.

[0060] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0061] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0062] In some embodiments, the non-combustion aerosol delivery system is an electronic 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.

[0063] 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.

[0064] 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 a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0065] 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.

[0066] In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0067] In some embodiments, an aerosol delivery system, such as an 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 generating power source. In some embodiments, the heat generating power 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 in proximity to the heat generating power source.

[0068] In some embodiments, the 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.

[0069] In some embodiments, consumables for use with an aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0070] An aerosol-forming material is, for example, a material that is capable of generating an aerosol when heated, irradiated, or energized in any other manner. The aerosol-forming material may be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or fragrances.

[0071] The aerosol-generating material may include a binder and an aerosol-forming agent. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. 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.

[0072] The aerosol-generating material may include or 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-forming agent, and one or more other ingredients, such as an active agent, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60%, 70%, 80%, 85% or 90% by weight of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such as a construction of individual pieces of film on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0073] The aerosol-generating film may include or be a sheet that can optionally be chopped to form chopped sheets.

[0074] The aerosol-generating materials may include one or more active agents and / or flavorants, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0075] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to provide thermal energy to the aerosol-generating material 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 generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, pressure increase, or electrostatic energy.

[0076] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which are intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery 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 emits heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0077] The susceptor is a heating material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. An aerosol delivery device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0078] The aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some implementations, the aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may include a power source, such as, for example, a battery or a rechargeable battery. In some implementations, the aerosol delivery device may also comprise the aerosol generating components. However, in other implementations, the aerosol product article may comprise the aerosol generating components in part or in whole.

[0079] Induction heating is a process in which an electrically conductive object, called a susceptor, is heated by penetrating the object with a varying magnetic field. 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 electric 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 generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of electric current, and when such eddy currents are generated within the object, their flow against the electrical resistance of the object heats the object. This process is called Joule heating, Ohmic heating, or resistive heating.

[0080] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by permeating the object with a varying magnetic field. The magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field permeates such a material, the magnetic dipoles align with the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field produced by an electromagnet, permeates a magnetic material, the orientation of the magnetic dipoles changes with the applied varying magnetic field. Such magnetic dipole reorientation causes the generation of heat within the magnetic material.

[0081] When an object is both conductive and magnetic, the penetration of a varying magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can strengthen the magnetic field, which can enhance Joule heating.

[0082] Various embodiments will now be described in more detail.

[0083] 1 shows a cross-sectional view of a schematic diagram of an aerosol delivery system according to one configuration. Aerosol delivery device 202 is shown comprising an outer housing 221, a power source 222, control circuitry 223, one or more inductive heating elements such as induction coils 224a, a receiving area or aerosol formation chamber 225, a mouth end 226, an air inlet 227, an air outlet 228, a touch-sensitive panel 229, an inhalation sensor 230, and an end-of-use indicator 231.

[0084] The one or more induction heating elements 224a may comprise one or more of: (i) a flat spiral coil, where the spiral coil may include a circular or oval spiral, a square or rectangular spiral, a trapezoidal spiral, or a triangular spiral; (ii) a multi-layer induction construction in which subsequent full or partial turns of the coil are provided on adjacent layers, optionally with a first layer spaced apart from a second layer in a first direction and a third layer spaced apart from the second layer in an opposite direction and within or near the first layer, such that the multi-layer induction construction forms a staggered structure; or (iii) a three-dimensional inductor coil, such as a regular helical or conical shaped inductor coil, optionally with a variable helical pitch.

[0085] The aerosol delivery device 202 may include a lid portion, a base portion, and a fixing portion.

[0086] The outer housing 221 may be formed from any suitable material, such as a plastic material. The outer housing 221 may be configured such that the power source 222, the control circuitry 223, the one or more induction coils 224a, the receiving area 225, and the inhalation sensor 230 are disposed within the outer housing 221. The outer housing 221 also defines an air inlet 227 and an air outlet 228. The touch sensitive panel 229 and the end of use indicator 231 may be disposed on the exterior of the outer housing 221.

[0087] The outer housing 221 further includes a mouth end 226. The outer housing 221 and the mouth end 226 may be formed as a unitary component (i.e., the mouth end 226 may form a portion of the outer housing 221).

[0088] Other configurations are contemplated in which the tip 226 may be detachable from the outer housing 221. The tip end 226 may comprise a removable component that is separate from but connectable to the outer housing 221, and may be removed for cleaning and / or replacement with another tip end 226. The tip end 226 may be retained within the housing 21 by one or more magnets.

[0089] According to various embodiments, one or more magnetic field shaping elements may be provided that are configured to shape, focus, concentrate or collimate the varying magnetic field generated by the one or more magnetic field generators, which may comprise one or more induction coils 224a. The one or more magnetic field shaping elements are not shown in Figures 1-4 for clarity, but are described in more detail below with reference to Figures 5 and 6.

[0090] Additionally, one or more ferritic elements (not shown) may be provided below the one or more induction coils 224a. The one or more ferritic elements have been found to improve the frequency response of the one or more induction coils 224a. In particular, the one or more ferritic elements help to reduce variations in the resonant frequency of the one or more induction coils 224a. The one or more ferritic elements help to improve the performance of the aerosol delivery device 202, for example, helping to ensure that a susceptor provided as part of the aerosol product article 204 heats up more quickly and becomes hotter than if the one or more ferritic elements were not provided.

[0091] The power source 222 may be configured to provide operating power to the aerosol delivery device 202. The power source 222 may comprise any suitable power source, such as a battery. For example, the power source 222 may include a rechargeable battery, such as a lithium ion battery ("LIB"). The power source 222 may be removable or may form an integrated part of the aerosol delivery device 202. The power source 222 may be recharged by connecting the aerosol delivery device 202 to an external power source (such as a mains power source) via an associated connection port, such as a USB port (not shown), or via a suitable wireless receiver (not shown).

[0092] Control circuitry 223 may be suitably configured or programmed to control the operation of aerosol delivery device 202 to achieve a particular operational function of aerosol delivery device 202. Control circuitry 223 may be considered to logically comprise various subunits or circuit elements associated with different aspects of the operation of aerosol delivery device 202. For example, control circuitry 223 may comprise a logical subunit for controlling the recharging of power source 222. Additionally, control circuitry 223 may comprise a logical subunit for communications, for example, to facilitate data transfer from or to aerosol delivery device 202. However, the primary function of control circuitry 223 is to control the aerosolization of aerosol generating material, as described in more detail below.

[0093] It will be appreciated that the functionality of control circuitry 223 can be implemented in a variety of different ways, for example, using one or more appropriately programmed programmable computers and / or one or more appropriately configured application specific integrated circuits, circuits, chips or chipsets configured to implement the desired functionality. Control circuitry 223 may be connected to or receive power from power source 222 and may be configured to distribute or control power to other components of aerosol delivery device 202.

[0094] The aerosol delivery device 202 may further comprise a receiving area 225 configured to receive the aerosol product article 204. The receiving area 225 may be of a size suitable for removably receiving the aerosol product article 204 therein. The aerosol product article 204 may include a carrier component or substrate (e.g., a card) 242, one or more susceptors or susceptor layers, and an aerosol-generating material 244 disposed on the one or more susceptors or susceptor layers. According to one construction, a single susceptor layer may be provided, the single susceptor layer comprising an aluminum or metal foil layer.

[0095] The aerosol delivery device 202 may include a lid and a base configured to engage with one another. A securing mechanism may be provided to secure the lid to the base. Various configurations of the lid and base are contemplated. The aerosol delivery device 202 may include a hinged door or removable portion of the outer housing 221 that allows access to the receiving area 225 such that a user may insert and / or remove the aerosol product article 204 into / from the receiving area 225. The hinged door or removable portion of the outer housing 221 may also function to retain the aerosol product article 204 within the receiving area 225 when closed.

[0096] According to an embodiment, one or more ferritic elements (not shown) may be provided below the one or more induction coils 224a. Thus, the one or more ferritic elements and the one or more induction coils 224a are provided on one side of the receiving area 225. One or more magnetic field shaping elements may be provided on the other side of the receiving area 225, e.g., above the receiving area 225.

[0097] When the aerosol product item 204 is used up or the user simply desires to switch to a different aerosol product item 204, the aerosol product item 204 may be removed from the aerosol delivery device 202 and a replacement aerosol product item 204 may be placed in its place within the receiving area 225.

[0098] The aerosol delivery device 202 may include a permanent opening in communication with the receiving area 225 through which the aerosol product article 204 can be inserted into the receiving area 225. In such implementations, a retention mechanism may be provided for retaining the aerosol product article 204 within the receiving area 225 of the aerosol delivery device 202.

[0099] The retention mechanism may comprise a locking mechanism configured to engage the lid with the base to hold the aerosol product article 204 in place during use to prevent relative movement of the aerosol product article 204. For example, the lid and base may be configured to hold the aerosol product article 204 in a position between the lid and base.

[0100] 2 shows a schematic diagram of a portion of an aerosol delivery device 202 according to one configuration. The aerosol delivery device 202 is shown with an aerosol product article 204 that includes an aerosol-generating material disposed within the aerosol delivery device 202. The combination of the aerosol delivery device 202 and the aerosol product article 204 together form an aerosol delivery system.

[0101] The aerosol product article 204 has a first upper surface 112 on which an aerosol-generating material 244 may be disposed. The aerosol product article 204 may comprise a carrier layer 242 (sometimes referred to herein as a carrier or substrate support layer) and a susceptor layer on which the aerosol-generating material 244 may be disposed. The aerosol-generating material 244 may be disposed as multiple doses of the aerosol-generating material. The aerosol product article 204 has a second lower surface 116 opposite the first surface 112. The first surface 112 and / or the second surface 116 may be smooth or rough.

[0102] The aerosol-delivery device 202 may include one or more inductive heating elements 224a positioned to face the second surface 116 of the aerosol product article 204. The one or more inductive heating elements 224a may be configured to transfer energy from a power source, such as a battery (not shown), to the aerosol-generating material 244 to generate an aerosol from the aerosol-generating material 244.

[0103] The aerosol delivery device 202 may have a moving mechanism 130 configured to move a particular portion (or, in some cases, a dose) of the aerosol product article 204, and in particular the aerosol-generating material 244. That portion of the aerosol-generating material 244 may be rotated relative to one or more induction heating elements or induction coils 224a, in this case such that that portion of the aerosol-generating material 244 is individually presented to the induction heating element or induction coil 224a. In the configuration shown in FIG. 2, the induction heating element 224a may comprise an induction coil, and the aerosol product article 204 includes a layer that functions as a susceptor.

[0104] The aerosol delivery device 202 may be configured such that at least one dose of the aerosol-generating material 244 is rotated about the axis A at an angle θ relative to the second surface 116. The control circuitry 223 may be configured to operate both the induction heating element or induction coil 224a and the movement mechanism 130 such that the aerosol product article 204 is rotated to align the individual portions of the aerosol-generating material 244 proximate to the induction heating element or induction coil 224a. The aerosol product article 204 may be substantially flat or planar. The carrier layer 242 of the aerosol product article 204 may be formed partially or entirely from paper or card.

[0105] 2 includes five doses (or portions) of aerosol-generating material 244. In other examples, the aerosol product article 204 may have more or fewer doses of aerosol-generating material 244. In some examples, the aerosol product article 204 may have doses of aerosol-generating material 244 arranged in individual doses, as shown in FIG.

[0106] In other examples, the doses may be in the form of a disk, which may be continuous or discontinuous around the circumference of the aerosol product article 204. In yet other examples, the doses may be in the form of annulus, ring, or any other shape. The aerosol product article 204 may or may not have a rotationally symmetric distribution of doses on the first surface 112 about the axis A. A symmetric distribution of doses allows equivalently positioned doses (within a rotationally symmetric distribution) to receive equivalent heating profiles from the induction heating element or induction coil 224a upon rotation about the axis A, if desired.

[0107] The aerosol product article 204 in this example includes an aerosol-generating material 244 disposed on a susceptor layer of the aerosol product article 204. However, in other implementations, the aerosol product article 204 may be formed solely from the aerosol-generating material 244. That is, in some implementations, the aerosol product article 204 may consist entirely of the aerosol-generating material 244. In this example, one or more susceptor elements may be provided as part of the aerosol delivery device 202.

[0108] The aerosol product article 204 may have a layered structure and may be formed from multiple materials. In one example, the aerosol product article 204 may have a layer formed from at least one of a thermally conductive material, a dielectric material, a permeable material, or an impermeable material.

[0109] In some implementations, the carrier layer 242 or substrate may be or include a metal element configured to be heated by a varying magnetic field and thus may function as a susceptor layer. In such implementations, the inductive heating element 224a may include one or more inductive coils 224a that, when energized, cause heating in the metal element of the aerosol product article 204. The degree of heating may be affected by the distance between the metal element or susceptor layer and the inductive coils 224a.

[0110] The arrangement shown in Figure 2 operates by allocating (or moving) multiple doses of aerosol-generating material 242 to an induction heating element or induction coil 224a. While this arrangement in Figure 2 may slightly increase the complexity of the moving mechanism 130 for effecting the movement to the aerosol product article 204, it provides an advantage by allowing the aerosol delivery device 204 to include a single induction heating element 224a that is used to heat multiple portions of the aerosol-generating material 244. It will be appreciated that a single heating element 224a requires a single control mechanism (such as control circuit 223) while multiple heaters may each require a separate control mechanism. Thus, this arrangement may reduce the cost and control complexity associated with the operation and control of the induction heating element 224a.

[0111] The shape of the aerosol delivery device 202 may be cigarette-shaped (one dimension longer than the other two dimensions) or may be other shapes. In one example, the aerosol delivery device 202 may have a shape in which two dimensions are longer than one other dimension, such as a compact disc player. Alternatively, the shape may be any shape that can adequately accommodate the aerosol product article 204, the one or more inductive heating elements or induction coils 224a, and the movement mechanism 130.

[0112] The aerosol product article 204 may include a carrier component 242, which may be formed from a card. The carrier component 242 may form the majority of the aerosol product article 204 and may serve as a base for one or more susceptors or susceptor layers on which the aerosol-generating material 244 is provided or deposited. The carrier component 242 may be approximately rectangular in shape. The carrier component 242 may have a length of 30-80 mm, a width of 7-25 mm, and a thickness of 0.2 mm. However, it should be understood that other configurations are contemplated in which the carrier component 242 may have different dimensions as desired.

[0113] The aerosol product article 204 may comprise multiple individual portions of the aerosol-forming material 244 disposed on a surface of the carrier component 242. The aerosol product article 204 may comprise 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, or more than 15 individual portions of the aerosol-forming material 244.

[0114] The individual portions of aerosol-generating material 244 may be arranged in an n by m array. However, it should be understood that in other implementations a greater or lesser number of individual portions may be provided and / or the portions may be arranged in a different format of the array (e.g., a 1 by 6 array). Other configurations are contemplated in which the aerosol product article 204 comprises a disk and the separate portions of aerosol-generating material 244 are provided within separate segments of the disk.

[0115] The aerosol-generating material 244 may be disposed at separate, distinct locations on a single surface of the component carrier 242. Although the separate portions of the aerosol-generating material 244 are shown as having a circular footprint, it should be understood that the separate portions of the aerosol-generating material 244 may take on any other footprint, such as a square, trapezoid, or rectangular, as desired. The separate portions of the aerosol-generating material 244 may be disposed separately from one another such that each of the separate portions may be individually or selectively energized (e.g., heated) to generate an aerosol.

[0116] The aerosol product article 204 may comprise multiple portions of aerosol-generating material 244 that are all formed from the same aerosol-generating material. Alternatively, the aerosol product article 204 may comprise multiple portions of aerosol-generating material 244, where at least two portions are formed from different aerosol-generating materials.

[0117] The one or more induction heating elements or coils 224a may be arranged such that a surface of the one or more induction heating elements or coils 224a forms part of a surface of the receiving area 225. That is, an outer or upper surface of the one or more induction heating elements or coils 224a is flush with the inner surface of the receiving area 225.

[0118] The one or more inductive heating elements or coils 224a may be configured such that when the aerosol product article 204 is received in the receiving area 225, each inductive heating element or coil 224a aligns with a corresponding individual portion of the aerosol-generating material 244. For example, if six inductive heating elements or coils 224a are arranged in a 2×3 array, the aerosol product article 204 may comprise a 2×3 array of six individual portions of the aerosol-generating material 244. However, as discussed above, the number of inductive heating elements or coils 224a may vary in different implementations. For example, according to various configurations, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 individual inductive heating elements or coils 224a may be provided.

[0119] Each of the inductive heating elements or coils 224a can be individually activated to heat a corresponding portion of the aerosol-generating material 244. Although the inductive heating elements or coils 224a are shown flush with the inner surface of the receiving area 225, in other implementations the inductive heating elements or coils 224a may protrude into the receiving area 225.

[0120] In configurations in which the aerosol product article 204 is configured to move in a specified or desired direction relative to one or more induction heater elements or induction coils 224a, the securing mechanism may be configured to engage the lid with the base to hold the aerosol product article 204 in a fixed position to prevent relative movement of the aerosol product article 204, thereby preventing relative movement in any direction other than the specified or desired direction.

[0121] For example, in an arrangement in which the aerosol product article 204 is configured to rotate about an axis of rotation relative to one or more induction heater elements or induction coils 224a to present a fresh area of ​​aerosol-generating material on the aerosol product article 204 to the one or more induction heater elements or induction coils 224a, the locking mechanism may be configured to engage the lid with the base to prevent relative movement of the aerosol product article 204 in directions other than rotation about the axis of rotation, while still allowing the aerosol product article 204 to be rotated relative to the one or more induction heater elements or induction coils 224a.

[0122] One or more induction coils 224a may be provided adjacent the receiving area 225 and may comprise substantially planar coils arranged such that the axis of rotation about which a given coil is wound extends within the receiving area 225 and is approximately perpendicular to the plane of the carrier component 242 of the aerosol product article 204.

[0123] The control circuitry 223 may include a mechanism for generating an alternating current through any one or more of the induction coils 224a. The alternating current generates an alternating magnetic field that heats the corresponding portion of the susceptor or susceptor layer. The heat generated by the susceptor or portion of the susceptor layer is correspondingly transferred to the portion of the aerosol-generating material 244.

[0124] The control circuit 223 may be configured to provide current to the induction coil 224a in response to receiving a signal from the touch-sensitive panel 229 and / or the inhalation sensor 230.

[0125] Various configurations have been described in which one or more susceptors are provided as part of the aerosol product article 204. However, other configurations in which one or more susceptors are disposed within or as part of the aerosol delivery device 202 are also contemplated. For example, one or more susceptors may be provided above one or more induction coils 224a, or may be positioned such that one or more susceptors contact a lower surface of the carrier component 242.

[0126] An aerosol product article 204 for use with the aerosol delivery device 202 may comprise a carrier component 242, one or more susceptor elements 224b, and one or more portions of aerosol-generating material 244a-f, as shown and described in more detail with reference to Figures 3A-3C.

[0127] FIG. 3A shows a top view of an aerosol product 204 of one configuration, FIG. 3B shows an end view of an aerosol product 204 of one configuration along its longitudinal (length) axis, and FIG. 3C shows a side view of an aerosol product 204 of one configuration along its width axis.

[0128] One or more susceptor elements 224b may be formed from aluminum foil, although it should be understood that in other implementations, other metals and / or conductive materials may be used. As seen in FIG. 3C, the carrier component 242 may include several susceptor elements 224b that correspond in size and position to the individual portions of aerosol-generating material 244a-f disposed on a surface of the carrier component 242. That is, the susceptor elements 224b may have similar widths and lengths as the individual portions of aerosol-generating material 244a-f.

[0129] The susceptor elements 224b are shown embedded in the carrier component 242. However, in other configurations, the susceptor elements 224b may be placed or disposed on a surface of the carrier component 242. According to another implementation, the susceptor may be provided as a single layer that substantially covers the carrier component 244. According to one configuration, the aerosol product article 204 may comprise a substrate or support layer, a single layer of aluminum foil that functions as a susceptor, and one or more regions of aerosol-generating material 244 deposited on the aluminum foil susceptor layer.

[0130] According to one configuration, an array of induction heating coils 224a may be provided to energize the individual portions of the aerosol-generating material 244. However, according to other configurations, a single induction coil 224a may be provided and the aerosol product article 204 may be configured to move relative to the single induction coil 224a. Thus, there may be fewer induction coils 224a than individual portions of the aerosol-generating material 244 provided on the carrier component 242 of the aerosol product article 204, such that relative motion between the aerosol product article 204 and the induction coil 224a is required to enable each of the individual portions of the aerosol-generating material 244 to be individually energized.

[0131] Alternatively, a single induction coil 224a may be provided and the aerosol product 204 may be rotated relative to the single induction coil 224a.

[0132] For example, a movable induction heating element may be provided within the receiving area 225 such that the induction heating element may move relative to the receiving area 225. In this manner, the movable induction heating element may be translated (e.g., across the width and length of the carrier component 242) such that the induction heating element 224a may be aligned with a respective one of the discrete portions of the aerosol-generating material 244.

[0133] Although implementations are described above in which individual, spatially discrete portions of aerosol-generating material 244 are deposited on carrier component 242, it should be understood that in other implementations, aerosol-generating material 244 may not be provided as individual, spatially discrete portions, but instead may be provided as a continuous sheet, film, or layer of aerosol-generating material 244. In these implementations, certain regions of the sheet of aerosol-generating material 244 may be selectively heated to generate aerosols in much the same manner as described above.

[0134] While it has been described above that the heating element 224a is configured to provide heat to the aerosol-generating material 244 (or a portion thereof) at an operating temperature at which an aerosol is generated from the portion of the aerosol-generating material 244, in some implementations, the one or more inductive heating elements or induction coils 224a and associated susceptor elements may be configured to preheat the portion of the aerosol-generating material to a preheat temperature (lower than the operating temperature) at which a smaller amount of aerosol or no aerosol is generated when the portion is heated at the preheat temperature.

[0135] Each of the one or more induction heating elements or induction coils 224a may provide the same heating profile to a respective aerosol generation region, but it will be appreciated that one or more of the induction heating elements or induction coils 224a may alternatively be configured to provide different heating profiles to different respective aerosol generation regions.

[0136] The aerosol delivery device 202 may include a rotation device configured to rotate the aerosol product article 204 about an axis of rotation. The rotation device may be configured to rotate the aerosol product article 204 relative to the one or more induction coils 224a such that one or more fresh aerosol-generating regions of the aerosol product article 204 are moved into proximity with the one or more induction coils 224a. The locking mechanism may be configured to allow the aerosol product article 204 to be rotated relative to the one or more induction coils 224a while preventing relative movement of the aerosol product article 204 in a direction other than rotation about the axis of rotation, such as the z-direction as shown in FIG. 1.

[0137] The lid may include a plenum and a tip. In some configurations, the tip and plenum may be integral with the lid. It will be appreciated that the integrated tip and lid ensure even compression on the aerosol product article 204. That is, when the tip and lid are a single integral piece, there is substantially no additional mechanical play or variation resulting from the connection between the tip and the lid. As a result, the force exerted by the lid on the aerosol product article 204 is substantially constant across the upper lid-facing surface of the aerosol-generating material.

[0138] However, other configurations are contemplated in which the aerosol delivery device 202 includes a removable mouthpiece that may be retained within the housing of the aerosol delivery device 202 by one or more magnets. The one or more magnets may also function as magnetic field shaping or magnetic flux concentrating elements, as described in more detail below. It is also contemplated that the plenum may be removable.

[0139] 4A shows an aerosol delivery device according to one embodiment comprising a lid 1006 and a base 1008. A fastening mechanism 1010 may be provided comprising a fastener, such as a slidable fastener, configured to clamp the lid 1006 to the base 1008 so as to engage the lid 1006 of the aerosol delivery device 202 with the base 1008. Alternatively or additionally, the fastening mechanism may comprise a rotatable fastener. The lid 1006 may pivot about a hinge mechanism 1034.

[0140] The lid 1006 and / or base 1008 may include one or more walls configured to form an aerosol chamber or an aerosol formation chamber when the lid 1006 engages the base 1008. The lid 1006 and / or base 1008 may apply pressure uniformly to the substantially planar aerosol product article via the one or more walls to prevent relative movement of the aerosol product article.

[0141] FIG. 4B shows the securing mechanism 1010 removed, and FIG. 4C shows the lid 1006 in an open position with the aerosol product 204 inserted or within the aerosol delivery device 202.

[0142] Aerosol delivery device 202 as shown in Figures 1-4 and described above further includes one or more magnets 250 as shown in Figures 5 and 6. One or more magnets 250 function to shape a magnetic field or focus a magnetic flux emanating from one or more inductor coils 224a disposed, for example, at a base of aerosol delivery device 202. It is also contemplated that one or more magnets 250 may be configured to secure a removable mouthpiece (not shown) to a housing of aerosol delivery device 202.

[0143] However, it is not required that one or more magnets 250 assist in securing the removable mouthpiece to the housing, and in fact it is contemplated that the mouthpiece 226 may be integral with the housing and may be non-removable.

[0144] 5 shows an embodiment of the aerosol delivery device 202 with the top lid and associated removable mouthpiece removed. The aerosol delivery device 202 comprises an aerosol generator. The aerosol generator may comprise one or more magnetic field generators, such as one or more inductor coils 224a. A test aerosol product or consumable 204 is shown disposed within the aerosol delivery device 202. The aerosol product or consumable 204 may be disc-shaped and may comprise a substrate that may comprise, for example, a layer of card with a layer of aluminum foil 243 adhered thereon. The aluminum foil layer 243 may have a thickness of 25 μm and may function as a susceptor.

[0145] One or more ferrite-based elements (not shown) may be provided beneath the one or more inductor coils 224a, which have been found to improve the frequency response of the one or more inductor coils 224a.

[0146] It will be appreciated that commercially available aerosol products or consumables 204 may further comprise a layer of aerosol-generating material (e.g., gel) disposed on the aluminum foil layer 243. However, in some examples for testing and device calibration purposes, test aerosol products 204 were tested that comprised only a card substrate with an aluminum foil layer 243 adhered thereto. In other examples, test aerosol products 204 were tested that comprised a card substrate, an aluminum foil layer 243 acting as a susceptor, and a layer of aerosol-generating material.

[0147] As discussed above, the aerosol delivery device 202 according to various embodiments further comprises one or more magnets 250. The one or more magnets 250 function to shape a magnetic field or focus a magnetic flux emitted from, for example, one or more inductor coils 224a disposed at the base of the aerosol delivery device 202. It is also contemplated that the one or more magnets 250 may be configured to secure a removable mouthpiece (not shown) to the housing of the aerosol delivery device 202.

[0148] However, it is not required that one or more magnets 250 assist in securing the removable mouthpiece to the housing, and in fact it is contemplated that the mouthpiece 226 may be integral with the housing and may be non-removable.

[0149] As shown in FIG. 5, the one or more magnets 250 may be positioned vertically above the one or more inductor coils 224a. The one or more inductor coils 224a are hidden from view and are located at the lower section or base of the aerosol delivery device 202. The location of the one or more inductor coils 224a is shown in dashed lines. The one or more magnets 250 function as one or more magnetic field shaping or flux concentrating elements. According to various embodiments, one, two, three or more magnets 250 may be provided and may function as magnetic field shaping or flux concentrating elements.

[0150] The inductor coil 224a may have a trapezoidal profile, as shown in Figure 5, or the inductor coil 224a may have a circular shape. Other embodiments are contemplated in which the inductor coil 224a may have a different profile.

[0151] For testing and calibration purposes, a thermocouple 260 is shown attached to the upper surface of the test aerosol product article 204, i.e., aluminum foil layer 243. It will be appreciated that the aluminum foil disk layer is the susceptor 243, which in use is heated by magnetic induction by the inductor coil 224a. If an aerosol-generating material is to be provided on the upper surface of the aluminum foil susceptor layer 243, the aerosol-generating material will be heated and form an aerosol at a particular temperature which may then be inhaled by a user.

[0152] Thermocouple 260 was provided for testing and calibration purposes. In particular, thermocouple 260 was provided to measure the temperature of susceptor 243 of aerosol product article 204 during testing and initial calibration of aerosol delivery device 202.

[0153] 6 illustrates an embodiment of the aerosol delivery device 202 in which a magnet 250 is provided above the induction coil 224a to shape the magnetic field emitted by the induction coil 224a or to concentrate the magnetic flux. An aerosol product article 204 is shown received in a receiving area 225 of the aerosol delivery device 202 and comprises a support or substrate layer 242, a susceptor layer 243, and a layer of aerosol-generating material 244. The support or substrate layer 242 may comprise a card and the susceptor layer 243 may comprise a layer of aluminum foil 243. Other elements of the aerosol delivery device 202 illustrated in FIG. 6 correspond to those illustrated and described above in relation to FIG. 1.

[0154] One or more ferrite-based elements (not shown) may be provided beneath the one or more inductor coils 224a, which have been found to improve the frequency response of the one or more inductor coils 224a.

[0155] The magnet(s) 250 as shown in Figures 5 and 6 may include, for example, a button shaped magnet. The magnet(s) 250 may have, for example, a diameter of 10 mm and a thickness of, for example, 1 mm. Other configurations are contemplated in which the magnet(s) 250 may have a diameter of less than 5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm, 10-11 mm, 11-12 mm, 12-13 mm, 13-14 mm, 14-15 mm, and greater than 15 mm. Constructions in which the magnet(s) 250 may have a thickness of less than 0.5 mm, 0.5-0.6 mm, 0.6-0.7 mm, 0.7-0.8 mm, 0.8-0.9 mm, 0.9-1.0 mm, 1.0-1.1 mm, 1.1-1.2 mm, 1.2-1.3 mm, 1.3-1.4 mm, 1.4-1.5 mm, and greater than 1.5 mm are also contemplated.

[0156] More generally, embodiments are contemplated in which one or more magnetic field shaping or flux concentrating elements (e.g., one or more magnets 250 or ferrite-based materials) are optionally provided above one or more induction coils 224a. The one or more magnetic field shaping or flux concentrating elements (e.g., one or more magnets 250) may have a circular or button shape. Alternatively, the one or more magnetic field shaping or flux concentrating elements (e.g., one or more magnets 250) may have a triangular, rectangular, square, elliptical, polygonal, regular or irregular shape.

[0157] The magnet(s) 250 may be formed from neodymium iron boron (NdFeB), samarium cobalt (SmCo), alnico, ceramic, or ferrite magnetic materials.

[0158] The one or more magnets 250 function as magnetic field shaping or flux concentrating elements. Embodiments are contemplated in which either a single magnetic field shaping or flux concentrating element is provided or in which multiple magnetic field shaping or flux concentrating elements are provided. The one or more magnetic field shaping or flux concentrating elements may comprise, for example, one or more permanent magnets 250. The one or more magnetic field shaping or flux concentrating elements 250 may be configured to shape a magnetic field or concentrate a magnetic flux generated by one or more magnetic field generators, which may comprise one or more inductor coils 224a.

[0159] Other embodiments are contemplated in which one or more of the magnetic field shaping elements may include a ferritic material that may not be magnetic. The ferritic material may include a ceramic compound consisting of iron oxide (Fe2O3) chemically combined with one or more additional metallic elements. For example, the ferritic material may include ferritic stainless steel (which may include 12% or more chromium).

[0160] The magnet(s) 250 (or ferrite based material) may be positioned at a position or distance of 8.3 mm above or spaced from the inductor coil 224a. However, according to other configurations, the magnet(s) 250 (or ferrite based material) may be positioned at a distance of less than 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, 10-11 mm, 11-12 mm, or more than 12 mm above or from the inductor coil 224a.

[0161] The inductor coil(s) 224a may be generally planar. For example, the inductor coil(s) 224a may have a trapezoidal shape. However, other configurations are contemplated in which the inductor coil(s) 224a may have different shapes, such as triangular, square, rectangular, pentagonal, hexagonal, circular, elliptical, or other shapes.

[0162] The one or more magnetic field shaping or flux concentrating elements may comprise one or more permanent magnets 250, ferromagnetic or ferrimagnetic materials. The one or more magnetic field shaping or flux concentrating elements (e.g., one or more magnets 250) may be centered with respect to the inductor coil 224a such that a central cylindrical axis of the one or more magnets 250 may be arranged to be coaxial with a longitudinal axis of the one or more inductor coils 224a. The inductor coil 224a may comprise, for example, a plurality of helical or circular tracks that may be arranged about the longitudinal axis. According to other embodiments, the one or more magnetic field shaping or flux concentrating elements may comprise a ferritic material, such as ferritic stainless steel.

[0163] 5, a thermocouple 260 was positioned to contact the upper surface of the aluminum foil susceptor 243 at a point on the axis defined by the central cylindrical axis of the magnet(s) 250 and the helical or longitudinal axis of the inductor coil 224a for testing and calibration purposes. The thermocouple 260 was provided to allow a physical measurement of the temperature of the susceptor 243 to be measured as it heats up via operation of the induction coil 224a during a use session.

[0164] The aerosol delivery device 202 comprises a body portion and may include a removable mouthpiece. One or more permanent magnets, ferromagnetic materials, or ferrimagnetic materials 250 may be configured to removably secure the removable mouthpiece to the body portion of the aerosol delivery device 202.

[0165] 5, one or more permanent magnets 250 function as one or more magnetic field shaping or flux concentrating elements. However, other embodiments are contemplated in which one or more inductors, inductor elements, inductor coils, electromagnets, or ferrite-based materials may be provided to function as one or more magnetic field shaping or flux concentrating elements.

[0166] 6, the aerosol delivery device 202 may have a receiving area 225 for receiving the aerosol product 204. One or more magnetic field shaping or flux concentrating elements may be disposed on an opposite side of the receiving area 225 from the inductor coil 224a. For example, the one or more magnetic field shaping or flux concentrating elements may be disposed in a lid of the aerosol delivery device 202, while the one or more inductor coils 224a may be disposed in a base of the aerosol delivery device 202. The receiving area 225 may be disposed between the base and the lid of the aerosol delivery device 202.

[0167] According to other embodiments, one or more magnetic field shaping or magnetic flux concentrating elements may be disposed in a base of aerosol delivery device 202 and one or more induction coils 224a may be provided in a lid of aerosol delivery device 202. Receiving area 225 may be provided between the base and the lid of aerosol delivery device 202.

[0168] One or more magnetic field shaping elements or magnetic flux concentrating elements may be configured to shape or concentrate the varying magnetic field generated by one or more magnetic field generators or inductor coils 224a onto a target area of ​​the aerosol product article 204.

[0169] The aerosol generator or induction coil 224a may be disposed on a first side of the receiving area 225, and one or more magnetic field shaping or flux concentrating elements (e.g., one or more magnets 250) may be disposed on a second, different side of the receiving area 225. The receiving area 225 may be intermediate the one or more induction coils 224a and the one or more permanent magnets 250.

[0170] Optionally, the aerosol delivery device 202 may further comprise an aerosol chamber configured to receive the aerosol generated from the aerosol product 204. The aerosol chamber was removed from the aerosol delivery device 202 shown in FIG. 5 for testing purposes.

[0171] The aerosol delivery device 202 may further comprise a first device configured to move, translate or rotate the aerosol product article 204 relative to the aerosol generator or inductor coil 224a during a use session. For example, the aerosol product article 204 may be rotated or translated relative to the aerosol generator or inductor coil 224a. Also referred to as a rotational drive mechanism as described above with reference to FIG. 2.

[0172] The aerosol delivery device 202 may comprise multiple magnetic field generators, i.e., the aerosol delivery device 202 may comprise multiple inductor coils 224a. The multiple magnetic field generators may be configured to generate aerosol from different portions of the aerosol product article 204 during a use session. Accordingly, the aerosol delivery device 202 may also comprise multiple aerosol chambers (not shown). At least some, or each, aerosol chamber may be configured to receive aerosol generated from different portions of the aerosol product article 204 during a use session.

[0173] An aerosol generating system is disclosed that comprises a combination of an aerosol delivery device 202 and an aerosol product article 204. The aerosol product article 204 may comprise an aerosol generating material and a susceptor 243, for example an aluminum foil. The aerosol product article 204 may be arranged in the form of a planar aerosol product article 204, i.e. having a width w, a length l and a depth d, where w>d and l>d. The susceptor 243 may comprise a metal foil, such as an aluminum foil. According to another construction, the susceptor 243 may comprise steel.

[0174] The aerosol delivery device 202 may further comprise a controller or processor configured to determine a calculated temperature (TCalc) of the susceptor 243 based on determining a resonant frequency of a resonant circuit including the inductor coil 224a and the susceptor 243. It will be appreciated that there is a correlation between the determined resonant frequency of the resonant circuit including the inductor coil 224a and the susceptor 243 and a corresponding temperature induced in the susceptor 243 located proximate to the inductor coil 224a. It will be appreciated that as the susceptor 243 heats up during a use session due to the actuation of the inductor coil 224a, the resistivity of the susceptor 243 increases and thus the resonant frequency of the resonant circuit decreases.

[0175] According to one configuration, the susceptor 243 may be heated by controlling the drive frequency f of the RLC resonant circuit. To heat the susceptor 243, the resonant frequency f of the RLC resonant circuit is r Then, determine its resonant frequency f r A controller may be provided that is configured to provide an AC or RF voltage at the

[0176] The resonant circuit may comprise a resistor, a capacitor and an inductor connected in series. The resonant circuit may be considered to have a resistance R, an inductance L and a capacitance C. The inductance L of the circuit is provided by an inductor 224a arranged for inductive heating of the susceptor 243. The inductive heating of the susceptor 243 is via an alternating magnetic field generated by the inductor 224a, which induces Joule heating and / or magnetic hysteresis losses in the susceptor 243. Part of the inductance L of the circuit may be due to the magnetic permeability of the susceptor 243. The alternating magnetic field generated by the inductor 224a is generated by an alternating current flowing through the inductor 224a. The alternating current flowing through the inductor 224a is an alternating current flowing through an RLC resonant circuit. The inductor 224a may be, for example, in the form of a coiled wire, for example a copper coil. The inductor 224a may comprise, for example, a LITZ (RTM) wire, for example a wire including several individually insulated wires twisted together. LITZ (RTM) wire, as known per se, may be particularly useful when drive frequencies f in the MHz range are used, since it may reduce power losses due to the skin effect. At these relatively high frequencies, lower values ​​of inductance are required. As another example, the inductor 224a may comprise a coiled track on a printed circuit board. The use of a coiled track on a printed circuit board may be useful, since it provides a rigid, self-supporting track with a cross-section that can be mass-produced at low cost and with high reproducibility, obviating any requirement for (possibly expensive) LITZ (RTM) wire.

[0177] The capacitance C of the circuit is provided by a capacitor. The capacitor may be, for example, a class 1 ceramic capacitor, such as a COG capacitor. The capacitance C may also include stray capacitance of the circuit. However, this is negligible or can be made negligible compared to the capacitance C provided by the capacitor.

[0178] The resistance R of the circuit may be provided by a resistance to the current flowing through the resonant circuit provided by a resistor, the resistance of the tracks or wires connecting the components of the resonant circuit, the resistance of the inductor 224a, and the susceptor 243 arranged for energy transfer with the inductor 224a. It will be appreciated that the circuit does not necessarily comprise a resistor, but the resistance R in the circuit may also be provided by the resistance of the connecting tracks or wires, the inductor 224a and the susceptor 243.

[0179] The circuit may be driven by an H-bridge driver. The H-bridge driver is a driving element for providing an alternating current in the resonant circuit. The H-bridge driver may be connected to a DC voltage source and an electrical ground. The DC voltage source may be, for example, from a battery. The H-bridge may be an integrated circuit or may comprise separate switching components, which may be solid-state or mechanical. The H-bridge driver may comprise, for example, a high-efficiency bridge rectifier. As known per se, the H-bridge driver may provide an alternating current in the circuit from a DC voltage source by inverting (and then restoring) the voltage on the circuit via the switching components. This may be useful, as it allows the RLC resonant circuit to be powered by a DC battery and allows the frequency of the alternating current to be controlled.

[0180] The H-bridge driver may be connected to a controller. The controller may control the H-bridge or its components to provide an AC current I in the RLC resonant circuit at a given drive frequency f. For example, the drive frequency f may be in the MHz range, e.g., in the range of 0.5 MHz to 4 MHz, e.g., in the range of 2 MHz to 3 MHz. It will be appreciated that other frequencies f or frequency ranges may be used depending, for example, on the particular resonant circuit (and / or its components), controller, susceptor 243, and / or drive elements used. For example, the resonant frequency f of the RLC circuit may be r It will be appreciated that the inductance L and capacitance C of the circuit depend on the inductor 224a, the capacitor, and the susceptor 243. The range of drive frequencies f depends on the resonant frequency f of a particular RLC circuit and / or susceptor 243. r It may be in the vicinity.

[0181] It will be appreciated that the resonant circuit and / or drive frequency or drive frequency range f used may be selected based on other factors for a given susceptor 243. For example, to improve the transfer of energy from the inductor 224a to the susceptor 243, it may be useful to ensure that the skin depth (i.e., the depth from the surface of the susceptor 243 into which the alternating magnetic field from the inductor 224a is absorbed) is less than the thickness of the susceptor 243 material, e.g., by a factor of 2-3. The skin depth varies for different materials and structures of the susceptor 243 and decreases with increasing drive frequency f. Thus, in some instances, it may be beneficial to use a relatively high drive frequency f. On the other hand, it may be beneficial to use a lower drive frequency f, e.g., to reduce the fraction of power supplied to the resonant circuit and / or drive elements that is lost as heat in the electronics. Thus, in some instances, a compromise between these factors may be selected as appropriate and / or desired.

[0182] The aerosol delivery device 202 may be equipped with a sensor for detecting inductive coupling between the induction coil 224a and the susceptor 243, and the controller or processor may input the detected inductive coupling into an algorithm to determine a corresponding calculated temperature (TCalc) of the susceptor 243.

[0183] It will therefore be appreciated that for testing and calibration purposes, two different temperature measurements can be obtained: (i) a directly measured temperature (TC) of the susceptor 243 measured directly by the thermocouple 260, and (ii) a calculated temperature (TCalc) determined by measuring the resonant frequency of the RLC drive circuit and using a known correlation or calibration function between the measured resonant frequency and the associated calculated temperature of the susceptor 243.

[0184] 7 shows how the thermocouple measured temperature (TC) and the inductively coupled calculated temperature (TCalc) of the aluminum foil susceptor 243 were determined to increase during a calibration routine run without the magnet 250 being present adjacent the inductor coil 224a, i.e., without the presence of any magnetic field shaping or flux concentrating elements. The calibration routine was run for a period of four seconds and a desired set temperature of 275° C. was set for the susceptor 243. That is, it was desired to heat the susceptor to a temperature of 275° C.

[0185] In this configuration, the inductor coil 224a was activated with the intent of heating the susceptor 243 to a temperature of 275°C as quickly as possible, and then the controller was set to maintain the temperature of the susceptor 243 at a temperature of 275°C.

[0186] The maximum temperature measured directly by the thermocouple (TC Max ) was determined to be 280.1° C., which was reached after a time of 1.8 seconds.

[0187] Figure 8 shows how the thermocouple measured temperature (TC) and inductively coupled calculated temperature (TCalc) of the aluminum foil susceptor 243 were determined to increase during a calibration routine performed with the magnet 250 present above the inductor coil 224a as shown in Figure 6. The magnet 250 acted as a magnetic field shaping or flux concentrating element.

[0188] The maximum temperature (TC) measured directly by thermocouple 260 Max ) was lower at 264.7° C., but importantly, this temperature was reached in a shorter period of time, i.e., after 1.2 seconds, which is 0.6 seconds faster than when magnet 250 was not present.

[0189] Thus, it will be appreciated that the magnet 250 functioning as a magnetic field shaping or flux concentrating element reduced the ramp-up time to a desired set temperature, which is particularly beneficial.

[0190] The difference between the maximum temperature of the aluminum susceptor 243, 280.1° C., measured directly by the thermocouple 260 with the magnet 250 removed, and with the magnet 250 present (i.e., 264.7° C.), were both within ±5% of the desired set point temperature of 275° C. Furthermore, this was within the tolerance limits of the calibration protocol, which were set at ±10%.

[0191] Temperature gradient (ps / ℃), maximum calculation temperature TCalc Max , maximum direct measurement thermocouple temperature TC Max , and the maximum thermocouple measurement temperature TC Max is summarized in the table shown in FIG. 9 for two different scenarios, namely when magnet 250 was not present and when magnet 250 was present.

[0192] The temperature gradient shown in FIG. 9 is a measure of the change in resonant waveform period per degree Celsius. According to various configurations, the temperature of the susceptor 243 can be determined by measuring the damped resonant frequency of a series resistor-inductor-capacitor network. The capacitance is fixed (PCB components), the resistance is partially due to the resistivity of the susceptor foil 243, and the inductance is mostly fixed by the inductor coil 224a. It will be appreciated that as the temperature of the susceptor 243 increases, both the foil resistivity and the z-height increase, which causes the measured resonant frequency to decrease. The temperature gradient as shown in FIG. 9 is a measure of the change in resonant waveform period per degree Celsius (period is 1 / frequency). For example, if the resonant frequency at 100° C. is 2.1980 MHz, then the time period=1 / 2.198 MHz=454.96 ns. If the resonant frequency at a temperature 1° C. higher, i.e., 101° C., is 2.1975 MHz, then the temperature gradient is 95 ps / ° C., i.e., 1 / (454.96 ns+95 ps)=2.1975 MHz. The time vs. temperature or resonant frequency vs. temperature response is non-linear, therefore determining the calculated temperature by measuring the resonant frequency is most accurate at the two temperatures used for calibration, which may be the ambient temperature (e.g., 22° C.) and a high temperature calibration point, e.g., 275° C.

[0193] 10 shows how the measured resonant frequency of a resonant circuit including the inductor coil 224a of the arrangement described above decreased over the course of the calibration routine, both with and without the presence of the removable magnet 250. The calibration routine was run for 4 seconds, setting a desired set point temperature of 275° C. for the susceptor 243.

[0194] From FIG. 10 it can be seen that the presence of the magnetic retainer and mouth magnet 250 appeared to have a negligible effect on the calculated temperature TCalc of the susceptor 243, which was determined by measuring the resonant frequency of the RLC drive circuit.

[0195] Therefore, the presence of magnet 250 does not affect the calibration process.

[0196] It will be appreciated that once manufactured, aerosol delivery devices require individual testing and calibration before being distributed commercially to end users.

[0197] Tests were performed using two different test aerosol products. The first test aerosol product included a card substrate 242 with an aluminum foil layer 243 adhered thereto. The second test aerosol product included a card substrate 242 with an aluminum foil layer 243 adhered thereto and an aerosol-generating material (i.e., gel) 244 disposed on the aluminum foil layer 243. The aluminum foil layer 243 of the first and second test aerosol products 204 functioned as a susceptor 243.

[0198] 11 shows images of a first test aerosol product or consumable 204 illustrating the resultant blister patterns resulting from operation of the aerosol delivery device 202 both with and without the presence of the removable magnet 250. This particular test utilized a single inductor coil 224a having a circular profile.

[0199] It can be seen that the heat generated within the aluminum foil susceptor 243 by the inductor coil 224a having a circular profile caused a corresponding circular blister pattern to appear on the surface of the test aerosol product article 204. The test aerosol product article 204 was rotated after each test, and it will be appreciated that the six blister patterns evident in FIG. 11 are the result of six separate tests both with and without the magnet 250 present. When the magnet 250 was present, the blister pattern had a diameter of about 10 mm. When the magnet 250 was not present, the blister pattern had a larger diameter of about 13 mm. Thus, the diameter of the susceptor foil surface blisters in the absence of the magnet 250 is about 3 mm wider.

[0200] The presence of magnet 250 (or ferrite-based element according to other embodiments) serves to localize the magnetic field lines through the aerosol product article 204, i.e., magnet 250 concentrates the magnetic flux of inductor coil 224a, and thus the blister pattern observed in the test aerosol product article 204 appears to have a smaller diameter (10 mm) when magnet 250 is positioned above the aerosol product article 204. Thus, magnet 250 functioned as a magnetic field shaping element or magnetic flux concentrating element.

[0201] It has been found that the presence of magnet 250 results in a significant improvement (i.e., a reduction) in the temperature rise time, i.e., the time it takes to reach the desired set point temperature from ambient temperature, which in the example shown in connection with FIG. 11 was a set point temperature of 300° C.

[0202] It will be appreciated that, according to various embodiments, the aerosol delivery device 202 is provided with one or more magnetic field shaping elements (e.g., one or more magnets 250 or ferrite-based materials) that function to shape, focus, concentrate, or collimate the varying magnetic field or magnetic flux generated or emitted by the one or more inductor coils 224a. The effect of shaping, focusing, concentrating, or collimating the varying magnetic field or magnetic flux generated or emitted by the one or more inductor coils 224a is to reduce the time it takes for the aerosol delivery device 202 to reach a desired set temperature.

[0203] Thus, a significant advantage of placing one or more magnets 250 (or ferrite-based materials) in close proximity to inductor coil 224a is that aerosol delivery device 202 has a reduced heat-up time. Heat-up times can be short enough that a user can now enjoy an on-demand puff. In particular, as shown in the table in FIG. 9 according to various configurations, heat-up times short enough, e.g., 1.2 seconds, can be achieved to allow a user to enjoy an on-demand puff. It will be appreciated that this is a significant development.

[0204] Further testing was performed using different types of vapor chambers, including square, circular and flat glass vapor chambers, both with and without the presence of one or more magnetic field shaping elements (or ferritic materials) configured to shape, focus, concentrate or collimate the varying magnetic field generated by one or more magnetic field generators.

[0205] A first type of consumable ("Type 1") was tested comprising a generally circular aerosol product article comprising a substrate having an aluminum foil layer, where for testing purposes the substrate did not contain an aerosol-generating material. The aerosol product article was rotated relative to the induction heating element. Eight samples were taken for each aerosol product article as the aerosol product article was rotating. A total of ten aerosol product articles were tested, resulting in a total of 80 data points.

[0206] A second type of consumable ("Type 2") was tested comprising a substantially slimline aerosol product article comprising a substrate having an aluminum foil layer, but for testing purposes, the substrate did not contain an aerosol-generating material. The aerosol product article was translated relative to the induction heating element. The consumable comprised a single-sided open consumable having five zones or individual portions. As the aerosol product article was rotated, five samples were taken for each aerosol product article. A total of 16 aerosol product articles were tested, resulting in a total of 80 data points.

[0207] The results of testing two different types of consumables are detailed in the table below. [Table 1]

[0208] From the various data points, the average minimum frequency, average maximum frequency, and average median frequency were determined. In addition, the average delta frequency delta and the maximum observed delta frequency were determined. As can be seen from the data presented in the table, for both types of consumables and all types of vapor chambers, the average delta frequency and the maximum observed delta frequency were lower when the vapor chamber was provided with a magnet, as shown by the values ​​highlighted in bold and underlined.

[0209] It will be appreciated that the larger values ​​of average delta frequency obtained in the vapor chamber without a magnet indicate a larger variation in the determined resonant frequency. In contrast, when the vapor chamber including a magnet was tested, the average delta frequency was higher.

[0210] It can thus be seen that the presence of the magnets (or ferrite-based elements) results in a more consistent (less variation) frequency response, allowing the susceptor to heat up more quickly. Overall, the reduction in average delta frequency results in improved performance.

[0211] According to various embodiments, the aerosol product article may comprise a generally circular or elliptical substrate having a first surface and a second surface. The substrate may comprise, for example, paper, card, or aluminum foil. Other embodiments are contemplated in which the substrate may comprise multiple layers arranged in a sandwich. For example, the substrate may comprise a paper or card substrate having a first aluminum foil layer disposed on a first surface and a second aluminum foil layer disposed on a second surface.

[0212] The aerosol product article may include an open-type or closed-type consumable. For example, it will be understood that an open-type consumable is a type of consumable including an aerosol product article in which an aerosol-generating material is provided on one or more outer or outermost surfaces of the aerosol product article. In contrast, it will be understood that a closed-type consumable includes an aerosol product article in which an aerosol-generating material is not provided on the outer or outermost surface of the consumable, but rather on one or more inner surfaces. For example, according to various embodiments, a closed-type consumable may be provided in which one or both of the outer or outermost surfaces of the aerosol product article include a gas-impermeable layer, such as a plastic or other material. For example, an aerosol product article is provided that includes an innermost substrate having one or more layers of aerosol-generating material provided on one or both sides of the substrate, and the aerosol product article is enclosed or otherwise contained within a housing made of a gas-impermeable material is contemplated. A closed-type consumable may include a housing having an air inlet and an aerosol outlet. The aerosol outlet may include a mouthpiece.

[0213] According to various embodiments, the aerosol product article may have a length (L), a width (W) and a thickness (T), where the length (L) of the aerosol product article is greater than the width (W) and / or the thickness (T). The aerosol product article may have a longitudinal axis and may have a first air flow input end and a second air flow output end. For example, the aerosol product article may comprise a prism having a first end face and a second end face. The first end face may comprise an area where air enters the aerosol product article in use, and the second end face may comprise an area where aerosol generated within the aerosol product article exits the aerosol product article in use.

[0214] Embodiments are contemplated in which the second end surface further comprises a mouthpiece. For example, the aerosol product article may comprise a distal end (which may be configured to allow air to enter the aerosol product article through which) and a proximal end (which may comprise a mouthpiece through which a user may inhale aerosol generated within the aerosol product article).

[0215] According to various embodiments, the aerosol generating material may be provided on either the first surface and / or the second surface of the substrate. For example, a single-sided or double-sided aerosol product article may be provided. A single-sided aerosol product article may be operated by a single arrangement of heating elements. A double-sided aerosol product article may be operated by a dual arrangement of heating elements provided on both sides of the aerosol product article during use.

[0216] Embodiments are contemplated in which the aerosol production article may be rotated and / or translated relative to the one or more aerosol generators. The one or more aerosol generators may include, for example, a single aerosol generator, or multiple aerosol generators may be arranged, for example, in an array. The aerosol generators may be provided in an n×m array, where n=2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10, and embodiments are contemplated in which m=2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10. For example, the aerosol generators may be provided in a 2×2 array, a 2×3 array, a 2×4 array, a 2×5 array, a 2×6 array, a 2×7 array, a 2×8 array, a 2×9 array, or a 2×10 array.

[0217] According to various embodiments, the one or more aerosol generators may comprise one or more resistive heaters or resistive heating elements. According to other embodiments, the one or more aerosol generators may comprise one or more inductive heaters or inductive heating elements. Embodiments are also contemplated in which multiple resistive and inductive heating elements may be provided.

[0218] The aerosol product article may be configured to be rotated and / or translated relative to the one or more aerosol generators such that the aerosol product article is positioned adjacent to the one or more aerosol generators and heated from only one side. Alternatively, the aerosol product article may be configured to be rotated and / or translated relative to the one or more aerosol generators such that the aerosol product article is inserted between a first set of aerosol generators and a second set of aerosol generators. According to such embodiments, the aerosol product article may be configured to be heated from two opposing sides simultaneously or sequentially.

[0219] Also contemplated are embodiments in which the aerosol product article may be prismatic. For example, the aerosol product article may include a triangular prism, a square prism, or a cylindrical prism. For example, the aerosol product article may include a cylindrical aerosol product article. The aerosol product article may be rotated and / or translated relative to one or more aerosol generators. For example, the aerosol delivery device may include a cavity into which a prismatic or cylindrical aerosol product article may be inserted. A matrix, strip, or array of aerosol generators may be provided at one or more locations around or along the cavity. The aerosol product article may then be rotated and / or translated relative to the aerosol generator such that different portions of the aerosol product article may be heated or otherwise accessed sequentially or incrementally.

[0220] Embodiments are contemplated in which the aerosol product article may be translated relative to one or more aerosol generators. For example, the aerosol product article may comprise multiple portions of aerosol-generating material, and the aerosol product article may be translated longitudinally such that multiple separate portions of the aerosol-generating material may be actuated or otherwise heated in series or sequentially.

[0221] Further embodiments are contemplated in which the aerosol generating article may comprise a cylinder or more generally a prism. A plurality of aerosol generators may be arranged around or centered on a cylindrical or prismatic aerosol generating article. It is contemplated that the aerosol generating article may be rotated within a static array of aerosol generators. Alternatively, the aerosol generating article may remain stationary and a plurality of aerosol generators may be rotated relative to the aerosol generating article. Yet another embodiment is contemplated in which both the aerosol generating article and one or more aerosol generators are movable. For example, the aerosol generating article may be rotated and / or translated at a first speed v1 and one or more aerosol generators may be rotated and / or translated at a second speed v2. Embodiments are contemplated in which v1 > v2 in the operating mode. Embodiments are contemplated in which v1 = v2 in the operating mode. Embodiments in which v1 < v2 in the operating mode are also contemplated.

[0222] According to various embodiments, the aerosol generating article may comprise a flat or planar consumable having a longitudinal axis. The aerosol generating article may be translated in a direction parallel to the longitudinal axis. Other embodiments are contemplated in which the aerosol generating article comprises a cylindrical consumable having a longitudinal axis. The cylindrical consumable may be rotated about its longitudinal axis and / or translated in a direction parallel to the longitudinal axis. The aerosol generating article may be single-sided or double-sided. The double-sided consumable may be heated from both sides during use.

[0223] To address various problems and advance the art, the present disclosure presents various embodiments by way of example. The advantages and features of the present disclosure are merely a representative sample of embodiments and are not exhaustive and / or exclusive. They are presented solely to aid in understanding and to teach the claimed invention. It is to be understood that the advantages, embodiments, examples, features, features, structures, and / or other aspects of the present disclosure should not be considered limitations on the present disclosure as defined by the claims or limitations on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claims. It will be understood that the various embodiments may suitably comprise, consist of, or essentially consist of various combinations of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein, and thus the features of the dependent claims may be combined with the features of the independent claims in combinations other than those expressly recited in the claims. The present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. an aerosol generator comprising one or more magnetic field generators; one or more magnetic field shaping elements configured to shape, focus, concentrate or collimate the varying magnetic field generated by the one or more magnetic field generators; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the aerosol generator comprises one or more inductors, inductor elements, or inductor coils.

3. The aerosol delivery device of claim 2 , wherein the one or more inductors, inductor elements, or inductor coils are substantially planar.

4. The aerosol delivery device of any one of claims 1 to 3, wherein the one or more magnetic field shaping elements comprise one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials.

5. 5. The aerosol delivery device of claim 4, further comprising a body portion and a removable mouthpiece, the one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials configured to releasably secure the mouthpiece to the body portion.

6. The aerosol delivery device of any one of claims 1 to 5, wherein the one or more magnetic field shaping elements comprise one or more inductors, inductor elements, inductor coils, or electromagnets.

7. The aerosol delivery device of any one of claims 1 to 6, further comprising a receiving area for receiving an aerosol product.

8. 8. The aerosol delivery device of claim 7, wherein the one or more magnetic field shaping elements are configured to shape, focus, concentrate or collimate the varying magnetic field generated by the one or more magnetic field generators onto a target area of ​​the aerosol product.

9. 9. The aerosol delivery device of claim 7 or 8, wherein the aerosol generator is disposed on a first side of the receiving area and the one or more magnetic field shaping elements are disposed on a second, different side of the receiving area.

10. The aerosol delivery device of any one of claims 1 to 9, further comprising one or more ferrite-based elements.

11. The one or more ferritic elements are iron oxides (FeO) chemically combined with one or more additional metallic elements. ２ O ３ 11. The aerosol delivery device of claim 10, comprising a ceramic compound consisting of:

12. 12. The aerosol delivery device of claim 10 or 11 when dependent on claim 9, wherein the one or more ferrite-based elements are disposed on the first surface of the receiving area.

13. 13. The aerosol delivery device of claim 12, wherein the one or more magnetic field generators have a first surface and a second surface, the first surface of the one or more magnetic field generators is positioned adjacent to the one or more ferrite-based elements, and the second surface of the one or more magnetic field generators is positioned adjacent to the first surface of the receiving area.

14. The aerosol delivery device of any one of claims 7 to 13, further comprising an aerosol chamber configured to receive an aerosol generated from the aerosol product.

15. 15. The aerosol delivery device of any one of claims 1 to 14, further comprising a first device configured to move, translate or rotate an aerosol product relative to the aerosol generator during a session of use.

16. 16. The aerosol delivery device of claim 1, comprising a plurality of magnetic field generators configured to generate aerosol from different portions of an aerosol product article during a session of use.

17. 17. The aerosol delivery device of claim 16, wherein the aerosol delivery device comprises a plurality of aerosol chambers, at least some, or each aerosol chamber configured to receive aerosol generated from different portions of the aerosol product article during a session of use.

18. an aerosol generator comprising one or more magnetic field generators; one or more magnetic flux concentrating elements configured to concentrate magnetic flux generated by the one or more magnetic field generators; An aerosol delivery device comprising:

19. 20. The aerosol delivery device of claim 18, wherein the aerosol generator comprises one or more inductors, inductor elements, or inductor coils.

20. 20. The aerosol delivery device of claim 19, wherein the one or more inductors, inductor elements, or inductor coils are substantially planar.

21. 21. The aerosol delivery device of any one of claims 18 to 20, wherein the one or more magnetic flux concentrating elements comprise one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials.

22. 22. The aerosol delivery device of claim 21, further comprising a body portion and a removable mouthpiece, the one or more permanent magnets, ferromagnetic materials or ferrimagnetic materials configured to releasably secure the mouthpiece to the body portion.

23. The aerosol delivery device of any one of claims 18 to 22, wherein the one or more magnetic flux concentrating elements comprise one or more inductors, inductor elements, inductor coils, or electromagnets.

24. The aerosol delivery device of any one of claims 18 to 23, further comprising a receiving area for receiving an aerosol product.

25. 25. The aerosol delivery device of claim 24, wherein the one or more magnetic flux concentrating elements are configured to concentrate a varying magnetic field generated by the one or more magnetic field generators onto a target area of ​​the aerosol product.

26. 26. The aerosol delivery device of claim 24 or 25, wherein the aerosol generator is disposed on a first side of the receiving area and the one or more magnetic flux concentrating elements are disposed on a second, different side of the receiving area.

27. The aerosol delivery device of any one of claims 18 to 26, further comprising one or more ferrite-based elements.

28. The one or more ferritic elements are iron oxides (FeO) chemically combined with one or more additional metallic elements. ２ O ３ 28. The aerosol delivery device of claim 27, comprising a ceramic compound consisting of:

29. 29. The aerosol delivery device of claim 27 or 28 when dependent on claim 26, wherein the one or more ferrite-based elements are disposed on the first surface of the receiving area.

30. 30. The aerosol delivery device of claim 29, wherein the one or more magnetic field generators have a first surface and a second surface, the first surface of the one or more magnetic field generators being positioned adjacent to the one or more ferrite-based elements, and the second surface of the one or more magnetic field generators being positioned adjacent to the first surface of the receiving area.

31. 31. The aerosol delivery device of any one of claims 24 to 30, further comprising an aerosol chamber configured to receive an aerosol generated from the aerosol product.

32. 32. The aerosol delivery device of any one of claims 18 to 31, further comprising a first device configured to move, translate or rotate an aerosol product relative to the aerosol generator during a session of use.

33. 33. The aerosol delivery device of any one of claims 18 to 32, wherein the aerosol delivery device comprises a plurality of magnetic field generators configured to generate aerosol from different portions of an aerosol product article during a session of use.

34. 34. The aerosol delivery device of claim 33, wherein the aerosol delivery device comprises a plurality of aerosol chambers, at least some, or each aerosol chamber configured to receive aerosol generated from different portions of the aerosol product article during a session of use.

35. An aerosol delivery device according to any one of claims 1 to 34; an aerosol product article comprising an aerosol-generating material and one or more susceptors; An aerosol generating system comprising:

36. 36. The aerosol generation system of claim 35, wherein the aerosol product article comprises a planar aerosol product article.

37. 37. The aerosol generating system of claim 35 or 36, wherein the susceptor comprises a metal foil.

38. 38. The aerosol generating system of claim 37, wherein the metal foil comprises an aluminum foil.

39. 39. The aerosol generation system of any one of claims 35 to 38, wherein the aerosol production article comprises: (i) a substantially circular, elliptical or polyhedral substrate having one or more portions of aerosol-generating material disposed on a first surface of the substrate and / or one or more portions of aerosol-generating material disposed on a second surface of the substrate; (ii) a substantially planar substrate having one or more portions of aerosol-generating material disposed on a first surface of the substrate and / or one or more portions of aerosol-generating material disposed on a second surface of the substrate; or (iii) a prismatic or cylindrical aerosol production article.

40. 40. The aerosol generating system of any one of claims 35 to 39, wherein the aerosol product comprises either an open consumable or a closed consumable.

41. 1. A method for generating an aerosol, comprising: Providing an aerosol delivery device according to any one of claims 1 to 34; introducing an aerosol product comprising an aerosol-generating material and one or more susceptors into the aerosol delivery device; A method comprising:

42. 42. The method of claim 41, further comprising activating the aerosol delivery device.

43. a receiving area for receiving the aerosol product; one or more aerosol generators, each comprising one or more magnetic field generators, the one or more aerosol generators being disposed on a first surface of the receiving area; one or more magnetic field shaping elements configured to shape, focus, concentrate or collimate the varying magnetic field generated by the one or more magnetic field generators, the one or more magnetic field shaping elements being disposed on a second distinct side of the receiving area; An aerosol delivery device comprising:

44. 44. The aerosol delivery device of claim 43, wherein the one or more magnetic field shaping elements comprise one or more inductors, inductor elements, inductor coils, electromagnets, or ferrite-based materials.

45. 45. The aerosol delivery device of claim 43 or 44, further comprising one or more ferrite-based elements.

46. The one or more ferritic elements are iron oxides (FeO) chemically combined with one or more additional metallic elements. ２ O ３ 46. ​​The aerosol delivery device of claim 45, comprising a ceramic compound consisting of:

47. 47. The aerosol delivery device of claim 45 or 46, wherein the one or more ferrite-based elements are disposed on the first surface of the receiving area.

48. 48. The aerosol delivery device of any one of claims 45 to 47, wherein the one or more magnetic field generators have a first surface and a second surface, the first surface of the one or more magnetic field generators being positioned adjacent to the one or more ferrite-based elements, and the second surface of the one or more magnetic field generators being positioned adjacent to the first surface of the receiving area.

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