Resistive heating element for aerosol delivery device

Abstract

A resistive heating element for an aerosol delivery device comprising a substrate and one or more conductive tracks disposed on the substrate, at least one of the one or more conductive tracks including a portion where the width or cross-sectional area of ​​the one or more conductive tracks is reduced to create an enhanced heating area, the enhanced heating area configured to generate a visual indication on the aerosol product upon completion of a usage session.

Description

[Technical field]

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

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products are so-called "heat-not-burn" products or tobacco heating devices or products that release compounds by heating a material without burning it. 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 and products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. Often, it is necessary to replace or change the medium used to provide a different aerosol for inhalation.

[0004] It is known to use resistive heaters to heat the aerosol product.

[0005] A conventional aerosol delivery device includes a cylindrical heating chamber into which a wand-shaped consumable is inserted.

[0006] One problem with known aerosol delivery devices is that a user may remove a used aerosol product article from the aerosol delivery device after a usage session, however, the user may find it difficult to distinguish between an unused aerosol product article and a used aerosol product article.

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

[0008] According to one aspect, A substrate; one or more conductive tracks provided on a substrate; Equipped with at least one of the one or more conductive tracks includes a portion where a width or cross-sectional area of ​​the one or more conductive tracks is reduced to create an enhanced heating area, the enhanced heating area configured to generate a visual indication on the aerosol product article upon completion of a usage session; A resistive heating element for an aerosol delivery device is provided.

[0009] According to various embodiments, a resistive heating element is disclosed having conductive tracks that create an enhanced heating area that is intended to generate a visual indication (e.g., charring) on ​​the aerosol product article at the end of a usage session to indicate to the user that the aerosol product article has been used.

[0010] In particular, resistive heating elements according to various embodiments are beneficial in that they allow a user to distinguish between unused and used aerosol product articles after a usage session.

[0011] Optionally, the visual indication may comprise charring, which will be understood to include partially burning or blackening a portion of the aerosol product article.

[0012] Optionally, the visual indication may comprise, for example, a permanent change in color of a thermochromic area provided on the aerosol product article.

[0013] Optionally, the one or more conductive tracks may comprise a first portion having a first width W1 and a second portion having a second width W2, W2 <W1である。

[0014] Optionally, W1 / W2 is in the range of 1.1 to 1.5, 1.5 to 2.0, 2.0 to 2.5, 2.5 to 3.0, 3.0 to 3.5, 3.5 to 4.0, 4.0 to 4.5, 4.5 to 5.0 or >5.0.

[0015] Optionally, the one or more conductive tracks comprise a first portion having a first cross-sectional area A1 and a second portion having a second cross-sectional area A2, A2 <A1である。

[0016] Optionally, A1 / A2 is in the range of 1.1 to 1.5, 1.5 to 2.0, 2.0 to 2.5, 2.5 to 3.0, 3.0 to 3.5, 3.5 to 4.0, 4.0 to 4.5, 4.5 to 5.0 or >5.0.

[0017] Optionally, the substrate comprises an electrical insulator.

[0018] Optionally, the substrate comprises zirconia (ZrO2).

[0019] Optionally, the one or more conductive tracks comprise a metal or a metal alloy.

[0020] Optionally, the metal or metal alloy comprises a silver-palladium (AgPa) alloy.

[0021] Optionally, the one or more conductive tracks form one or more loops.

[0022] Optionally, the resistive heating element further comprises a first electrode connected to one of the conductive tracks and a second electrode connected to one of the conductive tracks.

[0023] Optionally, one or more conductive tracks are deposited or printed on a substrate, and then the tracks and substrate are sintered.

[0024] Optionally, the resistive heating element further comprises a glass or protective coating applied to the conductive track or tracks.

[0025] According to another aspect, there is provided an aerosol delivery device comprising a resistive heating element as described above.

[0026] According to another aspect, The aerosol supply device as described above; Aerosol products and An aerosol generating system is provided comprising:

[0027] According to another aspect, inserting an aerosol product article into an aerosol delivery device comprising a resistive heating element, the resistive heating element comprising a substrate and one or more conductive tracks disposed on the substrate, at least one of the one or more conductive tracks including a portion where the width or cross-sectional area of ​​the one or more conductive tracks is reduced to create an area of ​​enhanced heating; operating the aerosol delivery device such that the enhanced heating region generates a visual indication on the aerosol product upon completion of the use session; A method for generating an aerosol comprising: [Brief description of the drawings]

[0028] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings. [Figure 1] FIG. 1 illustrates an aerosol delivery device positioned within a charging unit according to one embodiment. [Diagram 2] 1 shows a cross-sectional view of an aerosol delivery device positioned within a charging unit. [Diagram 3] FIG. 13 illustrates a resistive heating element according to one embodiment comprising two copper tracks connected in a loop configuration of conductive tracks, the loop configuration having a reduced width portion that creates an enhanced heating area configured to generate a visual indication on the aerosol product at the end of a usage session. [Figure 4]FIG. 1 illustrates a resistive heating element according to one embodiment connected to a printed circuit board ("PCB"), the resistive heating element comprising conductive tracks having reduced width portions that create enhanced heating areas configured to generate a visual indication on the aerosol product at the end of a usage session. [Diagram 5] FIG. 1 is a perspective view of a resistive heating element according to one embodiment, showing how the resistive heating element can be shaped to form a blade heating element, where in use the aerosol product article is pressed onto the blade heating element such that the heating element is inserted into the aerosol product article. [Figure 6] FIG. 2 is another view of a resistive heating element according to one embodiment, showing how the resistive heating element includes a reduced width portion that creates an enhanced heating area configured to generate a visual indication on the aerosol product at the end of a usage session. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] 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 or are not combusted to facilitate delivery of at least one substance to a user.

[0030] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0031] 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.

[0032] 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.

[0033] In some embodiments, the non-combustion aerosol delivery system is a hybrid system configured to generate 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 in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises 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.

[0034] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0035] In some embodiments, the present disclosure relates to consumables, also sometimes referred to as articles throughout the present disclosure, that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices.

[0036] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can 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 proximate to the heat generating power source.

[0037] In some embodiments, the non-combustible aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0038] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transport components, aerosol generators, aerosol generating areas, housings, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0039] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or in any other way energized. The aerosol-generating material may be in the form of, for example, a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0040] 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.

[0041] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0042] The 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 subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to 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.

[0043] A consumable is an article that comprises 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 comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating region, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also comprise an aerosol generator, such as a heater that emits heat to generate an aerosol in the aerosol-generating material during use. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0044] The non-combustible aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some embodiments, the non-combustible aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may comprise a power source, such as, for example, a battery or a rechargeable battery. In some embodiments, the non-combustible aerosol delivery device may also comprise an aerosol generating component. However, in other embodiments, the aerosol product article may comprise, in part or in whole, the aerosol generating component.

[0045] Various embodiments will now be described in more detail.

[0046] 1 shows an aerosol delivery device 100 according to one illustrated embodiment positioned within an elongated cavity of a charging unit 101. The charging unit 101 may include a power source (not shown). The power source may include, for example, a battery (disposable or rechargeable), a rechargeable supercapacitor, a rechargeable solid-state battery (SSB), or a rechargeable lithium-ion battery (LiB), a hermetically sealed battery, a pouch cell battery, or some combination thereof.

[0047] The aerosol delivery device 100 may be left in the charging unit 101 for a predetermined period of time to allow for sufficient charging of the aerosol delivery device 100. For example, the charging unit 101 may be configured to charge the aerosol delivery device 100 to full charge in a period of <10 minutes, 10-20 minutes, 20-30 minutes, 30-40 minutes, 40-50 minutes, 50-60 minutes, or >60 minutes.

[0048] The charging unit 101 and / or the aerosol delivery device 100 may optionally have an indicator to provide a user with a visual or other representation of the charge level of the aerosol delivery device 100. Additionally, there may be a separate indicator that provides a visual representation of the charge level of the charging unit 101. The current charge level of the aerosol delivery device 100 and / or the charging unit 101 may be determined by control means disposed in the aerosol delivery device 100 and / or the charging unit 101.

[0049] The visual indicator may comprise one or more light emitting diodes (LEDs), however, other embodiments are contemplated in which the visual indicator may be replaced by an audio indicator (e.g., a speaker) or a tactile indicator.

[0050] The aerosol delivery device 100 may include an outer housing that may have a tubular and / or cylindrical shape. However, other embodiments are envisioned in which the aerosol delivery device 100 may take other desired shapes, for example, the aerosol delivery device 100 may be box-shaped. According to one embodiment, the outer housing of the aerosol delivery device 100 may include an electrical insulator, for example, formed of polyetheretherketone ("PEEK").

[0051] According to one embodiment, the distal end of the aerosol supply device 100 may include one or more orientation features and / or one or more magnets for securing the distal end of the aerosol supply device 100 to a base portion of the charging unit 101.

[0052] The aerosol delivery device 100 may be inserted into a cavity of the charging unit 101 to recharge the aerosol delivery device 100 by receiving power from the charging unit 101. The charging unit 101 may include an internal battery for powering the aerosol delivery device 100. The charging unit 101 may also be connected to an external source of power.

[0053] The charging unit 101 may include a lid or cover 102 that may be slid by a user between an open position and a closed position. The lid or cover 102 is provided within the charging unit 101 and is provided at an entrance to a cavity configured to receive the aerosol delivery device 100.

[0054] The aerosol delivery system 100 includes an aerosol generator for generating an aerosol from an aerosol-generating material. According to one embodiment, the aerosol delivery system 100 includes a resistive heater for heating the aerosol product.

[0055] When the lid or cover 102 is in the open position, an opening to the cavity is exposed, thereby allowing a user to either remove the aerosol supply device 100 from the charging unit 101 (to use the aerosol supply device 100) or insert the aerosol supply device 100 into the charging unit 101 (to charge the aerosol supply device 100).

[0056] 2 shows a cross-sectional view illustrating aerosol delivery device 100 positioned or docked within a charging unit 101. Aerosol delivery device 100 comprises a main housing 105 with a resistive heating element 104 protruding into main housing 105. Aerosol delivery device 100 may further comprise a removable cap 106 that may be magnetically held to main housing 105.

[0057] The consumable cartridge 120 is attached to the removable cap 106 and comprises a tubular housing having a base portion 121. The base portion 121 of the consumable cartridge 120 has an opening through which the resistive heating element 104 is configured to protrude. An aerosol product article may be inserted into the aerosol delivery device 100 by inserting the aerosol product article through the opening in the removable cap 106 and then inserting the aerosol product article into the consumable cartridge 120 and over the heating element 104. The heating element 104 may have a blade-like profile and, during use, the aerosol product article may be pressed onto the heating element 120 such that the blade-like profile of the heating element 104 is inserted into a distal end of the aerosol product article. The heating element 104 is configured to internally heat the aerosol product article.

[0058] At the end of a usage session, when the aerosol product has been consumed, the removable cap 106 and attached consumable cartridge 120 may be removed from the main housing 105. It will be appreciated that the process of removing the removable cap 106 and attached consumable cartridge 120 has the effect of causing the base portion 121 of the consumable cartridge 120 to contact a bottom surface of the aerosol product. As the removable cap 106 and attached consumable cartridge 120 are withdrawn, the base portion 121 of the consumable cartridge 120 contacts a distal end of the aerosol product, thereby pulling or otherwise removing the aerosol product from the heating element 104.

[0059] Figure 3 shows a resistive heating element 104 according to an embodiment including a copper track 201 provided on a base substrate 202. According to one embodiment, the base substrate 202 may include zirconia (ZrO2). The track 201 may be formed in a loop configuration of the track 201. According to one embodiment, the track 201 may have a portion 300 with a reduced width and / or a reduced cross-sectional area. The portion 300 with a reduced width and / or a reduced cross-sectional area may include a portion of the track with a reduced width and / or cross-section relative to the remaining portion of the track. According to various embodiments, this creates a region of enhanced heating.

[0060] As shown in FIG. 3, according to one embodiment, one or more conductive tracks 201 may include a first portion having a first width W1 and a second portion having a second width W2, where W2 < W1. Optionally, W1 / W2 may be in the range of 1.1 to 1.5, 1.5 to 2.0, 2.0 to 2.5, 2.5 to 3.0, 3.0 to 3.5, 3.5 to 4.0, 4.0 to 4.5, 4.5 to 5.0, or > 5.0.

[0061] According to one embodiment, the enhanced heating region may be configured to produce a visual indication on the aerosol-generating article at the end of the usage session. For example, the heating element 104 may be configured to intentionally cause black charring on a portion of the aerosol-generating article to indicate to the user that the aerosol-generating article has been consumed or otherwise used after the usage session is complete.

[0062] Other embodiments are contemplated where the aerosol-generating article may include a thermochromic region. According to one embodiment, the enhanced heating region may be configured to cause a permanent change in the color of at least a portion of the thermochromic region. For example, the thermochromic region provided on the unused aerosol-generating article may be white, and the enhanced heating region may be configured to change the color of the thermochromic region, for example, to dark gray or black (thereby indicating to the user that the aerosol-generating article has been used).

[0063] The conductive tracks 201 may be formed, for example, from a silver-palladium (AgPd) alloy. The conductive tracks 201 may be electrically connected to the electrodes 200, which may be formed from copper. As shown in Figure 3, the electrodes 200 may each include a base connector portion having an opening 205. Electrical wires may be soldered to the electrodes 200 through the openings 205.

[0064] According to one embodiment, the conductive tracks 201 and the electrodes 200 may be printed or deposited on the substrate 202, and then the substrate 202 and the conductive tracks 201 and the electrodes 200 may be sintered. For example, according to one embodiment, the substrate 202, the conductive tracks 201 and the electrodes 200 may be heated to a temperature of about 700°C.

[0065] According to one embodiment, a glass coating may be applied to the top surface of the blade heating element 104 to provide a protective coating. The application of the glass coating to the heating element 104 may give the heating element 104 a blue appearance. According to one embodiment, a glass coating may be applied to one or both sides of the resistive heating element 204 to provide a protective coating.

[0066] FIG. 4 shows a resistive heating element 104 according to one embodiment, comprising a conductive track 201 having a reduced width portion 300 that creates an enhanced heating area configured to generate a visual indication on the aerosol product at the end of a usage session.

[0067] The resistive heating element 104 is shown mounted on a printed circuit board control unit. One or more electrical wires 206 may connect the control circuitry to the electrodes 200 of the heating element 104 to provide power to the conductive tracks.

[0068] FIG. 5 shows a perspective view of the main housing of an aerosol delivery device 100 according to one embodiment, showing a resistive heating element 104 protruding into the main housing of the aerosol delivery device.

[0069] 6 shows a perspective view of a resistive heating element 104 according to one embodiment. The resistive heating element 104 comprises a substrate 202 having a conductive track 201 disposed thereon. The conductive track 201 has a reduced width portion 300 that creates an enhanced heating area configured to generate a visual indication on the aerosol product at the end of a usage session.

[0070] According to various embodiments, at least one of the one or more conductive tracks 201 provided on the resistive heating element includes a portion where the width and / or cross-sectional area of ​​the conductive track 201 is reduced, thereby creating an enhanced heating area that is configured to generate a visual indication on the aerosol product upon completion of a usage session.

[0071] In particular, the enhanced heating region is configured to cause charring (i.e., blackening) of a portion of the aerosol product at the end of a usage session to indicate to a user that the aerosol product has been used.

[0072] As a result, the user is able to distinguish between unused and used aerosol product items.

[0073] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A substrate; one or more conductive tracks provided on said substrate; Equipped with at least one of the one or more conductive tracks includes a portion where a width or cross-sectional area of ​​the one or more conductive tracks is reduced to create an enhanced heating area, the enhanced heating area configured to generate a visual indication on the aerosol product article upon completion of a usage session. Resistive heating elements for aerosol delivery devices.

2. The resistive heating element of claim 1 , wherein the visual indication comprises charring.

3. 3. The resistive heating element of claim 1 or 2, wherein the visual indication comprises a permanent change in color of a thermochromic area disposed on the aerosol product article.

4. 4. The resistive heating element of claim 1, 2 or 3, wherein the one or more conductive tracks comprise a first portion having a first width W1 and a second portion having a second width W2, where W2<W1.

5. 5. The resistive heating element according to claim 4, wherein W1 / W2 is in the range of 1.1 to 1.5, 1.5 to 2.0, 2.0 to 2.5, 2.5 to 3.0, 3.0 to 3.5, 3.5 to 4.0, 4.0 to 4.5, 4.5 to 5.0 or >5.

0.

6. 6. The resistive heating element of claim 1, wherein the one or more conductive tracks comprise a first portion having a first cross-sectional area A1 and a second portion having a second cross-sectional area A2, where A2<A1.

7. 7. The resistive heating element according to claim 6, wherein A1 / A2 is in the range of 1.1 to 1.5, 1.5 to 2.0, 2.0 to 2.5, 2.5 to 3.0, 3.0 to 3.5, 3.5 to 4.0, 4.0 to 4.5, 4.5 to 5.0 or >5.

0.

8. The resistive heating element of any one of claims 1 to 7, wherein the substrate comprises an electrical insulator.

9. The substrate is made of zirconia (ZrO ２ 9. The resistive heating element of claim 8, comprising:

10. A resistive heating element according to any preceding claim, wherein the one or more conductive tracks comprise a metal or a metal alloy.

11. The resistive heating element of claim 10 , wherein the metal or metal alloy comprises a silver-palladium (AgPa) alloy.

12. A resistive heating element according to any one of the preceding claims, wherein the one or more conductive tracks form one or more loops.

13. 13. The resistive heating element of any one of claims 1 to 12, further comprising a first electrode connected to one of the conductive tracks and a second electrode connected to one of the conductive tracks.

14. A resistive heating element according to any one of the preceding claims, wherein the one or more conductive tracks are deposited or printed on the substrate and then the tracks and the substrate are sintered.

15. A resistive heating element according to any one of the preceding claims, further comprising a glass or protective coating applied to the one or more conductive tracks.

16. An aerosol supply device comprising the resistive heating element according to any one of claims 1 to 15.

17. An aerosol delivery device according to claim 16; an aerosol product; An aerosol generating system comprising:

18. inserting an aerosol product article into an aerosol delivery device comprising a resistive heating element, the resistive heating element comprising a substrate and one or more conductive tracks disposed on the substrate, at least one of the one or more conductive tracks including a portion where the width or cross-sectional area of ​​the one or more conductive tracks is reduced to create an area of ​​enhanced heating; operating the aerosol delivery device such that the enhanced heating region generates a visual indication on the aerosol product upon completion of a use session; A method for generating an aerosol comprising:

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