Aerosol Delivery Device

Abstract

An aerosol delivery device (202) is disclosed, comprising an aerosol generator (501) and a first device (700, 701) configured to determine a cleanliness state or a predicted cleanliness state of a first surface (503) disposed within the aerosol delivery device (202).

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 burning. 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. Summary of the Invention

[0006] According to one aspect, there is provided an aerosol delivery device comprising: An aerosol generator; and a first device configured to determine a cleanliness state or a predicted cleanliness state of a first surface disposed within the aerosol delivery device.

[0007] According to various configurations, an aerosol delivery device may be provided that includes an inductive heating element. A first (i.e., contact) surface may be provided between a portion of the aerosol delivery device and the aerosol product article when inserted into the aerosol delivery device during use. As a result, the first (i.e., contact) surface may become soiled over a period of time. According to various embodiments, an aerosol delivery device is provided that has a first device configured to determine a cleanliness state or a predicted cleanliness state of the first (i.e., contact) surface.

[0008] Optionally, the aerosol generator comprises one or more inductive coils or inductive heating elements.

[0009] Optionally, the first surface comprises a contact surface between the aerosol product article and the aerosol delivery device.

[0010] Optionally, the first surface comprises a surface of a barrier layer or a first layer.

[0011] Optionally, the barrier layer or the first layer comprises a thermal insulation layer.

[0012] Optionally, the barrier layer or first layer comprises a glass, ceramic or plastic layer.

[0013] Optionally, the barrier layer or the first layer is optically transmissive.

[0014] Optionally, the barrier layer or first layer has a thermal conductivity of less than 0.01 W / mK, 0.01-0.05 W / mK, 0.05-0.1 W / mK, 0.1-0.5 W / mK, 0.5-1 W / mK, 1-5 W / mK, 5-10 W / mK, 10-20 W / mK, 20-30 W / mK, 30-40 W / mK, or 40-50 W / mK.

[0015] Optionally, the blocking layer or the first layer is magnetically permeable.

[0016] Optionally, the first device comprises a controller or a processor.

[0017] Optionally, the first device is configured to determine (i) the number of puffs obtained by the user after a previous cleaning event, (ii) the number of actuations of the aerosol generator after a previous cleaning event, or (iii) the number of rotations or translations of the aerosol product after a previous cleaning event.

[0018] Optionally, the first device is configured to determine a distance or separation between a portion of the aerosol generator and a portion of the aerosol product disposed in the aerosol delivery device in use.

[0019] Optionally, the first device is configured to determine whether a rise time, corresponding to the time it takes to reach an operating temperature, has increased beyond a threshold time.

[0020] Optionally, if the first device determines that the rise time has increased beyond a threshold time, the first device is configured to determine that the first surface has a first cleanliness state.

[0021] Optionally, if the first device determines that the rise time has not increased beyond a threshold time, the first device is configured to determine that the first surface has a second cleanliness state.

[0022] Optionally, the first surface comprises a surface of a planar optical waveguide.

[0023] Optionally, the planar optical waveguide comprises an entrance surface, a waveguide portion having a longitudinal direction, and an exit surface, the entrance surface and / or the exit surface being disposed in a plane perpendicular to the longitudinal direction.

[0024] Optionally, the aerosol delivery device further comprises an optical transmitter configured to transmit electromagnetic radiation to the optical waveguide, and an optical detector configured to detect electromagnetic radiation exiting the optical waveguide.

[0025] Optionally, the aerosol delivery device further comprises a processor configured to determine an internal reflection angle or a critical angle of the planar optical waveguide, and the first device is configured to determine a cleanliness state or a predicted cleanliness state of the surface based on the determined internal reflection angle or critical angle.

[0026] Optionally, the aerosol delivery device further comprises an optical transmitter and an optical detector, the optical transmitter configured to emit electromagnetic radiation that is reflected by or transmitted through the first surface, and the optical detector configured to detect the electromagnetic radiation that is reflected by or transmitted through the first surface.

[0027] Optionally, the aerosol delivery device further comprises a layer having one or more optical markings and an optical device configured to view or examine the one or more optical markings, and the first surface comprises a surface of the layer having the one or more optical markings.

[0028] Optionally, the aerosol delivery device further comprises an optical device configured to view or interrogate a bar code, QR code or other optical marking provided on the aerosol product item.

[0029] Optionally, the optical device is configured to output a signal to the first device, and the first device is configured to determine a cleanliness state or a predicted cleanliness state of the first surface based on the signal output from the optical device.

[0030] Optionally, the first device comprises an imaging device for observing and analyzing images provided on components of the aerosol delivery device and / or the aerosol product item, and the first device is configured to determine a cleanliness status of the surface in response to analyzing one or more qualities of the observed images.

[0031] Optionally, the aerosol delivery device further comprises a heater or other cleaning device for cleaning the first surface.

[0032] Optionally, if the first device determines that the first surface has a cleanliness condition or a predicted cleanliness condition above or below a threshold, the first device is configured to activate a heater or other cleaning device to clean the first surface.

[0033] Optionally, if the first device determines that the first surface has a cleanliness state or a predicted cleanliness state above or below a threshold, the first device is configured to activate a heater to perform a heating cycle to clean the first surface by maintaining the first surface at a temperature of T°C for at least a time t1 before, during or after the use session, where optionally T is in the range of less than 50°C, 50-100°C, 100-150°C, 150-200°C, 200-250°C, 250-300°C or more than 300°C, and optionally t1 is in the range of less than 30 seconds, 30-60 seconds, 60-90 seconds, 90-120 seconds or more than 120 seconds.

[0034] Optionally, the aerosol delivery device further comprises a device configured to inform a user of the cleanliness state or the predicted cleanliness state determined by the first device. The device configured to inform a user of the cleanliness state or the predicted cleanliness state may be an indicator.

[0035] Optionally, the aerosol delivery device further comprises a device configured to advise a user to perform a cleaning routine if the first device determines that the surface has a first cleanliness state.

[0036] Optionally, the first device comprises one or more resistive, capacitive or inductive sensors.

[0037] According to another aspect, there is provided an aerosol generating system, comprising: an aerosol delivery device as described above; An aerosol generating system is provided, comprising:

[0038] Optionally, the aerosol product 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 shaped aerosol product article.

[0039] Optionally, the aerosol product comprises either an open consumable or a closed consumable.

[0040] According to another aspect, there is provided a method of generating an aerosol, comprising the steps of: Providing an aerosol delivery device comprising an aerosol generator; determining a cleanliness state or a predicted cleanliness state of a first surface disposed within the aerosol delivery device.

[0041] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0042] [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 a first or upper lid portion to a second or lower base portion of the aerosol delivery device. [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] FIG. 1 illustrates some components of an aerosol delivery device, in which a barrier or first layer is provided above an induction coil to interface with the aerosol product. [Figure 6] FIG. 2 is an enlarged cross-sectional view of a portion of the aerosol product article showing a barrier or first layer disposed between the induction coil and the aerosol product article. [Figure 7] A figure showing a portion of an aerosol delivery device according to one embodiment, in which the cleanliness of the blocking layer or first layer is determined by emitting electromagnetic radiation from an optical transmitter, passing the electromagnetic radiation through the blocking layer or first layer which forms an optical waveguide, and detecting the electromagnetic radiation emerging from the optical waveguide using an optical receiver. [Figure 8] FIG. 13 illustrates another arrangement in which the cleanliness of the barrier layer or first layer is determined by reflecting electromagnetic radiation from a first or upper surface of the barrier layer or first layer. [Figure 9] FIG. 13 shows another structure in which the cleanliness of the barrier layer or first layer is determined by transmitting electromagnetic radiation through the barrier layer or first layer in a direction perpendicular to the plane of the barrier layer or first layer. [Figure 10]FIG. 13 shows another construction in which the cleanliness of the barrier layer or first layer is determined by viewing optical markings provided in or on the barrier layer or first layer using an imaging device. [Figure 11] FIG. 13 shows a further configuration in which a heater can be operated to heat the barrier layer or first layer to clean the surface of the barrier layer or first layer if the cleanliness of the barrier layer or first layer is determined to be relatively low. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] 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.

[0044] 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.

[0045] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat 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.

[0052] In some embodiments, the non-combustion 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.

[0053] 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 delivery components, aerosol generators, aerosol generating areas, housings, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0054] An aerosol-generating material is, for example, a material that can generate an aerosol when heated, irradiated, or energized in any other manner. The aerosol-generating 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.

[0055] 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.

[0056] 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.

[0057] The aerosol-generating film may include or be a sheet that can optionally be chopped to form chopped sheets.

[0058] 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.

[0059] 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 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.

[0060] 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.

[0061] 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.

[0062] The non-combustion aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some implementations, the non-combustion 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 non-combustion aerosol delivery device may also comprise an aerosol generating component. However, in other implementations, the aerosol product article may comprise, in part or in whole, the aerosol generating component.

[0063] 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. The 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.

[0064] Magnetic hysteresis heating is the process by 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, for example an alternating magnetic field as 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.

[0065] 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.

[0066] FIG. 1 shows an aerosol delivery device 202 that may include a lid, a base, and a fixing portion according to one construction.

[0067] According to various embodiments, a barrier layer, which may comprise a thermal insulating layer, may be provided above the one or more inductive heating elements 224a. The barrier layer is not shown in FIG. 1 for clarity. According to various embodiments, a first device may be configured to determine a cleanliness state or a predicted cleanliness state of a surface of the barrier layer. The first device may comprise one or more resistive, capacitive, or inductive sensors.

[0068] The aerosol delivery device 202 may include an outer housing 221, which may be formed from any suitable material, such as a plastic material. The outer housing 221 may be configured such that a power source 222, a control circuit 223, one or more induction coils 224a, a receiving area 225, and an 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. A touch-sensitive panel 229 and an end-of-use indicator 231 may be disposed on the exterior of the outer housing 221.

[0069] The outer housing 221 may further include a mouth end 226. The outer housing 221 and the mouth end 226 may be formed as a single component (i.e., the mouth end 226 may form a part of the outer housing 221). The mouth end 226 is defined as the area of ​​the outer housing 221 that includes the air outlet 228 and is shaped such that a user may comfortably place their lips around the mouth end 226 to engage the air outlet 228.

[0070] The thickness of the outer housing 221 may decrease towards the air outlet 228 to provide a relatively thin portion of the aerosol delivery device 202 that may be more easily accepted by the user's lips.

[0071] 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).

[0072] Control circuitry 223 may be suitably configured or programmed to control the operation of aerosol delivery device 202 to provide 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.

[0073] It will be appreciated that the functionality of control circuitry 223 can be provided 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 provide 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.

[0074] 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 provided 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.

[0075] 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 so that a user may insert and / or remove the aerosol product item 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 item 204 within the receiving area 225 when closed.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] The aerosol product article 204 has a first or upper surface 112 on which the 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 or lower surface 116 opposite the first or upper surface 112. The first or upper surface 112 and / or the second or lower surface 116 may be smooth or rough.

[0081] According to various embodiments, a first surface disposed within the aerosol delivery device is monitored and a determination is made regarding a cleanliness state or predicted cleanliness state of the first surface. It is contemplated that the first surface being monitored forms part of the aerosol delivery device 202 and not the aerosol product article 204. Thus, it is contemplated that the monitoring or determination of the cleanliness state or predicted cleanliness state of either the first or upper surface 112 or the second or lower surface 116 of the aerosol product article 204 is made and thus the first surface being monitored is not the first (or upper) surface or the second (or lower) surface 112, 116 of the aerosol product article 204.

[0082] 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. According to various embodiments, a barrier layer, which may comprise a thermal insulating layer, may be provided on a first or upper surface of the one or more inductive heating elements 224a.

[0083] The aerosol delivery device 202 in one configuration 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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 generating device 204.

[0088] 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.

[0089] In some implementations, the carrier layer 242 or substrate may be or include a metal element that is 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.

[0090] The arrangement shown in Figure 2 operates by allocating (or moving) multiple doses of aerosol-generating material 244 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.

[0091] The shape of the aerosol delivery device 202 may be cigarette-shaped (one dimension longer than the other two dimensions) or may be some other shape. 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.

[0092] The aerosol product article 204 may include a carrier component 242, which may be formed from a card. The carrier component 422 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 needed. In some implementations, the carrier component 242 may include one or more protrusions extending along the length and / or width of the carrier component 242 to help facilitate handling of the aerosol product article 204 by a user.

[0093] The aerosol product article 204 may comprise multiple individual portions of the aerosol-generating material 244 disposed on a surface of the carrier component 242. According to one configuration, 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-generating material 244.

[0094] 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.

[0095] The aerosol-generating material 244 may be disposed at individual, separate locations on a single surface of the component carrier 242. Although the individual portions of the aerosol-generating material 244 are shown as having a circular footprint, it should be understood that the individual portions of the aerosol-generating material 244 may take any other footprint, such as a square, trapezoid, or rectangular, as desired. The individual portions of the aerosol-generating material 244 have a diameter d and a thickness t a The thickness of the individual parts t a may be any suitable value, for example, the thickness t a In some configurations, the thickness t a In other embodiments, the thickness t may be about 50 μm to about 200 μm, or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, suitably about 77 μm. a may be greater than 200 μm, for example, from about 50 μm to about 400 μm, or up to about 1 mm, or up to about 1.5 mm.

[0096] The individual portions of aerosol-generating material 244 may be disposed separately from one another such that each of the individual portions may be individually or selectively energized (eg, heated) to generate an aerosol.

[0097] 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.

[0098] The one or more induction heating elements or induction coils 224a may be arranged such that a surface of the one or more induction heating elements or induction coils 224a forms part of a surface of the receiving area 225. That is, an outer, first or upper surface of the one or more induction heating elements or induction coils 224a is flush with the inner surface of the receiving area 225. However, according to various embodiments, an insulating layer, in particular a thermal insulating layer, may be provided on the surface of the one or more induction heating elements or induction coils 224a, such that the insulating layer forms part of the surface of the receiving area 225.

[0099] The one or more induction heating elements or coils 224a may be configured such that when the aerosol product article 204 is received in the receiving area 225, each induction heating element or coil 224a aligns with a corresponding individual portion of the aerosol-generating material 244. For example, if six induction 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 induction 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 induction heating elements or coils 224a may be provided.

[0100] Each of the induction heating elements or induction coils 224a can be individually actuated to heat a corresponding portion of the aerosol-generating material 244. Although the induction heating elements or induction coils 224a are shown flush with the inner surface of the receiving area 225, in other implementations the induction heating elements or induction coils 224a may protrude into the receiving area 225. However, according to various embodiments, a barrier layer, particularly a thermal insulating layer, may be provided on a surface of one or more of the induction heating elements or induction coils 224a, such that the barrier layer forms part of the surface of the receiving area 225.

[0101] The receiving area 225 may comprise components that apply a force to a surface of the aerosol product article 204 to press the aerosol product article 204 against a surface of the aerosol delivery device 202 to prevent relative motion of the aerosol product article 204. As will be appreciated, the lid of the aerosol delivery device 202 may be configured to engage with the base, for example via a securing mechanism, such that the lid and / or base comprise components that apply a force to a surface of the aerosol product article 204 to secure the aerosol product article 204 against relative motion.

[0102] Additionally or alternatively, one or more induction heater elements or induction coils 224a may be configured to move toward or away from the aerosol product article 204 and may be pressed into a surface of the carrier component 242 that does not contain the aerosol-generating material 244.

[0103] 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.

[0104] 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 securing 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.

[0105] One or more induction coils 224a may be provided adjacent the receiving area 225 and may comprise substantially flat 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.

[0106] 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 transferred accordingly to the portion of the aerosol-generating material 244.

[0107] 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, and one or more susceptors may be disposed to contact the second or lower surface of the carrier component 242. According to various configurations, a barrier layer may be provided between at least a portion of one or more susceptors and one or more induction coils 224a. Additionally, configurations are contemplated in which one or more susceptors may be formed as an array of susceptor elements disposed within a barrier layer that forms a matrix around the array of susceptor elements. The barrier layer may have a depth or thickness that is greater than the depth or thickness of the array of susceptor elements. As a result, according to such configurations, a portion of the susceptor elements and a portion of the barrier layer may also contact the second or lower surface of the carrier component 242.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] The susceptor element 224b is shown embedded in the carrier component 242. However, in other configurations, the susceptor element 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.

[0112] 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.

[0113] Alternatively, a single induction coil 224a may be provided and the aerosol product 204 may be rotated relative to the single induction coil 224a.

[0114] 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.

[0115] While 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 an aerosol in much the same manner as described above. In particular, regions (corresponding to portions of the aerosol-generating material) may be defined on the continuous sheet of aerosol-generating material 244 based on the dimensions of one or more inductive heating elements 224a.

[0116] 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 the preheat temperature, a smaller amount of aerosol or no aerosol is generated when the portion is heated at the preheat temperature. In particular, in some implementations, the control circuitry 223 may be configured to provide power or energy before the start of a first predetermined period, i.e., before receiving a signal indicating the user's intent to inhale the aerosol. This may be particularly suitable for relatively thick portions of the aerosol-generating material, e.g., having a thickness of more than 400 μm, that require the supply of a relatively large amount of energy to reach the operating temperature.

[0117] It will be appreciated that while each of the one or more inductive heating elements or coils 224a may provide the same heating profile to the respective aerosol-generation region, one or more of the inductive heating elements or coils 224a may instead be configured to provide different heating profiles to the different respective aerosol-generation regions. For example, an aerosol-generation region located further from the mouthpiece 228 may be heated according to a heating profile that produces a larger amount of aerosol than an aerosol-generation region located closer to the mouthpiece 228, which may offset additional loss of aerosol due to condensation along the increased travel distance to provide a more consistent delivery of aerosol from the different aerosol-generation regions.

[0118] 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.

[0119] 4A shows an aerosol delivery device in one configuration, 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.

[0120] 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.

[0121] 5 shows a portion of the aerosol delivery device 202 in one configuration, comprising a component 500 that may comprise an aerosol chamber and a mouthpiece. The aerosol chamber may be configured to receive aerosol generated from a portion of the aerosol product article 204, and the aerosol may be transmitted forward to the mouthpiece so that the aerosol can be inhaled by a user.

[0122] As explained above, the component 500 (particularly the aerosol chamber) may be positioned to contact the aerosol product article 204. Additionally, the component 500 may be configured to push the aerosol product article down to the base of the aerosol delivery device 202. The aerosol product article 204 may be configured to contact the barrier layer or first layer 503 when generating an aerosol, such that over a period of time, the first or upper surface of the barrier layer or first layer 503 may accumulate dirt. In particular, the first or upper surface of the barrier layer or first layer 503 may be coated with dust, greasy deposits from contact with human skin (e.g., sebum released from sebaceous glands) or aerosol-generating materials over a period of time. More generally, the aerosol product article 204 may be configured to contact the barrier layer or first layer 503 when generating an aerosol, such that over a period of time, the first surface of the barrier layer or first layer 503 may accumulate dirt. In particular, the first surface of the barrier layer or first layer 503 may become coated over a period of time with dust, greasy deposits from contact with human skin (e.g., sebum released from the sebaceous glands), or aerosol-generating materials.

[0123] The blocking layer or first layer 503 may be substantially transparent to the magnetic field emitted by the one or more induction coils 501 .

[0124] The aerosol product article 204 is shown inserted into a portion of the aerosol delivery device 202. The aerosol product article 204 may comprise a base support layer 504 (which may comprise a card), an aluminum foil susceptor layer 506, and an aerosol-generating material layer 507 (e.g., a gel). A consumable bed 500 is shown, with a PCB inductor coil 501 disposed within the consumable bed 500. The inductor coil 501 is adhered by an adhesive layer 502 to the rear surface of a blocking layer 503, which may be fixed to the consumable bed 500 and is non-rotatable.

[0125] As will be appreciated, according to various configurations, the component 500 may be removed from contact with the aerosol product article 204, thereby allowing the aerosol product article 204 to rotate relative to the induction coil 501.

[0126] 5, induction coil 501 may be configured to heat region 505 of susceptor 506, thereby heating a corresponding region of aerosol-generating material provided in layer 507 containing aerosol-generating material. As a result, a dose of aerosol may be emitted from aerosol-generating layer 507, and the resulting aerosol may then be captured by an aerosol chamber provided in component 500. The aerosol may then be transmitted onward from the aerosol chamber to a mouthpiece, which may be provided in component 500.

[0127] Once the dose of aerosol has been released, the aerosol product article 204 may then be rotated so that a fresh portion of aerosol generating material is positioned above the induction coil 501. For example, the aerosol product article 204 may be rotated 6, 7, 8, 9, 10, 11, 12 or more times during a use session.

[0128] According to one configuration, an aerosol delivery device is disclosed that includes an aerosol generator. The aerosol generator may include, for example, one or more induction coils or induction heating elements. A first device is configured to determine a cleanliness state or a predicted cleanliness state of a surface disposed within the aerosol delivery device 202. The first device may include a controller, which may be configured to determine the number of puffs obtained by a user after a previous cleaning event. Alternatively, the controller may determine the number of actuations of the aerosol generator after a previous cleaning event, or the number of rotations or translations of the aerosol product 204 after a previous cleaning event.

[0129] For example, the controller may determine that a user has obtained N puffs from the aerosol delivery device 202 since the aerosol delivery device 202 was last subjected to a cleaning event. Alternatively, the controller may determine that the induction coil 501 has been activated N times since the aerosol delivery device 202 was last subjected to a cleaning event. According to another configuration, the controller may determine that there have been N rotations or translations of the aerosol product article 204 within the aerosol delivery device 202 since the aerosol delivery device 202 was last subjected to a cleaning event.

[0130] According to various configurations, the controller may determine that the surface of the aerosol delivery device has a first cleanliness state indicating that the surface may require cleaning if N is greater than a threshold value. Similarly, the controller may determine that the surface of the aerosol delivery device has a second cleanliness state indicating that the surface may not require cleaning if N is less than a threshold value.

[0131] According to one configuration, the controller may be configured to determine a distance or separation between a portion of the aerosol generator and a portion of the aerosol product article 204 disposed within the aerosol delivery device 202 during use. For example, the controller may be configured to sense or determine a separation distance between a first or upper surface of the barrier layer 503 and a second or lower surface of the susceptor layer 506 of the aerosol product article.

[0132] If the separation distance is determined to be above the threshold value, this may indicate that the first or upper surface of the barrier layer 503 is covered with dirt, dust, or deposits of aerosol-generating material and therefore the barrier layer 503 requires cleaning.

[0133] The controller may also make the determination that the first surface of the aerosol delivery device 202 requires cleaning by determining whether a ramp-up time, which corresponds to the time it takes to reach an operating temperature, has increased beyond a threshold value. For example, the aerosol delivery device 202 may have a desired ramp-up time of 1.2 seconds, i.e., it may be desirable to be able to heat the portion 505 of the susceptor layer 506 to a temperature of 275° C. or 300° C. within a time period of 1.2 seconds. The controller may be configured to determine the temperature of the susceptor layer 506 by monitoring the resonant frequency of the one or more induction coils 501. As the temperature of the portion of the susceptor layer 506 increases, the resonant frequency of the one or more induction coils 501 may decrease.

[0134] If the controller determines that the temperature rise time has increased beyond a threshold value (e.g., 1.5 seconds), the controller may determine that a first surface of the aerosol delivery device 202, such as the first or upper surface of the barrier layer or first layer 503, has a first cleanliness state indicating that the surface requires cleaning to maintain optimal operation of the aerosol delivery device 202.

[0135] Similarly, if the controller determines that the temperature rise time has not increased beyond a threshold (e.g., 1.5 seconds), the controller may determine that the first surface has a second cleanliness state indicating that it does not require cleaning.

[0136] According to various configurations, the cleanliness of the first surface (monitored or determined by the controller) may comprise a first (i.e., contact) surface between the aerosol product article and the aerosol delivery device. The first (i.e., contact) surface may comprise, for example, a surface of a barrier layer or a surface of the first layer 503. According to various configurations, the first surface may not be intended to come into contact with the aerosol-generating material 507. For example, as shown in FIG. 5, the first surface may comprise a first or upper surface of the barrier layer 503 that contacts a second or lower surface of the base support layer 504 in use.

[0137] 6 shows an enlarged cross-sectional view of a portion of the aerosol delivery device 202 in one configuration with the aerosol product article 204 inserted into the aerosol delivery device 202. The aerosol product article 204 contacts a barrier layer or first layer 503 disposed between the induction coil 501 and the aerosol product article 204.

[0138] The barrier layer or first layer 503 may comprise a thermal insulation layer or first layer 503 comprising a glass, ceramic or plastic layer. The barrier layer or first layer 503 may be optically transparent and may have a thermal conductivity of less than 0.01 W / mK, 0.01-0.05 W / mK, 0.05-0.1 W / mK, 0.1-0.5 W / mK, 0.5-1 W / mK, 1-5 W / mK, 5-10 W / mK, 10-20 W / mK, 20-30 W / mK, 30-40 W / mK and 40-50 W / mK.

[0139] 7 shows a configuration in which the cleanliness of the blocking layer or first layer 503 can be determined by emitting electromagnetic radiation from an optical transmitter 700. The electromagnetic radiation then passes through the blocking layer or first layer 503 forming an optical waveguide. According to various configurations, the electromagnetic radiation is internally reflected within the blocking layer or first layer 503. The electromagnetic radiation is then configured to exit the blocking layer or first layer 503 and is detected by an optical receiver 701. It will be understood that the efficiency of the internal reflection process within the waveguide is determined in part by the refractive index of the first or upper surface (or first surface) of the blocking layer or first layer 503. When the first or upper surface (or first surface) of the blocking layer or first layer 503 is soiled due to repeated contact with the aerosol product, the accumulation of the soil on the first or upper surface (or first surface) of the blocking layer or first layer 503 affects or changes the refractive index of the first or upper surface (or first surface) of the blocking layer or first layer 503. As a result, the refractive index of the first or upper surface (or first surface) of the blocking layer or first layer 503 may change over time. For example, the refractive index of the blocking layer or first layer 503 for electromagnetic radiation having a wavelength of λ nm may be n1, which may be changed by the soiling to a value n2, where n2 is either greater than n1 or n2 is less than n1.

[0140] An arrangement is disclosed in which a first device is configured to determine a cleanliness state or predicted cleanliness state of a surface disposed within the aerosol delivery device 202. The first device may comprise an optical device that may comprise an optical transmitter 700 and an optical detector 701. The optical transmitter 700 may be configured to transmit electromagnetic radiation that is at least partially internally reflected within the blocking layer or first layer 503 and then detected by the optical detector 701.

[0141] Optionally, an arrangement is contemplated in which the aerosol delivery device 202 further comprises a device configured to inform a user of the cleanliness status or predicted cleanliness status of the first surface. The device may comprise an indicator, such as, for example, a user display or a lighting arrangement.

[0142] The aerosol delivery device 202 may further comprise a device configured to advise the user to perform a cleaning routine. For example, if the first device determines that a first surface of the aerosol delivery device 202 potentially requires cleaning, this determination may be communicated to the user, for example, by a visual alert or indication (e.g., on a user display) and / or by haptic feedback before, during or after a usage session.

[0143] The optical device may further comprise a processor for determining the internal reflection angle. According to one arrangement, a change in the internal reflection angle may indicate an altered (e.g., decreased) cleanliness condition.

[0144] According to one configuration, the blocking layer or first layer 503 may be planar to form a planar optical waveguide. The planar optical waveguide comprises an entrance surface, a waveguide portion having a longitudinal direction, and an exit surface, the entrance surface and / or the exit surface being disposed in a plane perpendicular to the longitudinal direction. Light or electromagnetic radiation may be transmitted through the blocking layer or first layer 503. The optical transmitter 700 may be disposed in a lid or base of the aerosol delivery device 202. The optical receiver 701 may be disposed in a lid or base of the aerosol delivery device 202.

[0145] 8 illustrates another configuration in which the cleanliness of the barrier layer or first layer 503 may be determined by reflecting electromagnetic radiation from the first or upper surface (or first surface) of the barrier layer or first layer 503. If the first or upper surface (or first surface) of the barrier layer or first layer 503 becomes soiled due to repeated contact with the aerosol product, the accumulation of soil on the first or upper surface (or first surface) of the barrier layer or first layer 503 affects or changes the refractive index of the first or upper surface (or first surface) of the barrier layer or first layer 503. As a result, the refractive index of the first or upper surface (or first surface) of the barrier layer or first layer 503 may change over time. For example, the refractive index of the blocking layer or first layer 503 for electromagnetic radiation having a wavelength of λ nm may be n1, which may be altered by contamination to a value n2, where n2 is either greater than n1 or n2 is less than n1.

[0146] 9 shows another arrangement in which the cleanliness of the barrier or first layer is determined by transmitting electromagnetic radiation through the barrier or first layer 503 in a direction perpendicular to the plane of the barrier or first layer 503. The electromagnetic radiation may be emitted by an optical transmitter 700 and detected by an optical detector 701.

[0147] FIG. 10 shows another configuration in which the cleanliness of the barrier layer or first layer 503 may be determined by viewing optical markings 800 provided in or on the barrier layer or first layer 503 using an imaging device 801.

[0148] The portion of the aerosol delivery device 202 may further comprise a transparent or semi-transparent barrier layer or first layer having one or more optical markings. The transparent or semi-transparent barrier layer or first layer may comprise a first surface that is desired to be kept clean. According to another configuration, the optical device may be configured to examine a bar code or another optical marking provided on the portion of the aerosol product item 204. According to this embodiment, the first device may be configured to determine a cleanliness state or predicted cleanliness state of a first surface disposed within the aerosol delivery device 202, the first surface comprising a portion of the barrier layer or first layer 503 including the optical marking 800.

[0149] 11 shows a further configuration in which a heater 900 can be operated to heat the barrier layer or first layer 503 to clean the surface of the barrier layer or first layer 503 if the cleanliness of the barrier layer or first layer 503 is determined to be relatively low. Thus, a configuration is disclosed in which an aerosol generator comprises a heater 900, in which the heater 900 can be activated to clean the first surface if the first surface of the aerosol delivery device 202 is determined to have a cleanliness state below a threshold. In the configuration shown in FIG. 11, the heater 900 is disposed below the barrier layer or first layer 503. However, other configurations are contemplated in which the heater 900 can be disposed in other locations, such as above the barrier surface or first layer 503, or around the periphery of the separation layer or first layer 503.

[0150] According to various embodiments, an aerosol delivery device is provided that includes an aerosol chamber that is movable between a first position where the aerosol chamber contacts the aerosol product article and a second position where the aerosol chamber does not contact the aerosol product article. A first mechanism may be configured to move the aerosol chamber between the first and second positions. According to various embodiments, the aerosol product article may include a generally circular or elliptical substrate having a first surface and a second surface. The substrate may include, for example, paper, card, or aluminum foil. Other embodiments are contemplated in which the substrate may include multiple layers arranged in a sandwich. For example, the substrate may include a paper or card substrate having a first aluminum foil layer disposed on the first surface and a second aluminum foil layer disposed on the second surface.

[0151] 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.

[0152] 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.

[0153] 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).

[0154] 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.

[0155] Embodiments are contemplated in which the aerosol product 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 m=2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10, embodiments are contemplated. 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.

[0156] 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 in which multiple resistive and inductive heating elements may be provided are also contemplated.

[0157] 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 disposed 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 an embodiment, the aerosol product article may be configured to be heated from two opposing sides simultaneously or sequentially.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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 present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An aerosol delivery device comprising: An aerosol generator; a first device configured to determine a cleanliness state or a predicted cleanliness state of a first surface disposed within the aerosol delivery device.

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

3. 3. The aerosol delivery device of claim 1 or 2, wherein the first surface comprises an interface between an aerosol product article and the aerosol delivery device.

4. 4. The aerosol delivery device of claim 1, 2 or 3, wherein the first surface comprises a surface of a barrier layer or a first layer.

5. The aerosol delivery device of claim 4 , wherein the barrier layer or the first layer comprises a thermal insulation layer.

6. 6. The aerosol delivery device of claim 4 or 5, wherein the barrier layer or first layer comprises a glass, ceramic, or plastic layer.

7. 7. The aerosol delivery device of claim 4, 5 or 6, wherein the barrier layer or first layer is optically transmissive.

8. 8. The aerosol delivery device of claim 4, wherein the barrier layer or first layer has a thermal conductivity of less than 0.01 W / mK, 0.01-0.05 W / mK, 0.05-0.1 W / mK, 0.1-0.5 W / mK, 0.5-1 W / mK, 1-5 W / mK, 5-10 W / mK, 10-20 W / mK, 20-30 W / mK, 30-40 W / mK, or 40-50 W / mK.

9. The aerosol delivery device of any one of claims 4 to 8, wherein the barrier layer or first layer is magnetically permeable.

10. 10. The aerosol delivery device of claim 1, wherein the first device is configured to determine (i) the number of puffs obtained by a user after a previous cleaning event, (ii) the number of actuations of the aerosol generator after a previous cleaning event, or (iii) the number of rotations or translations of the aerosol product after a previous cleaning event.

11. 11. The aerosol delivery device of claim 1, wherein the first device is configured to determine a distance or separation between a portion of the aerosol generator and a portion of an aerosol product disposed within the aerosol delivery device in use.

12. 12. The aerosol delivery device of claim 1, wherein the first device is configured to determine whether a rise time corresponding to the time it takes to reach an operating temperature has increased beyond a threshold time.

13. 13. The aerosol delivery device of claim 12, wherein the first device is configured to determine that the first surface has a first cleanliness state if the first device determines that the rise time has increased beyond a threshold time.

14. 14. The aerosol delivery device of claim 12 or 13, wherein the first device is configured to determine that the first surface has a second cleanliness state if the first device determines that the rise time has not increased beyond a threshold time.

15. The aerosol delivery device of any one of claims 1 to 14, wherein the first surface comprises a surface of a planar optical waveguide.

16. 16. The aerosol delivery device of claim 15, wherein the planar optical waveguide comprises an entrance surface, a waveguide portion having a longitudinal direction, and an exit surface, the entrance surface and / or the exit surface being arranged in a plane perpendicular to the longitudinal direction.

17. 17. The aerosol delivery device of claim 15 or 16, further comprising an optical transmitter configured to transmit electromagnetic radiation into the optical waveguide and an optical detector configured to detect electromagnetic radiation exiting the optical waveguide.

18. 18. The aerosol delivery device of claim 15, 16, or 17, further comprising a processor configured to determine an internal reflection angle or a critical angle of the planar optical waveguide, the first device configured to determine a cleanliness state or a predicted cleanliness state of the surface based on the determined internal reflection angle or critical angle.

19. 19. The aerosol delivery device of any one of claims 1 to 18, further comprising an optical transmitter and an optical detector, the optical transmitter configured to emit electromagnetic radiation that is reflected by or transmitted through the first surface, and the optical detector configured to detect the electromagnetic radiation that is reflected by or transmitted through the first surface.

20. 20. The aerosol delivery device of any one of claims 1 to 19, further comprising a layer having one or more optical markings and an optical device configured to view or examine the one or more optical markings, wherein the first surface comprises a surface of the layer having the one or more optical markings.

21. 21. The aerosol delivery device of claim 1, further comprising an optical device configured to view or inspect a bar code, QR code or other optical marking provided on the aerosol product.

22. 22. The aerosol delivery device of claim 20 or 21, wherein the optical device is configured to output a signal to the first device, and the first device is configured to determine a cleanliness state or a predicted cleanliness state of the first surface based on the signal output from the optical device.

23. An aerosol delivery device as described in any one of claims 1 to 22, wherein the first device comprises an imaging device for observing and analysing an image provided on a component of the aerosol delivery device and / or an aerosol product item, and the first device is configured to determine a cleanliness state of the first surface in response to an analysis of one or more qualities of the observed image.

24. The aerosol delivery device of any one of claims 1 to 23, further comprising a heater or other cleaning device for cleaning the first surface.

25. 25. The aerosol delivery device of claim 24, wherein if the first device determines that the first surface has a cleanliness condition or a predicted cleanliness condition above or below a threshold, the first device is configured to activate the heater or other cleaning device to clean the first surface.

26. 26. The aerosol delivery device of claim 25, wherein if the first device determines that the first surface has a cleanliness state or a predicted cleanliness state above or below a threshold, the first device is configured to activate the heater to perform a heating cycle to clean the first surface by maintaining the first surface at a temperature of T°C for at least a time t1 before, during or after a use session, where optionally T is in a range of less than 50°C, 50-100°C, 100-150°C, 150-200°C, 200-250°C, 250-300°C or more than 300°C, and optionally t1 is in a range of less than 30 seconds, 30-60 seconds, 60-90 seconds, 90-120 seconds or more than 120 seconds.

27. The aerosol delivery device of any one of claims 1 to 26, further comprising a device configured to notify a user of the cleanliness status or predicted cleanliness status determined by the first device.

28. 28. The aerosol delivery device of any one of claims 1 to 27, further comprising a device configured to advise a user to perform a cleaning routine if the first device determines that the surface has a first cleanliness state.

29. The aerosol delivery device of any one of claims 1 to 28, wherein the first device comprises one or more resistive, capacitive or inductive sensors.

30. 1. An aerosol generating system comprising: An aerosol delivery device according to any one of claims 1 to 29; and an aerosol production article.

31. 31. The aerosol generation system of claim 30, wherein the aerosol product 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 shaped aerosol product article.

32. 32. The aerosol generating system of claim 30 or 31, wherein the aerosol product comprises either an open consumable or a closed consumable.

33. 1. A method for generating an aerosol, comprising: Providing an aerosol delivery device comprising an aerosol generator; determining a cleanliness state or a predicted cleanliness state of a first surface disposed within the aerosol delivery device.

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