Aerosol Delivery Device

Abstract

An aerosol delivery device is provided. The aerosol delivery device is for use with an article that includes an aerosol-generating material. The aerosol delivery device includes a housing. The housing includes a plurality of perforations. Each perforation has a dimension of less than 50 microns. The aerosol delivery device includes a light source disposed within the housing adjacent the plurality of perforations such that when the light source is activated, light from the light source visibly passes through the perforations and when the light source is not activated, the light source is not visible to the naked eye through the perforations.

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device.The present invention also relates to an aerosol delivery system. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to those tobacco-burning articles by creating products that release compounds without combustion. An example of such a product is a heating device that releases compounds by heating a material rather than burning it. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] According to some embodiments described herein, there is provided an aerosol delivery device for use with an article including an aerosol-generating material, the aerosol delivery device comprising: a housing with a plurality of perforations, each perforation having a dimension of less than 50 microns; and a light source disposed within the housing adjacent the plurality of perforations, the light source positioned such that when the light source is activated, light from the light source visibly passes through the perforations and when the light source is not activated, the light source is not visible to the naked eye through the perforations.

[0004] Optionally, when the light source is not activated, the perforations are not visible to the naked eye.

[0005] Optionally, the housing comprises a button. Optionally, the perforations are provided in the button.

[0006] Optionally, the perforations are formed by etching, optionally by laser etching.

[0007] Optionally, the perforations have a size between 5 microns and 50 microns. Optionally, the perforations have a size between 5 microns and 20 microns. Optionally, the perforations have a size between 30 microns and 40 microns.

[0008] Optionally, the plurality of perforations forms an array. Optionally, the array is circular. Optionally, the array is annular.

[0009] Optionally, the device comprises a plurality of light sources disposed within the housing adjacent the plurality of perforations, each light source configured to illuminate a respective portion of the array.

[0010] Optionally, the multiple light sources are evenly spaced circumferentially around the array.

[0011] Optionally, the plurality of light sources comprises four light sources.

[0012] Optionally, the multiple light sources are configured to illuminate sequentially to indicate progress through a start-up phase of a usage session.

[0013] Optionally, the multiple light sources are configured to sequentially dim to indicate time remaining in a usage session.

[0014] Optionally, a portion of the plurality of light sources are configured to illuminate to indicate a charge status of the aerosol delivery device.

[0015] Optionally, the aerosol delivery device further comprises a further plurality of perforations, each having a dimension of less than 50 microns, and a further light source disposed in the housing adjacent to the further plurality of perforations, wherein when the further light source is activated, light from the further light source visibly passes through the further plurality of perforations and when the further light source is not activated, the further light source is positioned such that the further light source is invisible to the naked eye through the further plurality of perforations, wherein the further light source is configured to illuminate to indicate whether the device is operating at a first temperature in the first mode or a second temperature in the second mode, the second temperature being higher than the first temperature.

[0016] According to some embodiments described herein, there is provided an aerosol delivery device for use with an article including an aerosol-generating material, the aerosol delivery device comprising a plurality of light sources arranged in a circular array.

[0017] Optionally, the multiple light sources are evenly spaced circumferentially around the circle.

[0018] Optionally, the plurality of light sources comprises four light sources.

[0019] Optionally, the multiple light sources are configured to illuminate sequentially to indicate progress through a start-up phase of a usage session.

[0020] Optionally, the multiple light sources are configured to sequentially dim to indicate time remaining in a usage session.

[0021] Optionally, a portion of the plurality of light sources are configured to illuminate to indicate a charge status of the aerosol delivery device.

[0022] Optionally, the aerosol delivery device comprises a further light source disposed within the housing, the further light source configured to illuminate to indicate whether the device is operating in the first mode at a first temperature or in the second mode at a second temperature, the second temperature being higher than the first temperature.

[0023] According to some embodiments described herein, there is provided an aerosol delivery device for use with an article including an aerosol-generating material, the aerosol delivery device comprising a housing including a plurality of perforations.

[0024] According to some embodiments described herein, there is provided a system comprising an article including an aerosol-generating material and an aerosol delivery device as described anywhere above.

[0025] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0026] [Figure 1] FIG. 2 is a front view of the aerosol delivery device. [Diagram 2] 2 is a schematic cross-sectional side view of the aerosol delivery device of FIG. 1. [Diagram 3] 2 is a perspective view of a button assembly for the aerosol delivery device of FIG. 1. [Figure 4] FIG. 4 is a cutaway perspective view of the button assembly of FIG. 3. [Diagram 5] 2 is a perspective view of a portion of the aerosol delivery device of FIG. 1. [Figure 6] 2 is an exploded perspective view of a user interface assembly for the aerosol delivery device of FIG. 1. [Figure 7] 7 is an exploded perspective view of a light guide for the user interface assembly of FIG. 6. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] The term "aerosol-generating material" as used herein is a material capable of generating an aerosol when, for example, heated, irradiated, or excited in any other way. The aerosol-generating material may be in the form of, for example, a solid, liquid, or gel, which may or may not contain active substances and / or flavorings. The aerosol-generating material may include any plant-based material, such as a tobacco-containing material, and may also include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The aerosol-generating material may further include other non-tobacco products, which may or may not contain nicotine, depending on the product. The aerosol-generating material may be in the form of, for example, a solid, liquid, gel, wax, etc. The aerosol-generating material may also be, for example, a combination or mixture of materials. The aerosol-generating material may also be known as "smoking material".

[0028] The aerosol-generating material may include a binder and an aerosol former. Optionally, additional actives and / or fillers may be present. Optionally, a solvent, such as water, may be present in which one or more components of the aerosol-generating material may or may not be dissolved. In some embodiments, the aerosol-generating material is substantially free of plant material. In some embodiments, the aerosol-generating material is substantially free of tobacco.

[0029] The aerosol-generating material may include or be an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some amount of fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0030] The aerosol-generating material may include an aerosol-generating film. The aerosol-generating film may include or be a sheet, which may optionally be chopped to form a chopped sheet. The aerosol-generating sheet or chopped sheet may be substantially free of tobacco.

[0031] According to this disclosure, a "non-combustion" aerosol delivery system is an aerosol delivery system in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0032] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery.

[0033] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or an electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0034] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0035] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, where one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not include 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, a tobacco product or a non-tobacco product.

[0036] Typically, a non-combustion aerosol delivery system can include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0037] 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.

[0038] In some embodiments, the non-combustion aerosol delivery system, e.g., the 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 an exothermic power source. In some embodiments, the exothermic power source includes a carbon substrate that can be excited to deliver power in the form of heat to the aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

[0039] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0040] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may comprise an aerosol generating material, an aerosol generating material storage region, an aerosol generating material transport component, an aerosol generator, an aerosol generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0041] The aerosol generating device can accept an article that includes the aerosol generating material for heating. An "article" in this context is a component that includes or contains the aerosol generating material in use, which is heated in use to volatilize the aerosol generating material and optionally other components. A user can insert the article into the aerosol generating device before the article is heated to generate an aerosol that the user then inhales. The article can be of a predetermined or specific size, for example, configured to be placed in a heating chamber of the device sized to receive the article.

[0042] 1 shows an aerosol delivery device 100 for generating an aerosol from an aerosol-generating material. Broadly speaking, device 100 can be used to heat a replaceable article 300 that includes an aerosol-generating material to generate an aerosol or other inhalable intermediate that is inhaled by a user of device 100. Article 300 and device 100 together form an aerosol delivery system.

[0043] The device 100 comprises a body 101. The body 101 comprises a chamber 105 (see FIG. 2). A housing 102 surrounds and houses the various components of the body 101. An opening 103 is formed at one end of the body 101 and communicates with the chamber 105. An article 300 may be at least partially inserted into the chamber 105 through the opening 103 for heating by the aerosol generator 150 (see FIG. 2). In use, the article 300 may be heated by one or more components of the aerosol generator 150.

[0044] Housing 102 includes a button assembly 200 that, when pressed, operates device 100. For example, a user can turn on device 100 by manipulating button assembly 200. The button assembly is described further below in connection with Figures 3 and 4.

[0045] The aerosol generator 150 defines a longitudinal axis X.

[0046] 2 shows a cross-sectional schematic view of device 100. Device 100 includes electrical components such as a connector / port 160 that can accept a cable for charging a battery of device 100. For example, connector 160 may be a charging port, such as a USB charging port. In some examples, connector 160 may also, or instead, be used to transfer data between device 100 and another device, such as a computing device.

[0047] The device 100 includes a power source 170, e.g., a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, e.g., lithium batteries (e.g., lithium ion batteries), nickel batteries (e.g., nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the aerosol generator 150 to provide power to heat the aerosol-generating material under the control of the controller when needed.

[0048] The device 100 includes an electronics module 112. The electronics module 112 may include, for example, a printed circuit board (PCB). The PCB may support at least one controller, such as a processor, and a memory. The PCB may further include one or more electrical tracks for electrically connecting various electronic components of the device 100 to one another. For example, battery terminals may be electrically connected to the PCB such that power may be distributed throughout the device 100.

[0049] The body 101 comprises an end surface of the device 100. The end of the device 100 closest to the opening 103 is sometimes known as the proximal end (or mouth end) 104 of the device 100, as it is closest to the user's mouth. In use, the user inserts the article 300 into the opening 103, operates the aerosol generator 150 to begin heating the aerosol-generating material, and inhales the aerosol generated within the device. The aerosol thereby flows through the device 100 along a flow path towards the proximal end of the device 100.

[0050] The other end of the device, furthest from the opening 103, is sometimes known as the distal end 106 of the device 100, as it is the end furthest from a user's mouth in use. When a user inhales aerosol generated within the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 are described by reference to the relative positions of such features with respect to one another in the proximal-distal direction along the longitudinal axis.

[0051] As used herein, one-piece component means a component of device 100 that cannot be separated into two or more components after assembly of device 100. Integrally formed refers to two or more features that are formed into the one-piece component during the manufacturing stage of the component.

[0052] An air flow passage 180 extends through the body 101. The air flow passage 180 extends to an opening 190. The opening 190 serves as an air inlet.

[0053] In one example, the aerosol generator 150 comprises an induction heating system including a magnetic field generator. The magnetic field generator comprises an inductor coil assembly. The aerosol generator 150 comprises a heating element. The heating element is also known as a susceptor.

[0054] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material, such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. In this specification, a device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0055] The aerosol generator 150 is an induction heating assembly, which comprises various components for heating the aerosol-generating material of the article 300 by an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may comprise an induction element, for example one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element creates a varying magnetic field. The varying magnetic field penetrates a susceptor appropriately positioned relative to the induction element to generate eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore the flow of eddy currents against this resistance causes the susceptor to heat by Joule heating. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat may be further generated by magnetic hysteresis losses in the susceptor, i.e., by the varying orientation of the magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. In comparison with, for example, heating by conduction, in induction heating, heat is generated inside the susceptor, allowing for rapid heating, and furthermore, no physical contact is required between the induction heater and the susceptor, allowing for increased freedom of construction and application.

[0056] The inductor coil assembly includes an inductor coil. In some embodiments, the number of inductor coils varies. In some embodiments, more than one inductor coil is used. The inductor coil further includes a coil support. The coil support is tubular.

[0057] The heating element is part of a heating assembly. The heating element in this example is hollow and thus defines at least a portion of a container in which the aerosol-generating material is received. For example, the article 300 can be inserted into the heating element. The heating element is tubular with a circular cross-section. The heating element has a generally constant diameter along its axial length.

[0058] The heating element is formed from an electrically conductive material suitable for heating by electromagnetic induction. The susceptor in this example is formed from carbon steel. It will be appreciated that other suitable materials may be used, for example ferromagnetic materials such as iron, nickel, or cobalt.

[0059] In other embodiments, the features acting as heating elements may not be limited to being inductively heated. Thus, the features acting as heating elements may be heatable by electrical resistance. Thus, the aerosol generator 150 may include electrical contacts for electrical connection with a device for electrically activating the heating element by passing a flow of electrical energy through the heating element.

[0060] The container and article 300 are dimensioned such that the article 300 is received by the heating element. This helps ensure that heating is most efficient. The article 300 in this example includes an aerosol-generating material. The aerosol-generating material is disposed within the container. The article 300 may further include other components, such as a filter, a winding material, and / or a cooling structure.

[0061] An airflow passage 180 extends from the heating element. The airflow passage 180 is located at a first distal end. The airflow passage 180 protrudes from the heating element. The airflow passage 180 extending from the heating element is defined by a flow path member 182. The heating element 220 and the flow path member 182 form part of an air flow path arrangement 181.

[0062] The flow path member 182 extends between the heating element and the opening 190. The flow path member 182 is tubular. The flow path member 182 defines a bore. The flow path member extends axially along its length.

[0063] Figure 3 shows a perspective view of a button assembly 200 for aerosol delivery device 100. Figure 4 shows a cross-sectional perspective view of button assembly 200. In some embodiments, button assembly 200 is used with other device components. The button forms part of housing 102.

[0064] The button assembly 200 includes a button member 202 and a support frame 220. The button member 202 is movably coupled to the support frame 220. The button member 202 is coupled to the support frame 220 by a flexible membrane 208. The flexible membrane 208 seals the button assembly 200 against the ingress of foreign objects.

[0065] The support frame 220 is coupled to the outer cover 108 of the housing 102 (see FIG. 1). The outer cover 108 of the aerosol delivery device 100 includes an opening. The button assembly 200 is disposed adjacent to the opening 109 (see FIG. 1). The button member 202 protrudes through the opening 109. The button member 202 forms part of the exterior surface of the aerosol delivery device 100 and therefore may be considered part of the housing 102. The support frame 220 is coupled to the housing 102. The support frame 220 is secured to the housing 102 by sonic welding or another suitable fastener.

[0066] The button member 202 is formed of aluminum. The button member 202 includes a plurality of perforations 204. The perforations 204 are formed in an array. The perforations 204 extend from a front surface 202a of the button member 202 to a rear surface of the button member 202. That is, the perforations 204 extend through the entire thickness of the button member 202. The front surface 202a of the button member is exposed to the exterior of the aerosol delivery device 100. The perforations 204 are formed by laser etching. Alternative etching means are envisaged.

[0067] The perforations 204 have a dimension between 5 microns and 50 microns. In this embodiment, the perforations have a diameter of 35 microns. It will be understood that the term "including a dimension" is intended to mean a measurement from one edge of the perforation to another edge. The dimension may be the diameter of the perforation 204 or the width of the perforation 204. The dimension does not have to be the maximum dimension of the perforation. In some embodiments, the perforations may be elongated slots and the dimension may be the width of the slot, the length of the slot being greater than 50 microns. In some embodiments, the perforations are not all the same shape.

[0068] A light source 206 is disposed within the housing 102. The light source 206 is adjacent to the plurality of perforations 204. The light source 206 is separated from the button member 202 by a clearance 210. The clearance 210 provides a space to accommodate the light source 206 when the button member 202 is depressed. The light source 206 is an LED. In this embodiment, the light source 206 comprises three LEDs. In some embodiments, a different number of LEDs may be provided. In some embodiments, there is no clearance and the light source is configured to move with the button member 202.

[0069] The light sources 206 are arranged such that when activated, light from the light sources 206 passes visibly through the perforations 204. The perforations 204 and the light sources 206 are arranged such that when not activated, the light sources 206 are not visible to the naked eye through the perforations. This is because the perforations 204 have a dimension between 5 microns and 50 microns. It has been found that if the perforations have a dimension less than 50 microns, they are not visible from outside the device. It has been found that if the perforations have a dimension less than 50 microns, the light sources 206 are not visible from outside the device except when illuminated. The perforations 204 act as light guides. In this embodiment, the perforations 204 are arranged in three groups or portions corresponding to the three LEDs. The groups are separated by portions of the button member 202 that do not contain perforations or have a lower density of perforations.

[0070] 5 shows an end of aerosol delivery device 100. Aerosol delivery device 100 includes a user interface 400. User interface 400 is located at proximal end 104 of aerosol delivery device 100. That is, user interface 400 is located at the same end of aerosol delivery device 100 as opening 103. This allows a user to see the user interface when aerosol delivery device 100 is in use, because proximal end 104 of aerosol delivery device 100 is typically pointed toward the user when the device is in use.

[0071] The user interface 400 comprises a circular portion 402 and a central portion 404. The circular portion 402 comprises a number of segments. The segments may be independently illuminated. The segments are evenly spaced around the circumference of the circular portion 402. In this embodiment, the circular portion 402 comprises four segments. In other embodiments, the circular portion 402 may comprise a different number of segments, for example, 12 segments.

[0072] The segments are illuminated to indicate one or more of battery charge status, session ramp up, and session time remaining. The term "session ramp up" will be understood to mean the period after a user has started a session but before the device is ready to inhale, i.e., the period during which the heating element is heating up to operating temperature. For example, if all segments are shown, this may indicate a full charge, session ramp up is complete, or maximum session time remaining.

[0073] The central portion 404 may be illuminated or dimmed to indicate the operating mode of the aerosol delivery device 100. The aerosol delivery device is operable in a boost mode and a base mode. In the boost mode, the heating element is heated to a higher operating temperature or heated to an operating temperature more quickly compared to the base mode. The boost mode is indicated by illumination of the central portion 404 of the user interface. The base mode is indicated by a lack of illumination of the central portion 404 of the user interface.

[0074] 6 shows an exploded view of a user interface assembly 500. The user interface assembly 500 comprises a printed circuit board (PCB) 506 with multiple LEDs 512, 514 arranged in a stack, a light guide 516, a masking element 526, and a transmissive element 530. Light is emitted by the LEDs 512, 514. The light is then guided by the light guide 516. The light is then partially blocked by the masking element 526 and partially transmitted through the transmissive element 530.

[0075] PCB 506 is flexible. PCB 506 includes power management and control circuitry for buttons 532, 534 and LEDs 512, 514. PCB 506 is connected to power source 170. PCB 506 may be connected to other control circuitry within aerosol delivery device 100. PCB 506 fits into a corner of aerosol delivery device 100. PCB 506 includes a user interface portion 508 and a button portion 510. User interface portion 508 and button portion 510 are connected by a flexible joint 511. In this embodiment, flexible joint 511 extends over a 90 degree angle. In some embodiments, the entire PCB 506 is flexible.

[0076] The user interface portion 508 comprises a plurality of LEDs 512, 514. The plurality of LEDs 512, 514 includes a circular arrangement of LEDs 512. The LEDs of the circular arrangement 512 are evenly spaced around the circumference of the circular arrangement. The plurality of LEDs 512, 514 further includes a central arrangement of LEDs 514 arranged in a circle. In some embodiments, the central arrangement 514 comprises a single LED. In this embodiment, the circular arrangement 512 comprises twelve LEDs. In this embodiment, the central arrangement 514 comprises five LEDs. In some embodiments, the circular arrangement comprises any number of LEDs greater than or equal to three LEDs, for example, four LEDs. The central arrangement of LEDs 514 is positioned to illuminate the central portion 404 of the user interface 400. The circular arrangement of LEDs 512 is positioned to illuminate the circular portion 402 of the user interface 400.

[0077] The light guide 516 is twin shot molded. The term "twin shot molding" will be understood to refer to a process in which two materials are injected into a single mold (i.e., without opening the mold) during fluid manipulation. In a typical twin shot molding process, a first polymer is injected into a mold, which is subsequently rotated (without opening) and a second polymer is injected. The light guide 516 comprises a translucent layer 518 and an opaque layer 520. The twin shot molding process allows the opaque layer 520 and the translucent layer 518 to be created as a single piece in a single mold. The opaque layer 520 and the translucent layer 518 bond at a molecular level as a result of temperature during the twin shot molding process.

[0078] The light guide 516 includes at least one pin 524. The pin 524 is received in a recess 525 in the PCB 506. The pin 524 positions the light guide 516 on the PCB 506. The light guide 516 is described in more detail below in connection with FIG.

[0079] The masking element 526 is opaque. The masking element 526 is formed of polyethylene terephthalate (PET). In some embodiments, the masking element 526 is formed of a different material. The masking element 526 is a printed layer on the transparent element 530. In some embodiments, the masking element 526 is a separate component rather than a printed layer on the transparent element 530. The masking element 526 has an annular shape. The masking element 526 defines a central opening 528. The central opening 528 overlaps the central arrangement of LEDs 514. The central opening 528 is positioned such that light from the central arrangement of LEDs 514 is transmitted through the central opening 528. The masking element 526 is surrounded by the circular arrangement of LEDs 512. It will be appreciated that the masking element 526 is axially displaced from the circular arrangement of LEDs 512 and is only surrounded laterally by the circular arrangement of LEDs 512. The term "lateral direction" will be understood to mean a direction in the plane of the masking element 526. Light from the circular arrangement of LEDs 512 is transmitted around the outer edge of the masking element 526. The light guide 516 is configured to guide the light from the central arrangement of LEDs 514 through a central opening 528 of the masking element 526. The light guide 516 is configured to guide the light from the circular arrangement of LEDs 512 past the outer edge of the masking element 526. The light guide 516 is configured to prevent significant light from the circular arrangement of LEDs 512 from being transmitted through the central opening 528 of the masking element 526.

[0080] The transmission element 530 is transparent or translucent. The transmission element 530 forms an outer surface of the user interface assembly 500. The transmission element 530 is formed of polymethylmethacrylate. In some embodiments, the transmission element 530 is formed of a different material. In this embodiment, the transmission element 530 is a circular disk.

[0081] The aerosol delivery device 100 further comprises a mode selection button 532 and an activation button 534. In some embodiments, the mode selection button 532 and / or the activation button 534 are provided by the button assembly 200.

[0082] The mode selection button 532 and the activation button 534 are located on the button portion 510 of the PCB 506. The mode selection button 532 and the activation button 534 protrude through an opening in the housing 102. In other embodiments, the mode selection button 532 and the activation button 534 may protrude through the same opening in the housing 102. The mode selection button 532 and the activation button 534 are located on a side of the housing 102. It will be appreciated that the side of the housing 102 is the face of the housing that joins the proximal end 104 and the distal end 106 of the housing 102. This allows a user to access the buttons 532, 534 without obscuring the user interface 400 when using the aerosol delivery device 100. This arrangement is facilitated by the flexible coupling 511 of the PCB 506.

[0083] In use, a user presses the mode selection button 532 to toggle between the boost and base modes of operation. The mode of operation of the aerosol delivery device 100 is indicated by the illumination or dimming of the central portion 404 of the user interface 400. The user then presses the activation button 534 to begin a usage session. The circular portion 402 of the user interface 400 is initially dimmed in its entirety to indicate the beginning of a warm-up period. Power is provided to the heating element. As the temperature of the heating element increases, segments of the circular portion 402 of the user interface 400 are sequentially illuminated to indicate progress toward the operating temperature. To accomplish this, the LEDs of the circular component 512 may be sequentially illuminated individually or in groups. Once the heating element reaches the operating temperature, all of the LEDs of the circular component 512 are illuminated. This indicates to the user that the operating temperature has been reached and the user can begin inhaling. The user then puffs on the device. As the usage session progresses, the LEDs of the circular component 512 are sequentially dimmed to indicate progress over the usage session. The LEDs 512 of the circular arrangement may be dimmed sequentially, either individually or in groups. The device's electronics module 112 may determine progress through a usage session based on counting the number of detected puffs on the device. Puffs may be detected through a pressure sensor, or temperature monitoring of the heating element, or in any other manner. Alternatively, the electronics module 112 may determine progress through a usage session based on the amount of time that has elapsed since the user pressed the activation button 534. Once the usage session is complete, all of the LEDs of the circular arrangement 512 are dimmed. This indicates to the user that the usage session is over and that the aerosol-generating material in the article 300 has been used up.

[0084] 7 shows an exploded view of light guide 516. Light guide 516 comprises a transparent or translucent portion 518 and an opaque portion 520. Translucent or transparent portion 518 is formed of talc filled polycarbonate. In some embodiments, translucent or transparent portion 518 is formed of a different material. Opaque portion 520 is formed of polycarbonate. In some embodiments, opaque portion 520 is formed of a different material. Opaque portion 520 surrounds transparent or translucent portion 518. Opaque portion 520 defines a cavity for receiving transparent or translucent portion 518. Opaque portion 520 includes an opening 522 through which light can pass. Light guide 516 is formed in a two shot molding process.

[0085] In another embodiment, the transmissive element 530 and the masking element 526 are replaced by an opaque member comprising perforations. The perforations each have a dimension between 5 microns and 50 microns, for example 35 microns. The opaque member may be formed of aluminum. The perforations are formed by laser etching. The perforations act as light guides. The perforations comprise a circular structure to provide the circular portion 402 of the user interface 400. The perforations further comprise a central structure disposed within the circular structure to provide the central portion 404 of the user interface 400.

[0086] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as a representative sample of embodiments and are not intended to be comprehensive and / or exclusive. It should be understood that 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 to the equivalents of the claims, and that other embodiments may be used and changes 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. Moreover, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An aerosol delivery device for use with an article containing an aerosol-generating material, comprising: a housing comprising a plurality of perforations, each perforation having a dimension less than 50 microns; a light source disposed within the housing adjacent the plurality of perforations, the light source positioned such that when the light source is activated, light from the light source passes visibly through the perforations and when the light source is not activated, the light source is not visible to the naked eye through the perforations; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the housing comprises a button, and the perforation is provided in the button.

3. The aerosol delivery device of claim 1 or 2, wherein the perforations are formed by laser etching.

4. The aerosol delivery device of any one of claims 1 to 3, wherein the perforations have a dimension between 5 microns and 50 microns, optionally between 30 microns and 40 microns.

5. The aerosol delivery device of any one of claims 1 to 4, wherein the plurality of perforations form an array, optionally the array being circular.

6. The aerosol delivery device of claim 5 , comprising a plurality of light sources disposed within the housing adjacent the plurality of perforations, each light source configured to illuminate a respective segment of the array.

7. The aerosol delivery device of claim 6 , wherein the plurality of light sources are evenly spaced circumferentially around the array.

8. The aerosol delivery device of claim 6 or 7, wherein the plurality of light sources comprises four light sources.

9. The aerosol delivery device of any one of claims 6 to 8, wherein the multiple light sources are configured to illuminate sequentially to indicate progress through a start-up stage of a usage session.

10. The aerosol delivery device of any one of claims 6 to 9, wherein the multiple light sources are configured to sequentially dim to indicate time remaining in a usage session.

11. The aerosol delivery device of any one of claims 1 to 10, wherein a portion of the plurality of light sources are configured to illuminate to indicate a charging status of the aerosol delivery device.

12. a further plurality of perforations, each having a dimension less than 50 microns; and a further light source disposed on the housing adjacent the further plurality of perforations, the further light source positioned such that when the further light source is activated, light from the further light source passes visibly through the further plurality of perforations, and when the further light source is not activated, the further light source is not visible to the naked eye through the further plurality of perforations; Equipped with the further light source is configured to illuminate to indicate whether the device is operating at a first temperature in a first mode or at a second temperature in a second mode, the second temperature being greater than the first temperature; The aerosol delivery device according to any one of claims 1 to 11.

13. An aerosol delivery device for use with an article containing an aerosol-generating material, the aerosol delivery device comprising a plurality of light sources arranged in a circular array.

14. The aerosol delivery device of claim 13 , wherein the plurality of light sources are evenly spaced circumferentially around the circle.

15. The aerosol delivery device of claim 13 or 14, wherein the plurality of light sources comprises four light sources.

16. The aerosol delivery device of any one of claims 13 to 15, wherein the multiple light sources are configured to illuminate sequentially to indicate progress through a start-up stage of a usage session.

17. The aerosol delivery device of any one of claims 13 to 16, wherein the multiple light sources are configured to sequentially dim to indicate time remaining in a usage session.

18. The aerosol delivery device of any one of claims 13 to 17, wherein a portion of the plurality of light sources are configured to illuminate to indicate a charging status of the aerosol delivery device.

19. a further light source disposed in the housing; the further light source is configured to illuminate to indicate whether the device is operating at a first temperature in a first mode or at a second temperature in a second mode, the second temperature being greater than the first temperature; The aerosol delivery device according to any one of claims 13 to 18.

20. A system comprising an article containing an aerosol-generating material and the aerosol delivery device of any one of claims 1 to 19.

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