Aerosol device and method for transferring consumables

Abstract

An apparatus for aerosolizing a consumable at high temperatures without burning the consumable, using a moving aerosol-generating substrate to gradually heat portions of the substrate, thereby releasing the consumable from different portions of the substrate. The aerosol-generating substrate is disposed within an aerosol generating device, in which a portion of the aerosol-generating substrate is surrounded by an induction heating element. The portion of the aerosol-generating substrate surrounded by the induction heating element is capable of releasing the consumable when the induction heating element is activated. A drive mechanism advances the aerosol-generating substrate through the induction heating element, causing another portion of the aerosol-generating substrate to enter the induction heating element, which heats and releases more of the consumable.

Description

[Technical Field]

[0001] The present invention relates to an apparatus for aerosolizing pharmaceuticals by high temperature non-combustion induction heating methods, and uses thereof. The present invention further relates to methods and apparatus for producing aerosols from tobacco and / or other non-pharmaceutical substances using similar methods and apparatus. [Background technology]

[0002] When faced with conditions that cause physical discomfort, such as disease states, disorders, illnesses, or general physical disorders, most people turn to medications, such as drugs, supplements, and herbs, to provide immediate relief from the symptoms resulting from the underlying condition. There are certain legal and widely available over-the-counter (OTC) medications and supplements that are effective when used for a variety of common conditions. There are also certain controlled narcotics and medicines that are prescribed by doctors for a variety of more serious conditions.

[0003] One of the most common routes of administration for these OTC and prescription drugs is oral administration. However, as with any oral delivery of a drug, the drug must pass through the digestive tract. Oral administration has several drawbacks. For example, because the drug must pass through the digestive system, the onset of drug activation is slow. In addition, the drug may be inactivated or destroyed in the digestive tract, thereby losing its effectiveness or efficacy. The drug itself may also cause digestive problems or side effects such as loss of appetite, diarrhea, and stomach acid. Furthermore, patients may be unwilling or unable to swallow oral medications in pill form.

[0004] Certain drugs are intended to affect the brain or its functions or activity, but given the accepted methods of ingestion, i.e., gastrointestinal, intravenous, or intramuscular, these drugs may also have a variety of unpleasant side effects due to the nature of the ingestion or injection, including, but not limited to, gastrointestinal complications, digestive disorders, high blood pressure, and / or headaches, as well as user reluctance to self-administer drugs by injection.

[0005] Other delivery routes exist, such as intradermal injection, patching, inhalation, etc. Each of these has its own advantages and disadvantages. Therefore, there is still room for improvement in the routes of drug administration.

[0006] For example, there are many drugs that are safer, more effective, and more efficient in terms of both safety and efficacy when taken via inhalation of aerosols, such as gases, vapors, mists, and other inhalants, containing the drug or its active ingredients, rather than by gastrointestinal, intravenous, or intramuscular delivery.

[0007] In addition, certain methods for aerosolizing and delivering these drugs also have drawbacks, particularly methods that aerosolize the drug itself, thereby altering the drug's molecular or chemical structure, or methods that aerosolize at elevated temperatures, which increases the duration of heating and can increase the risk of altering the active ingredient's molecular or chemical structure. Other drawbacks of current aerosolization techniques include the transportation, storage, and commercialization of some of these drugs in cartridges that are leaky and are often designed and constructed with environmentally unfriendly cartridge materials that contain non-biodegradable plastics and other materials.

[0008] To ensure intact delivery of the drug by high temperature, non-combustion induced methods, it is preferred that the method of aerosolization does not alter the chemical or fundamental molecular structure of the drug or other materials that comprise the drug, or if such alterations occur, do not interfere with and / or alter the efficacy of the drug.

[0009] Thus, there remains a need for improvements to the route of drug administration. In particular, there remains a need for improvements to methods of aerosolizing inhaled drugs that do not destroy the active ingredient as a result of energy deficiency or long heating times, nor add other chemicals to the aerosol, and that would also provide the added benefit of metering, monitoring, and measuring the exact dosage to the inhaler. There is also a need for consumable embodiments that are biodegradable and do not contain materials inconsistent with environmentally friendly processing.

[0010] In addition to drug delivery systems, heat-not-burn (HNB) devices are a type of device commonly used to heat tobacco below the temperature that causes combustion, thereby generating an aerosol containing nicotine and other tobacco components, which is then made available to the device user. In some embodiments, a heating element, or susceptor, is placed within a solid tobacco product with a coil wrapped around the tobacco product and susceptor, causing the susceptor to heat via an induction mechanism. Unlike traditional cigarettes, the goal is not to burn the tobacco, but rather to heat the tobacco sufficiently to release nicotine and other components via the generation of an aerosol. Igniting and burning a cigarette produces unwanted toxins, which can be avoided by using an HNB device. However, there is a delicate balance between providing enough heat to effectively release tobacco components in aerosol form while not burning or lighting the tobacco. Current HNB devices on the market do not find that balance, either heating the tobacco to temperatures that produce an inadequate amount of aerosol or overheating the tobacco, producing an unpleasant or "burnt" flavor profile. In addition, current methodologies leave the internal components of conventional HNB devices fouled with burnt tobacco by-products and accidental combustion by-products.

[0011] Furthermore, to ensure rapid, energy-efficient transformation from a solid or liquid state to an aerosol state via high-temperature, non-combustion induction heating, the formulation must be configured to eliminate airflow between the formulation and the susceptor of the induction system.

[0012] For the reasons stated above, there is a need for a device that affects the temperature to which tobacco is heated via an induction method to increase the efficiency and flavor profile of the aerosol produced while reducing the risk of combustion at temperatures that would normally be sufficient for ignition. There is also a need for a device that uses unique consumables that are inexpensive to manufacture and that, when used within an associated device, provides a satisfying user experience by moving the consumables past an induction coil for successive puffs. Summary of the Invention

[0013] The present invention relates to devices and methods for delivering consumables in an aerosolized state for inhalation administration and ingestion using a high temperature, non-combustion induced method of aerosolizing embodiments of formulation design and construction.

[0014] In particular, the present invention relates to further improvements in non-combustion heating devices, such as those described in U.S. Patent No. 10,750,787, PCT / US2019 / 012204, and PCT / US2020 / 040779. Generally, non-combustion heating devices convert a consumable into an aerosol containing some of its components, while limiting the by-products most commonly associated with combustion, such as smoke, ash, tar, and certain other potentially harmful chemicals. The devices do this by using high temperatures without burning the consumable by encasing the consumable within a housing containing an internal susceptor. The present invention may involve using an induction heating element wrapped around the consumable-containing package to heat the susceptor using a magnetic field generated by the induction heating element, thereby positioning and gradually advancing heat along the consumable tobacco part by moving either the heating element, the consumable, or both.

[0015] Another object of the present invention is a consumable tobacco part comprising at least one container containing a consumable tobacco formulation and an induction heating source. The container may be paper, fabric, plastic, woven fabric, or any other material sufficiently porous to transport the aerosol generated during heating of the consumable. The consumable may be assembled by sandwiching a susceptor within the consumable formulation between two top and bottom sheets of this material, which may then be folded together to enclose the consumable formulation. Several of these "packets" may be used in a single consumable, or only one packet may be used.

[0016] In an alternative embodiment, the container may be an aluminum shell with a pre-drilled opening. The container may be coated with a gel that seals the opening until an induction heating process melts the gel and opens the opening. In some embodiments, the gel may include a flavoring agent that can add or enhance flavor to the tobacco aerosol.

[0017] In some embodiments, multiple containers may be stacked within a cardboard tube with spaces between them, each container having an overwrap at the bottom end and channels on either side to allow the generated aerosol to pass through. Upon activation of the induction heating source, pre-installed openings are opened, allowing the flavor to combine with the aerosol and travel through the tube, making it available to the user of the device.

[0018] Using these methods and devices, the device requires less mass to heat, heats up quickly, cools down quickly, and conserves power, allowing for greater utilization between recharge sessions, in contrast to well-known current commercial non-combustion heating devices.

[0019] Another object of the present invention is to create a consumables storage package that is easy to replace and minimizes contamination of the inside of the case during use so that cleaning of the case is reduced.

[0020] Another object of the present invention is to move the susceptor or consumable relative to the heating element in order to heat sections of the consumable independently of other sections. "Section" in this context refers to either physically separated consumable material or adjacent consumable material that is heated sequentially as it moves through the induction coil or vice versa.

[0021] Another object of the present invention is to aerosolize a consumable that can be compressed around a susceptor to eliminate any airflow between the consumable and the susceptor. For example, the aerosol-generating substrate can include an inert, non-reactive compound that is mixed with a form of the consumable and then tightly compressed around the susceptor. The formulation can be aerosolized using a handheld, high-temperature induction heating device configured for consumable embodiments.

[0022] Thus, the devices, methods, and formulations of the present invention can be used to aerosolize a variety of consumable products, preferably medications, including, but not limited to, medications configured to increase bronchial efficiency, support tobacco and nicotine cessation, aid relaxation, reduce anxiety, block destructive thoughts, manage pain, improve concentration, aid restful sleep, aid sexual activity, increase energy and alertness, and counteract the adverse effects of overdosing on certain other medications. In addition, these consumable products may contain tobacco, cannabis, or other substances that can be ingested by consumers via inhalation. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a side view of the interior of an embodiment of the present invention assembled in an HNB device. [Figure 2A] FIG. 1 is a perspective view of an embodiment of the present invention assembled into a consumables containing package. [Figure 2B] 2B is a perspective view of the embodiment shown in FIG. 2A with portions of the consumable containment package cut away and / or removed to reveal the susceptor. [Figure 2C] 2C is a cross-sectional view of the embodiment shown in FIG. 2A taken along line 2C-2C. [Figure 2D] 2B is an exploded view of the consumables storage package shown in FIG. 2A. [Figure 2E] FIG. 10 is a perspective view of a consumable containment package having another embodiment of a susceptor with portions of the consumable containment package cut away and / or removed to reveal the susceptor. [Figure 3A] 1 is a perspective view of an embodiment of a consumables containing package. [Figure 3B] FIG. 3B is a perspective view of the embodiment shown in FIG. 3A with portions of the consumables containing package and consumables removed to show the internal configuration. [Figure 3C] FIG. 3B is an exploded view of the embodiment shown in FIG. 3A. [Figure 4A] FIG. 10 is a perspective view of another embodiment of the present invention. [Figure 4B] FIG. 4B illustrates the embodiment of FIG. 4A in an open configuration. [Figure 5A] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 5B] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 5C] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 5D] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 6A] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 6B] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 6C] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 7A] 10A-10C are a series of perspective views of another embodiment of the present invention in which a consumable is inserted into an HNB device and moves through a housing. [Figure 7B]10A-10C are a series of perspective views of another embodiment of the present invention in which a consumable is inserted into an HNB device and moves through a housing. [Figure 7C] 10A-10C are a series of perspective views of another embodiment of the present invention in which a consumable is inserted into an HNB device and moves through a housing. [Figure 7D] 10A-10C are a series of perspective views of another embodiment of the present invention in which a consumable is inserted into an HNB device and moves through a housing. [Figure 7E] 10A-10C are a series of perspective views of another embodiment of the present invention in which a consumable is inserted into an HNB device and moves through a housing. [Figure 8A] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. [Figure 8B] 10A-10C are a series of perspective views of another embodiment of the present invention in which consumables move through a housing. DETAILED DESCRIPTION OF THE INVENTION

[0024] The detailed description set forth below in connection with the accompanying drawings is intended as a description of the presently preferred embodiment of the invention and is not intended to represent the only form in which the invention may be constructed or utilized. The description sets forth the functions and sequence of steps for constructing and operating the invention in connection with the illustrated embodiment. However, it should be understood that the same or equivalent functions and sequences may be accomplished by various embodiments that are also intended to be encompassed within the spirit and scope of the invention.

[0025] Non-combustion heating device

[0026] The present invention is a device for generating an aerosol for inhalation from a consumable-containing product in a manner that minimizes combustion of the consumable-containing product and utilizes relatively high temperatures. For purposes of this application, the term "consumable" shall be interpreted broadly to encompass any type of medicine, drug, compound, active agent, ingredient, or other agent, whether the consumable is used to treat a condition or disease, for nutritional, supplemental, or recreational purposes. By way of example only, consumables may include, but are not limited to, pharmaceuticals, nutritional supplements, and over-the-counter drugs such as tobacco, cannabis, hemp, lavender, kava, coffee, caffeine, lobelia, hoodia, melatonin, epimedium, guarana, and ginseng.

[0027] 1-2E and described more fully in U.S. Pat. No. 10,750,787, PCT / US2019 / 012204, and PCT / US2020 / 040779, which are incorporated herein by reference in their entireties. The apparatus 100 includes a consumable-containing package 102 and an aerosol-generating device 200. The consumable-containing package 102 includes an aerosol-generating substrate 104 that releases an activator (the consumable) when heated, and a susceptor 106 embedded therein for heating the aerosol-generating substrate 104. The device 100 generates aerosol through a non-combustion, heat-based process in which the aerosol-generating substrate 104 is exposed to aerosol-heat conditions, such as high aerosolization temperatures and the absence of oxygen, that do not burn the aerosol-generating substrate 104 within the consumable-containing package 102 but instead release an active ingredient (the consumable) from the aerosol-generating substrate 104 in the form of an inhalable aerosol product. Thus, the aerosol-generating substrate 104 is any product containing an active ingredient that can be released into aerosol form when heated to the appropriate temperatures and conditions. Any description of the present invention with respect to specific applications, such as tobacco products, is provided by way of example only and is not intended to be limiting. As such, the present invention is not limited to use solely with tobacco products.

[0028] 1 , the aerosol generating device 200 includes a receptacle 151 for receiving the consumable containing package 102, an induction heating element 160 for heating the susceptor 106, a system controller 166 for controlling the induction heating element 160, and a power source 220 for powering the device 100. A user interface 230 operatively connected to the controller 166 can be provided to enhance ease of operation. A trigger 232 can be provided to start the device 100, or the device 100 can be activated via the user interface 230.

[0029] 2A-2E, the consumable-containing package 102 is a component that, when heated, releases a consumable (i.e., an active agent) in aerosol form. The consumable-containing package 102 includes an aerosol-generating substrate 104 and a susceptor 106 that is surrounded by the aerosol-generating substrate 104 and heats the aerosol-generating substrate 104 from the inside out via an induction heating system. In some embodiments, the consumable-containing package 102 may have a housing 108 that at least partially houses the aerosol-generating substrate 104 and the susceptor 106. For example, the aerosol-generating substrate 104 may be completely covered by the housing 108. In some embodiments, the aerosol-generating substrate 104 may be partially covered by the housing 108 so that a portion of the aerosol-generating substrate 104, such as all or part of the edge, top, bottom, or any other portion of the aerosol-generating substrate 104, is exposed. In some embodiments, the consumable containment package 102 may further comprise a housing 150 for holding one or more aerosol-generating substrates 104 with an embedded susceptor 106, with a housing 108, or without a housing 108.

[0030] Susceptor

[0031] The susceptor 106 is a component that is heated via induction and heats the aerosol-generating substrate 104 from the inside out. As such, the susceptor 106 is made of a metal that can be heated via induction, such as a ferrous metal. Other metals or materials capable of inductively heating the aerosol-generating substrate 104 may also be used. To maximize efficient heating of the aerosol-generating substrate 104, the susceptor 106 generally conforms to the shape of the largest cross-sectional area of the aerosol-generating substrate 104 so as to maximize the surface area of the aerosol-generating substrate 104 that contacts the susceptor 106, although other configurations may also be used.

[0032] The susceptor 106 may be mechanically extruded, fabricated from sintered or otherwise fused metal particles, metal wool, stamped, pressed, or any number of other methods capable of producing a satisfactory susceptor. Some of these methods are described in U.S. Pat. No. 10,750,787, PCT / US2019 / 012204, PCT / US2020 / 040779, and U.S. Application No. 17 / 687,470, all of which are incorporated herein by reference in their entireties. In some embodiments, the aerosol-generating substrate 104 may be combined with or incorporated into the susceptor 106 by co-extruding it with the susceptor 106 to create a layer of the aerosol-generating substrate 104 on top of or on the bottom of the susceptor 106 layer. In some embodiments, two layers of aerosol-generating substrates 104a, 104b can be co-extruded with a susceptor 106 therebetween to create a sandwich around the compressible susceptor 106 between the two layers of aerosol-generating substrates 104a, 104b. The co-extruded material can then be cut to size.

[0033] In some embodiments in which the susceptor 106 is steel wool or metal particles, the consumable may be incorporated directly into the susceptor 106, for example, in a fluid (e.g., liquid, semi-liquid, sticky, etc.) or loose solid (e.g., powder, grains, granules, etc.) form. In that case, the susceptor 106 has the dual function of a heating element and an aerosol-generating substrate 104. As such, the aerosol-generating substrate 104 may be a susceptor 106 combined with a consumable incorporated therein.

[0034] Aerosol-generating substrate

[0035] The aim of the aerosol-generating substrate 104 is to minimize the amount of air to which the aerosol-generating substrate 104 is exposed. This eliminates or mitigates the risk of oxidation or combustion during storage or the heating process. As a result, in certain settings, when used with prior art devices that allow for greater air exposure, the aerosol-generating substrate 104 can heat to temperatures that would otherwise cause combustion.

[0036] As such, in some embodiments, the aerosol-generating substrate 104 is fabricated from a consumable in powder form that is compressed into a rigid, compressed pellet, rod, or cuboid. Compression of the consumable reduces oxygen entrapment within the aerosol-generating substrate 104 and limits oxygen migration into the aerosol-generating substrate 104 during storage and heating.

[0037] In some embodiments, the aerosol-generating substrate 104 may be a single elongated section defining a major axis A in the form of a rod or bar, as shown in Figures 2A-2E. The aerosol-generating substrate 104 may also be an elongated cylinder or tube having a circular cross-section, an elliptical cross-section, a rectangular cross-section, a polygonal cross-section, etc. In some embodiments, the aerosol-generating substrate 104 may be a plurality of cylindrical tablets or pellets stacked on top of each other.

[0038] In a preferred embodiment, the aerosol-generating substrate 104 may be a slightly elongated rectangular prism in shape defining a major axis A, as shown in Figures 3A-3C and 4A-4B. Other rectangular prism shapes may also be used, as well as combinations of generally flat and / or rounded sides in a generally rectangular prism shape.

[0039] The susceptor 106 preferably extends along the longitudinal axis A and substantially the entire length L of the aerosol-generating substrate 104, and may similarly be elongated and embedded in the aerosol-generating substrate 104. The susceptor 106 may also extend substantially the width W of the aerosol-generating substrate 104. In other embodiments, the susceptor 106 may extend beyond the width (or diameter) and length of the aerosol-generating substrate 104, or may be substantially shorter than either dimension.

[0040] In some embodiments, the aerosol-generating substrate 104 may assume any other shape, including spherical, ovoid, elliptical, and even amorphous. Generally, the susceptor 106 may be shaped to match the shape of the aerosol-generating substrate 104 to maximize surface area contact between the susceptor 106 and the aerosol-generating substrate 104. However, the susceptor 106 may also have other shapes, including multiple susceptors 106 sparsely dispersed within the aerosol-generating substrate 104.

[0041] In yet another alternative embodiment, the aerosol-generating substrate 104 may be formed into tiny pellets, grains, powder, or other forms that can be encapsulated to further reduce the air available to the consumable.

[0042] In some embodiments, the aerosol-generating substrate 104 may comprise a ground consumable source that is fabricated in powder form and then combined with the susceptor 106 by compacting it snugly around the susceptor 106. By way of example only, the consumable source may be a plant, seed, flower, root, leaf, plant component, or any other source from which a consumable can be extracted. These components may be dried, ground, and mixed with other ingredients known for making pellets and tablets, and then compacted around the susceptor 106 to form pellets, tablets, or rods around the susceptor 106. The compressed pellets, tablets, or rods may be contained within a container 108 to form the consumable-containing package 102.

[0043] Storage body

[0044] The present invention relates to the configuration of the consumable package 102 and the structure for moving the consumable package 102 past the induction coil 160 to sequentially heat sections of the consumable package 102 .

[0045] In some embodiments, best seen in FIGS. 2A-2E , the housing 108 includes an aerosol-generating substrate 104 with a susceptor 106 embedded therein. In some embodiments, the housing 108 may be configured with holes 120 that allow the aerosol to escape from the housing 108, or the housing 108 may be a permeable membrane, paper, fabric, or other material that allows the aerosol to escape. The aerosol-generating substrate 104 may be disposed within a housing 150 that may mimic a cigarette. In some embodiments, a filter 140 may surround the housing 108. The housing 150 may have an end cap 154 at one end 152 and a mouthpiece 158 at the opposite end 156. The end cap 154 may be made of some type of filter material. The mouthpiece 158 allows a user to draw heated consumable aerosol from the aerosol-generating substrate 104 along the housing 150, toward the mouthpiece 158, and into the user's mouth. As such, the mouthpiece 158 may also include a filter of some kind, similar to that of the end cap 154. Adjacent to the mouthpiece 158 may be a number of holes 446 through which air may be drawn when the user draws a puff on the housing 150 by sucking on the mouthpiece 158.

[0046] In a preferred embodiment, the container 108 comprises a top sheet 108a and a bottom sheet 108b, which may be two separate sheets or one continuous sheet. The sheets 108a, 108b may comprise a permeable material to allow the escape of the aerosol, which may be filter paper, porous paper, fabric, plastic, membrane, perforated metal, tea bag material, or cigarette filter media (cellulose), or any other suitable material.

[0047] The permeable nature of the housing 108 exposes the aerosol-generating substrate 104 to air, potentially subjecting it to oxidation / deterioration. To prevent this, holes or openings in the housing 108 may be temporarily sealed with a coating. The coating is preferably fabricated from a composition that melts and / or becomes permeable at the temperature at which the consumable aerosol is generated. Thus, as the susceptor 106 heats, the aerosol-generating substrate 104 can become very hot without burning due to the lack of air inside the housing 108. At the point when the susceptor 106 reaches a high temperature, the consumable aerosol that begins to form cannot escape. Once the coating melts or becomes permeable, the consumable aerosol can escape from the housing 108 for inhalation. In a preferred embodiment, the coating may be propylene glycol alginate (“PGA”) gel or food-grade starch. The coating may also include flavoring. Thus, as the coating dissolves away and the consumable aerosol is released, the flavoring is also released with the consumable aerosol. In some embodiments, the flavoring can be mixed with the additive.

[0048] In a preferred embodiment, the housing 108 comprises a top portion 108a and a bottom portion 108b, which may be separate pieces or one continuous piece. Preferably, the housing top portion 108a and the bottom portion 108b have a pre-formed cup-shaped recess or cavity 109 for surrounding the aerosol-generating substrate 104, as shown in Figure 3C. Alternatively, one or both of the housing top portion 108a and the bottom portion 108b may be flat and then pressed or stretched around the aerosol-generating substrate 104 during production.

[0049] In a preferred embodiment, to securely close the housing 108 around the aerosol-generating substrate 104, the ends 124, 126 of the housing 108 may have folds 130, 132, as shown in FIGS. 4A and 4B . Prior to folding, the two portions 108a, 108b of the housing may be joined or sealed by conventional methods, such as adhesives, mechanical fasteners, crimping, RF welding, or any suitable method, to seal the housing 108. Similarly, after folding, the sealed / joined ends 124, 126 may be adhered to the outer surface of the housing 108, as shown in FIG. 4A . Alternatively, the ends 124, 126 of the housing 108 need not be sealed before folding, but instead must be held in the folded pattern by adhesives, mechanical fasteners, crimping, RF welding, or any suitable method. In yet another alternative, the housing 108 may be held in place simply by the fold itself, without any sealing or joining.

[0050] Thus, a method of manufacturing a consumable-containing package 102 for use in an aerosol generating device 200 includes combining an aerosol-generating substrate 104 containing a consumable with a susceptor 106, covering the aerosol-generating substrate 104 with a housing 108, folding the ends 124, 126 of the housing 108 to enclose the aerosol-generating substrate 104, and placing the assembly within a housing 150.

[0051] In some embodiments, the housing 108 may be eliminated altogether, and the aerosol-generating substrate 104 simply enclosed by the housing 150. In such embodiments, the aerosol is emitted directly from the aerosol-generating substrate 104 into the flow path between the aerosol-generating substrate 104 and the housing 150. As with the housing embodiment, the exterior of the aerosol-generating substrate 104 does not reach combustion temperatures due to rapid inside-out induction heating.

[0052] In embodiments where the housing 108 is porous or absent, the freshness of the consumables may be maintained through the use of airtight packaging, which may be filled with nitrogen or other inert gas to prevent oxidation. Such packaging may be used for large packages of consumable-containing packages 102, for example, with tobacco products, where multiple consumable-containing packages 102 may be used per day. Alternatively, individual packaging may be used for pharmaceutical-containing consumable-containing packages 102, where the consumables are only used periodically.

[0053] chassis

[0054] In a preferred embodiment, the housing 108 is configured to be permeable to aerosol so that aerosol can escape from the housing 108. The aerosol-generating substrate 104 can be placed inside the housing 150, with or without the housing 108, as described above. The housing 150 is preferably less permeable to aerosol or impermeable. The housing 150 can mimic a cigarette. As such, the housing 150 can be an elongated structure having a first end 152 and a second end 156 opposite the first end 152. The housing 150 is inserted into the device 200 such that the induction heating element 160 surrounds the housing 150. Electrical current passing through the induction heating element 160 can then heat the susceptor 104 embedded in the aerosol-generating substrate 104, resulting in heating of the aerosol-generating substrate from the inside out. When the aerosol-generating substrate 104 is heated by the susceptor 106, an aerosol containing the consumable product is generated. When a user draws on the housing 150, for example by sucking on the second end 156, the aerosol escapes from the container 108 but not from the housing 150. Due to the negative pressure created by sucking on the second end 156, the aerosol is drawn through any space between the aerosol-generating substrate 104 and the housing 150 toward the second end 156. Openings at or around the first end 152 may be used to facilitate airflow around the exterior of the aerosol-generating substrate 104 and toward the second end 156. Such openings may include one-way or controlled-flow valves.

[0055] Various strategies can be employed to accommodate multiple dosing regimens using a single consumable-containing package 102. For example, the induction heating element 160 can be wrapped around a portion of the consumable-containing package 102. Only the portion of the consumable-containing package 102 surrounded by the heating element 160 is heated, releasing the consumable. The position of the induction heating element 160 relative to the consumable-containing package 102 can then be modified so that the induction heating element 160 surrounds a new portion of the consumable-containing package 102 that has not yet been heated sufficiently to release the consumable. To achieve this new position, either the induction heating element 160 is movable and the aerosol-generating substrate 104 remains stationary, the aerosol-generating substrate 104 is movable and the induction heating element 160 remains stationary, or both the induction heating element 160 and the aerosol-generating substrate 104 are movable. In some embodiments, neither the induction heating element 160 nor the aerosol-generating substrate 104 moves. Rather, the induction heating element 160 can be wrapped around the entire length of the aerosol-generating substrate 104, with particular sections of the induction heating element 160 being operable to heat only particular portions 104c, 104d, 104e of the aerosol-generating substrate 104 at a given time.

[0056] 5A-5D, 6A-6C, 7A-7E, and 8A-8B, in a preferred embodiment, the aerosol-generating substrate 104 is moved along the length of the housing 150 while the induction heating element 160 remains stationary. By way of example only, the aerosol-generating device 200 may include a drive mechanism 448 that may be operatively connected to or otherwise engaged with the aerosol-generating substrate 104 when the aerosol-generating substrate 104 is inserted into the aerosol-generating device 200. The drive mechanism 448 may be configured to advance the aerosol-generating substrate 104 through the housing 150. Advancement of the aerosol-generating substrate 104 through the housing 150 may cause various portions 104c, 104d, 104e of the aerosol-generating substrate to be surrounded by the induction heating element 160. Thus, in use, the aerosol-generating substrate 104 can be inserted into the housing 150 in such a manner that the aerosol-generating substrate 104 can move through the housing 150 from the end cap 154 to the mouthpiece 158 so that portions 104, 104d, and 104e of the aerosol-generating substrate 104 pass progressively through the induction heating element 160 in sequence.

[0057] In a preferred embodiment, the drive mechanism 448 includes a rod 550 and a rotatable collar 552 operably connected to or otherwise engaged with the rod 550 for advancing the rod 550. The collar 552 may be operated by a miniature motor operably connected to the controller 166. The rod 550 is insertable through the end cap 154 into the housing 150 until the rod 550 contacts the first end 105 of the aerosol-generating substrate 104. In this position, the second end 107 of the aerosol-generating substrate 104c may be surrounded by an induction heating element 160 (see, e.g., Figures 5A, 5B, 6A, and 7B). When the induction heating element 160 is activated, the aerosol-generating substrate 104 is heated only in the portion surrounded by the induction heating element 160. Upon actuation of the drive mechanism 448, the collar 552 advances the rod 550 toward the second end 156 of the housing 150. This movement causes a new portion 104d of the aerosol-generating substrate (closer to the first end 105 of the aerosol-generating substrate 104) to be surrounded by the induction heating element 160 (see, for example, Figures 5C, 6B, and 7D). Activation of the induction heating element 160 can now heat the new portion 104d of the aerosol-generating substrate 104 that was not previously heated, thereby releasing another dose of the consumable product as an inhalable aerosol. The collar 552 can again advance the aerosol-generating substrate through the housing 150, thereby placing yet another unheated portion 104e of the aerosol-generating substrate 104 (closer to the first end 105, if not already there) within the heating range of the induction heating element 160 (see, for example, Figures 5D, 6C, and 7E). This process can continue until the entire aerosol-generating substrate 104 is heated and the consumable aerosol is released.

[0058] In a preferred embodiment, the rod 550 may be a jackscrew having threads 554 on a first end 556, as shown in FIGS. 7A-7E. The threads 554 on the first end 556 of the rod 550 may mate with a rotatable collar 552. Actuation of the drive mechanism 448 rotates the collar 552, which in turn advances the rod 550. Alternatively, the collar 552 may be fixed, and the rod 550 may engage a rotating mechanism such that, upon rotation, the rod 550 advances. Other forms of drive mechanism 448 for incrementally advancing the aerosol-generating substrate 104 along a linear path may be used, such as a drive mechanism 448 having a telescoping action, a sliding action, a rolling action, or the like, or any combination thereof. Additionally, advancement of the aerosol-generating substrate may be by a smooth, gradual motion or a more abrupt, stepped motion. In an alternative embodiment, the aerosol-generating substrate 104 or some structure attached thereto is threaded and engageable with the threads on the housing 150, so that rotating the housing 150 or the aerosol-generating substrate 104 will advance the aerosol-generating substrate 104.

[0059] In some embodiments, to prevent movement of the aerosol-generating substrate 104 when not in use and prior to connection with the rod 550, the aerosol-generating substrate 104 can be bonded to the inside of the housing 150, with the first end 105 of the aerosol-generating substrate 104 adjacent to the rod 550. The bond between the aerosol-generating substrates 104 can be strong enough that general movement and shaking of the housing 150 will not cause the aerosol-generating substrate 104 to move within the housing 150. Thus, movement associated with transportation and shipping of the housing will not be sufficient to cause the aerosol-generating substrate 104 to release from the bonding agent. Additionally, the bond between the aerosol-generating substrate 104 and the housing 150 can be strong enough that the rod 550 can be operatively connected to the aerosol-generating substrate 104. However, advancement of the rod 550 is sufficient to break the bond between the aerosol-generating substrate 104 and the housing 150, allowing the aerosol-generating substrate 104 to advance through the housing 150. The new connection between the rod 550 and the aerosol-generating substrate 104 is strong enough to prevent the aerosol-generating substrate 104 from moving around within the housing 150 during movement after the bond between the aerosol-generating substrate 104 and the housing 150 is broken. Alternatively, if the bond is a temperature-sensitive material, the bond may be broken or weakened when the aerosol-generating substrate 104 is heated for the first time, before the rod 550 is advanced.

[0060] However, to prevent unwanted movement of the aerosol-generating substrate 104 after initial use, such as when the device is tossed into a handbag or tossed on a counter, the aerosol-generating substrate 104 may have a friction fit within the housing 150 that prevents movement other than that caused by the rod 550, or the aerosol-generating substrate 104 may be affixed to or otherwise engaged with the rod 550 to prevent movement independent of the rod 550. Alternatively, the aerosol-generating substrate 104 may be engaged with a housing or other structure that has threads or other structure that prevents unwanted movement of the aerosol-generating substrate 104.

[0061] In some embodiments, advancement of rod 550 may only advance aerosol-generating substrate 104 through housing 150. In some embodiments, as shown in FIGS. 8A-8B , end cap 154 may also advance through housing 150. As such, aerosol-generating substrate 104 may be connected to end cap 154, and rod 500 may be connected to or otherwise engaged with end cap 154. Thus, advancement of rod 500 advances end cap 154 through housing 150, which in turn advances aerosol-generating substrate 104 through housing 150.

[0062] Having established the general principles of the consumable-containing package 102, variations that achieve the same objective are also contemplated. For example, in some embodiments, the aerosol-generating substrate 104 may comprise two elongated sections 104a, 104b. The two elongated sections 104a, 104b of the aerosol-generating substrate 104 may be defined by a plane parallel to and cutting through the longitudinal axis A. The two elongated sections 104a, 104b may therefore be rectangular or semi-cylindrical sections that, when interlocked, form a larger rectangular or fully cylindrical aerosol-generating substrate 104.

[0063] In some embodiments, the housing 108 may be made of a porous material. For example, the housing 108 may be porous paper wrap or other similar material. As such, the holes would function as openings 120 by allowing aerosol from the aerosol-generating substrate 104 to escape upon heating. Furthermore, the aerosol-generating substrate 104 may be compressed to exclude oxygen, so that combustion is still unlikely at operating temperatures and during the short periods that the aerosol-generating substrate 104 is exposed to high temperatures. Even if the exterior of the housing 108 is exposed to oxygen along the flow path between the housing 108 and the housing 150, the exterior of the housing 108 never reaches combustion temperatures because induction heating rapidly heats the consumable from the inside out.

[0064] In embodiments in which the housing 108 is a porous material, the housing 108 allows the aerosol to pass through the pores of the housing 108 and exit laterally or radially outward from the housing 108. This allows the aerosol to enter the flow path created between the housing 150 and the housing 108.

[0065] In a preferred embodiment, the aerosol-generating substrate 104 is rectangular and the housing 150 is cylindrical, thereby creating four flow paths between the aerosol-generating substrate 104 and the housing 108, and between the generally planar surface of the rectangular and cylindrical walls (i.e., above, below, and along the sides of the aerosol-generating substrate 104, to the left and right). A rectangular shape is the preferred shape for the aerosol-generating substrate 104, and a cylindrical shape is the preferred shape for the housing 108, although any shape may be used for either.

[0066] In some embodiments, the housing 108 may be thicker and sufficiently porous to allow aerosol to pass through the pores longitudinally along axis A through the length of the housing 108. In such embodiments, a designated flow path between the housing 150 and the housing 108 may not be necessary, since the aerosol can pass through the housing 108. Such porous materials may include cigarette paper, cellulose or other filter media, or any suitable material for the purpose.

[0067] The container 108 containing the aerosol-generating substrate 104 may then be inserted into the housing 150 to form the consumable-containing package 102. When the susceptor 106 is heated, the consumable is aerosolized and escapes into the porous container 108. When a user utilizes the mouthpiece 158, the negative pressure created within the housing 150 induces airflow toward the mouthpiece 158, causing the aerosolized consumable to pass through the holes in the container 108 toward the mouthpiece 158, where it may be inhaled by the user.

[0068] The foregoing description of the preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims and the equivalents of the appended claims.

Claims

1. 1. A device for generating an aerosol, comprising: (a) an aerosol-generating substrate; (b) a susceptor embedded within the aerosol-generating substrate; (c) a housing containing the aerosol-generating substrate; and (d) an aerosol generating device for receiving the housing, (i) a drive mechanism operatively connected to the aerosol-generating substrate to drive the aerosol-generating substrate through the housing; and (ii) an induction heating element surrounding at least a portion of the housing, the drive mechanism being configured to advance the aerosol-generating substrate through the housing such that portions of the aerosol-generating substrate pass sequentially through the induction heating element; an aerosol generating device comprising: An apparatus comprising:

2. 2. The device of claim 1, wherein the housing further comprises an end cap and a mouthpiece opposite the end cap, and the drive mechanism comprises a rod operably connected to the aerosol-generating substrate through the end cap.

3. 3. The device of claim 2, wherein the rod is threaded at a first end to incrementally advance the aerosol-generating substrate.

4. The device of claim 2 , wherein the drive mechanism advances the end cap.

5. 3. The apparatus of claim 2, wherein the drive mechanism advances the aerosol-generating substrate while the end cap remains stationary.

6. 6. The device of claim 5, wherein the aerosol-generating substrate is rectangular in shape.

7. 7. The device of claim 6, wherein the aerosol-forming substrate is at least partially present within a housing.

8. 1. A method for aerosolizing a consumable product contained throughout an aerosol-generating substrate with an aerosol generating device, comprising: (a) surrounding a first portion of the aerosol-generating substrate with an induction heating element, wherein a susceptor is embedded within the aerosol-generating substrate; (b) heating the susceptor by activating the induction heating element, thereby aerosolizing the consumable located on the first portion of the aerosol-generating substrate; (c) advancing the aerosol-generating substrate so that a second portion of the aerosol-generating substrate is surrounded by the induction heating element; and (d) activating the induction heating element, thereby aerosolizing the consumable located in the second portion of the aerosol-generating substrate. A method comprising:

9. 9. The method of claim 8, wherein the aerosol-forming substrate is present within an enclosure and the induction heating element surrounds the enclosure.

10. The method of claim 9 , wherein advancing the aerosol-generating substrate comprises a drive mechanism operatively engaging the aerosol-generating substrate.

11. 11. The method of claim 10, wherein the housing comprises an end cap at a first end and a mouthpiece at a second end opposite the first end, and the drive mechanism comprises a rod operably connected to the aerosol generation device via the end cap.

12. The method of claim 11 , wherein the drive mechanism advances the end cap.

13. The method of claim 11 , wherein the drive mechanism advances the aerosol-generating substrate without advancing the end cap.

14. The method of claim 11 , wherein the aerosol-generating substrate is rectangular in shape.

15. 1. A method for manufacturing a device for generating an aerosol, comprising: (a) providing an aerosol-generating substrate containing a consumable; (b) embedding a susceptor within the aerosol-generating substrate; (c) placing the aerosol-generating substrate within an enclosure; (d) providing an aerosol generating device, the aerosol generating device comprising: (i) an induction heating element configured to surround at least a portion of the housing; and (ii) a drive mechanism operatively connected to the consumable-generating substrate to advance the aerosol-generating substrate through the induction heating element; To provide, to set up A method comprising:

16. 16. The method of claim 15, further comprising providing an end cap positioned at a first end of the housing and a mouthpiece at a second end of the housing.

17. 17. The method of claim 16, further comprising engaging a rod from the drive mechanism with the aerosol-generating substrate through the end cap.

18. 18. The method of claim 17, further comprising advancing the end cap to advance the aerosol-generating substrate through the induction heating element.

19. 18. The method of claim 17, further comprising advancing the aerosol-generating substrate without advancing the end cap.

20. 18. The method of claim 17, wherein the aerosol-generating substrate is rectangular in shape.

Images