Aerosol Delivery Device

Abstract

The present invention provides an aerosol delivery device configured to receive at least a portion of an article (130) containing an aerosol-generating material, the aerosol delivery device comprising: a first heating unit (110) arranged to heat the aerosol-generating material to form an aerosol during use; a second heating unit (120) arranged to heat the aerosol-generating material to form an aerosol during use; and a controller configured to control the first and second heating units according to a heating mode during an aerosol generation session, wherein during the heating mode, the controller is configured to control the first heating unit to begin heating to a first target operating temperature T1 (308) at the beginning of the session and to control the second heating unit to begin heating to a second target operating temperature T2 (404) at a time t1 (402) after the start of the aerosol-generation session, where t1 > 85 seconds.

Description

[Technical Field]

[0001] The present invention relates to aerosol delivery devices, aerosol delivery systems, and articles. [Background technology]

[0002] (background) Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts to provide alternatives to these tobacco-burning articles have been made 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 can be, for example, tobacco or other non-tobacco products that may or may not contain nicotine. Summary of the Invention

[0003] (overview) According to some embodiments described herein, there is provided an aerosol delivery device configured to receive at least a portion of an article including an aerosol-generating material, the aerosol delivery device comprising: a first heating unit configured to heat the aerosol-generating material to form an aerosol during use; a second heating unit configured to heat the aerosol-generating material to form an aerosol during use; and a controller configured to control the first and second heating units according to a heating mode during an aerosol generation session, wherein during the heating mode, the controller is configured to control the first heating unit to begin heating to a first target operating temperature T1 at the beginning of the session and to control the second heating unit to begin heating to a second target operating temperature T2 at a time t1 after the start of the aerosol-generation session, where t1 is greater than 85 seconds.

[0004] T2 may be less than 160° C. T2 may be substantially 150° C.

[0005] During the heating mode, the controller can be configured to control the second heating unit to heat to a third target operating temperature T4 at a time t3 after the start of the aerosol generation session, where t3>t1 and T4>T2.

[0006] During the heating mode, the controller can be configured to control the second heating unit to reduce the temperature of the second heating unit to a second heating unit step-down temperature T3 at a time t2 after the start of the aerosol generation session.

[0007] t2 may be less than t1.

[0008] T3 may be greater than T2.

[0009] T3 may be less than 220°C. T3 may be less than 210°C. T3 may be substantially 200°C.

[0010] During the heating mode, the controller can be configured to control the second heating unit to reduce the temperature of the second heating unit to a second heating unit step-down temperature T3 more than 30 seconds before the end of the aerosol generation session.

[0011] During the heating mode, the controller can be configured to control the second heating unit to reduce the temperature of the second heating unit to a second heating unit step-down temperature T3 substantially 35 seconds before the end of the aerosol generation session.

[0012] During the heating mode, the controller is configured to control the first heating unit to reduce the temperature of the first heating unit to a first heating unit step-down temperature T5 at time t4 after the start of the aerosol generation session, where T5 is less than T1.

[0013] T3 may be less than or equal to T5. T3 may be equal to T5.

[0014] t4 may be greater than t2. t4 may be less than t3.

[0015] During the heating mode, the controller is configured to control the first heating unit to heat to a first unit maximum operating temperature during the aerosol generation session and to control the second heating unit to heat to a second unit maximum operating temperature during the aerosol generation session, the first unit maximum operating temperature being higher than the second unit maximum operating temperature.

[0016] T1 may be the first unit maximum operating temperature. T1 and / or the first unit maximum operating temperature may be less than 260°C. T1 and / or the first unit maximum operating temperature may be less than 250°C. T1 and / or the first unit maximum operating temperature may be substantially 240°C.

[0017] T4 may be the second unit maximum operating temperature. T4 and / or the second unit maximum operating temperature may be less than 240°C. T4 and / or the second unit maximum operating temperature may be less than 230°C. T4 and / or the second unit maximum operating temperature may be substantially 220°C.

[0018] The first heating unit and the second heating unit can be configured to heat different portions of the aerosol-forming material.

[0019] The first heating unit and the second heating unit may be spatially separated.

[0020] The aerosol delivery device can have a mouth end and the first heating unit can be positioned closer to the mouth end than the second heating unit.

[0021] The first heating unit may include a first induction heating unit, and the second heating unit may include a second induction heating unit.

[0022] During the heating mode, the controller can be configured to control the second heating unit to not heat until time t1.

[0023] The heating mode may be a base heating mode, and the controller is further configured to heat according to a boost heating mode, in which the device is configured to generate aerosol at a higher rate for a shorter duration than in the base heating mode.

[0024] t1 may be greater than 90 seconds. t1 may be greater than 95 seconds. t1 may be substantially 100 seconds.

[0025] The aerosol-forming material may be a non-liquid aerosol-forming material. The aerosol-forming material may include tobacco. The aerosol-generating device may be a tobacco heating product.

[0026] According to some embodiments described herein, an aerosol delivery system is provided that includes the aerosol delivery device described above and an article.

[0027] According to some embodiments described herein, there is provided a method for controlling an aerosol delivery device according to a heating mode. The aerosol delivery device is configured to receive at least a portion of an article including an aerosol-generating material. The method includes controlling a first heating unit of the aerosol delivery device to initiate heating to a first target operating temperature T1 at the beginning of an aerosol generation session, and controlling a second heating unit of the aerosol delivery device to initiate heating to a second target operating temperature T2 at a time t1 after the start of the aerosol generation session, where t1 is greater than 85 seconds.

[0028] The aerosol delivery system may include any of the features of the aerosol delivery device described above. The method may include any of the functional steps described with respect to the aerosol delivery device.

[0029] Embodiments will now be described, by way of example only, and with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0030] [Figure 1A] FIG. 1 is a schematic diagram of a heating assembly of an aerosol generating device. [Figure 1B] FIG. 1 is a cross-sectional view of a heating assembly having an aerosol generating product disposed therein. [Figure 2A] 1 is a schematic cross-sectional view of an aerosol generator. [Figure 2B] FIG. 1 is a perspective view of an aerosol product. [Figure 3] 10 is a graph showing a temperature profile in a first heating mode. [Figure 4] 10 is a graph showing a temperature profile in a second heating mode. DETAILED DESCRIPTION OF THE INVENTION

[0031] (Detailed explanation) As used herein, "the" may be used to mean "the" or "the or each" as appropriate. Features described in particular with respect to "at least one heating unit" may be applicable to the first, second, or additional heating units, if present. Furthermore, features described with respect to "first" or "second" integers may be equally applicable integers. For example, features described with respect to a "first" or "second" heating unit may be equally applicable to other heating units in different embodiments. Similarly, features described with respect to a "first" or "second" operating mode may be equally applicable to other configured operating modes.

[0032] Generally, references to a "first" heating unit in a heating assembly do not indicate that the heating assembly includes multiple heating units unless otherwise specified; rather, a heating assembly that includes a "first" heating unit must simply include at least one heating unit. Thus, a heating assembly that includes only one heating unit clearly falls within the definition of a heating assembly that includes a "first" heating unit.

[0033] Similarly, references to a "first" and a "second" heating unit in a heating assembly do not necessarily indicate that the heating assembly includes only two heating units; more heating units may be present. Rather, in this example, the heating assembly must simply include at least a first and a second heating unit.

[0034] When an event is referenced, such as reaching a maximum operating temperature, occurring "within" a particular time period, the event can occur any time between the beginning and the end of the time period.

[0035] As used herein, the term "aerosol-forming material" includes materials that, upon heating, provide volatile components, typically in the form of an aerosol. Aerosol-forming materials include any tobacco-containing material, such as one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials may also include other non-tobacco products, some of which may or may not contain nicotine. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, or the like. Aerosol-forming materials may also be, for example, a combination or blend of materials. Aerosol-forming materials are sometimes known as "smoking materials." In preferred embodiments, the aerosol-forming material is a non-liquid aerosol-forming material. In particularly preferred embodiments, the non-liquid aerosol-forming material includes tobacco.

[0036] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or energized by any other means. The aerosol-generating material can be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active substance and / or a flavoring. In some embodiments, the aerosol-generating material can include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid can be a dried gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material can include, for example, about 50%, 60%, or 70% by weight of an amorphous solid to about 90%, 95%, or 100% by weight of an amorphous solid.

[0037] The aerosol-forming materials may include one or more active agents and / or flavorings, one or more aerosol precursor materials, and optionally one or more other functional materials.

[0038] Devices are known that heat an aerosol-forming material without burning or combusting the aerosol-forming material to volatilize at least one component of the aerosol-forming material, typically to form an inhalable aerosol. Such devices are sometimes described as "aerosol-generating devices," "aerosol delivery devices," "non-combustion heating devices," "tobacco heating products," "tobacco heating product devices," "tobacco heating devices," and the like. In a preferred embodiment of the present invention, the aerosol-generating device of the present invention is a tobacco heating product. The non-liquid aerosol-forming material for use in tobacco heating products comprises tobacco.

[0039] Similarly, there are so-called e-cigarette devices, which are typically aerosol-generating devices that vaporize a liquid form of aerosol-generating material, which may or may not contain nicotine. The aerosol-generating material may be in the form of, or provided as part of, a rod, cartridge, cassette, or the like that can be inserted into the device. A heater for heating and vaporizing the aerosol-generating material may be provided as a "permanent" part of the device.

[0040] An aerosol-generating device can accept an article, also called a "smoking article," that includes an aerosol-generating material for heating. An "article," "aerosol-generating article," or "smoking article" in this context is a component that, during use, includes or contains the aerosol-generating material (which is heated to volatilize the aerosol-generating material), and optionally other components in use. A user can insert the article into the aerosol-generating device before it is heated to generate an aerosol. The user then inhales the aerosol. The article can be, for example, of a predetermined or specific size configured to be placed within a heating chamber of a device sized to accept the article.

[0041] An aerosol generating device according to a preferred embodiment of the present invention comprises a plurality of heating units, each arranged to heat rather than combust aerosol-forming material during use.

[0042] A heating unit typically refers to a component configured to receive electrical energy from an electrical energy source and provide thermal energy to an aerosol-forming material. A heating unit includes a heating element. A heating element is typically a material configured to provide heat to an aerosol-forming material during use. A heating unit that includes a heating element may include any other necessary components, such as components for converting the electrical energy received by the heating unit. In other examples, the heating element itself may be configured to convert electrical energy into thermal energy.

[0043] The heating unit may include a coil. In some examples, the coil is configured to heat at least one electrically conductive heating element during use, such that thermal energy is conducted from the at least one electrically conductive heating element to the aerosol-forming material, thereby heating the aerosol-forming material.

[0044] In some examples, the coil is configured to, during use, generate a varying magnetic field that penetrates the at least one heating element, thereby causing inductive heating and / or magnetic hysteresis heating of the at least one heating element. In such an arrangement, each heating element may be referred to as a "susceptor." A coil configured, during use, to generate a varying magnetic field that penetrates the at least one conductive heating element, thereby causing inductive heating of the at least one conductive heating element, may be referred to as an "induction coil" or "inductor coil."

[0045] The device may include heating element(s), e.g., conductive heating element(s), which may be suitably positioned or positionable relative to the coil to enable heating of such heating element(s). The heating element(s) may be in a fixed position relative to the coil. Alternatively, at least one heating element, e.g., at least one conductive heating element, may be included in an article for insertion into the heating zone of the device, which article also includes the aerosol-generating material and is removable from the heating zone after use. Alternatively, both the device and such article may include at least one respective heating element, e.g., at least one conductive heating element, and the coil may cause heating of the heating element(s) of each of the device and article when the article is in the heating zone.

[0046] In some examples, the coil is helical. In some examples, the coil surrounds at least a portion of a heating zone of a device configured to receive an aerosol-forming material. In some examples, the coil is a helical coil surrounding at least a portion of the heating zone.

[0047] In some examples, the device includes a conductive heating element at least partially surrounding the heating zone, and the coil is a helical coil surrounding at least a portion of the conductive heating element. In some examples, the conductive heating element is tubular. In some examples, the coil is an inductor coil.

[0048] In some examples, the heating unit is an induction heating unit. In preferred embodiments, the device is configured such that the first (induction) heating unit reaches its maximum operating temperature at a rate of at least 100°C per second. In particularly preferred embodiments, the device is configured such that the first (induction) heating unit reaches its maximum operating temperature at a rate of at least 150°C per second.

[0049] Induction heating systems can also be advantageous because the magnitude of the varying magnetic field can be easily controlled by controlling the power supplied to the heating unit. Furthermore, induction heating does not require a physical connection between the source of the varying magnetic field and the heat source, which can result in greater freedom and control in designing the heating profile and lower costs.

[0050] In other examples, the first and / or second heating units may include resistive heating units. The resistive heating units may be comprised of resistive heating elements, i.e., the resistive heating elements themselves convert electrical energy into thermal energy, so that the resistive heating units may not need to include separate components to convert the electrical energy received by the heating units.

[0051] The use of electrical resistance heating can be advantageous because it is easier to control the heat release rate and generate lower amounts of heat than using combustion to generate heat, and therefore allows for greater control over the generation of aerosol from tobacco compositions.

[0052] References are made throughout this specification to the temperature of a heating element. The temperature of a heating element may also conveniently be referred to as the temperature of a heating unit that includes the heating element. This does not necessarily mean that the entire heating unit is at a given temperature. For example, when referring to the temperature of an induction heating unit, it does not necessarily mean that both the induction element and the susceptor have such a temperature. Rather, in this example, the temperature of the induction heating unit corresponds to the temperature of a heating element configured within the induction heating unit. For the avoidance of doubt, the temperature of a heating element and the temperature of a heating unit may be used interchangeably.

[0053] As used herein, a "temperature profile" refers to the temperature change of a material over time. For example, the fluctuating temperature of a heating element or heating unit measured at the heating element or heating unit during a smoking session may be referred to as the temperature profile of the heating element or heating unit. During use, the heating element or heating unit provides heat to the aerosol-generating material to generate an aerosol. Thus, the temperature profile of the heating element or heating unit induces a temperature profile of the aerosol-generating material disposed near the heating element or heating unit.

[0054] As used herein, a "puff" refers to a single inhalation by a user of the aerosol generated by the aerosol generating device.

[0055] During use, the device preferably heats the aerosol-generating material to provide an inhalable aerosol. The device may be referred to as "ready for use" when at least a portion of the aerosol-generating material reaches a minimum operating temperature and the user can inhale a puff containing a sufficient amount of aerosol. In some embodiments, the device may be ready for use within approximately 20 seconds, 15 seconds, or 10 seconds after powering the first heating unit. Preferably, the device is ready for use within approximately 20 seconds, 15 seconds, or 10 seconds after the device is activated. The device may begin powering a heating unit, such as the first heating unit, when the device is activated, or may begin powering the heating unit after the device is activated. The device is preferably configured to begin powering the first heating unit some time after device activation, such as at least 1 second, 2 seconds, or 3 seconds after device activation. The device is preferably configured such that power is not supplied to the first heating unit or any heating units present in the heating assembly until at least 2.5 seconds after device activation. This advantageously extends the life of the battery by avoiding unintentional activation of the heating unit.

[0056] The aerosol-generating device can be ready for use more quickly than corresponding aerosol-generating devices known in the art, improving the user experience. Generally, the device is ready for use some time after the first heating unit reaches its maximum operating temperature. This is because it takes some time to transfer sufficient thermal energy from the heating unit to the aerosol-generating material to generate an aerosol. Preferably, the device is ready for use within 20 seconds, 15 seconds, or 10 seconds after the first heating unit reaches its maximum operating temperature.

[0057] It has been found that the characteristics of an aerosol generated from an aerosol-generating material can depend on the rate at which the aerosol-generating material is heated. For example, an aerosol generated from an aerosol-generating material heated by a heating unit configured to rapidly change temperature can improve the user experience. It has been found that in one embodiment in which the aerosol-generating material includes menthol, rapidly increasing the temperature of the heating unit can increase the rate at which the menthol is delivered to the user in the aerosol, thereby reducing the amount of menthol component wasted by static heating (i.e., not forming part of the aerosol inhaled by the user).

[0058] In some embodiments, the sensory experience of a user resulting from the aerosol produced by the device is similar to smoking a combustible cigarette, such as a factory-made cigarette.

[0059] The device may indicate that it is ready for use via an indicator. In a preferred embodiment, the device may be configured such that the indicator indicates that the device is ready for use within about 20 seconds, 15 seconds, or 10 seconds after power is applied to the first heating unit. In a particularly preferred embodiment, the device is configured such that the indicator indicates that the device is ready for use within about 20 seconds, 15 seconds, or 10 seconds after activation of the device. In another preferred embodiment, the device is configured such that the indicator indicates that the device is ready for use within about 20 seconds, 15 seconds, or 10 seconds after the first heating unit reaches its maximum operating temperature.

[0060] As used herein, a "use session" refers to a single period of use of an aerosol generating device by a user. A use session begins when power is first applied to at least one heating unit present in the heating assembly. The device is ready for use a certain amount of time after the start of the use session. A use session ends when power is no longer applied to any of the heating units in the aerosol generating device. The end of a use session may coincide with the aerosol product being depleted (when the total yield (mg) of particulate matter in each puff is determined by the user to be unacceptably low). A session preferably includes multiple puffs. The duration of a session may be less than 7 minutes, or less than 6 minutes, or less than 5 minutes, or less than 4 minutes 30 seconds, or less than 4 minutes, or less than 3 minutes 30 seconds. In some embodiments, a use session may have a duration of 2 to 5 minutes, or 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or suitably 4 minutes. A session may begin when a user presses a button or switches on the device, causing at least one heating unit to begin increasing in temperature upon activation or shortly thereafter.

[0061] As used herein with respect to a heating element or heating unit, "operating temperature" refers to any heating element temperature at which the element can heat the aerosol-generating material to generate sufficient aerosol for a satisfactory puff without burning the aerosol-generating material. The maximum operating temperature of a heating element is the highest temperature the element reaches during a smoking session. The minimum operating temperature of a heating element refers to the lowest heating element temperature at which the heating element can generate sufficient aerosol from the aerosol-generating material for a satisfactory puff. When multiple heating elements or heating units are present in an aerosol-generating device, each heating element or heating unit has an associated maximum operating temperature. The maximum operating temperature of each heating element or heating unit may be the same or may vary from one heating element or heating unit to another.

[0062] In a preferred embodiment of the aerosol-generating device, each heating element or heating unit is preferably configured to heat, rather than combust, the aerosol-generating material. The temperature profile of each heating element or heating unit preferably induces the temperature profile of the associated portion of the aerosol-generating material, although the temperature profile of the heating element or heating unit and the temperature profile of the associated portion of the aerosol-generating material may not exactly match. For example, there may be "bleed-through" in the form of conduction, convection, and / or radiation of thermal energy from one portion of the aerosol-generating material to another. There may be changes in the conduction, convection, and / or radiation of thermal energy from the heating element or heating unit to the aerosol-generating material. Depending on the heat capacity of the aerosol-generating material, there may be a time lag between the change in the temperature profile of the heating element or heating unit and the change in the temperature profile of the aerosol-generating material.

[0063] The device preferably includes a controller for controlling each heating unit present within the device. The controller may include a PCB. The controller is preferably configured to control the power supplied to each heating unit, thereby controlling the "programmed heating profile" of each heating unit present within the device. For example, the controller may be programmed to control the current supplied to multiple inductors to control the resulting temperature profile of the corresponding induction heating element or induction heating unit. As between the temperature profile of the heating element / unit and the temperature profile of the aerosol-generating material described above, the programmed heating profile of a heating element or heating unit may not exactly match the observed temperature profile of the heating element or heating unit for the same reasons described above.

[0064] The term "operating temperature" can also be used in reference to an aerosol-generating material. In this case, the term refers to any temperature of the aerosol-generating material itself at which sufficient aerosol is generated from the aerosol-generating material for a satisfactory puff. The maximum operating temperature of an aerosol-generating material is the highest temperature reached by any portion of the aerosol-generating material during a smoking session. In some embodiments, the maximum operating temperature of an aerosol-generating material is greater than 200°C, 210°C, 220°C, 230°C, 240°C, 250°C, 260°C, or 270°C. In some embodiments, the maximum operating temperature of an aerosol-generating material is less than 300°C, 290°C, 280°C, 270°C, 260°C, or 250°C. The minimum operating temperature is the lowest temperature of an aerosol-generating material at which sufficient aerosol is generated from the material to generate sufficient aerosol for a satisfactory "puff." In some embodiments, the minimum operating temperature of the aerosol-forming material is greater than 90° C., 100° C., 110° C., 120° C., 130° C., 140° C., or 150° C. In some embodiments, the minimum operating temperature of the aerosol-forming material is less than 150° C., 140° C., 130° C., or 120° C.

[0065] Various preferred embodiments of the present invention aim to reduce the time it takes for an aerosol generating device to be ready for use and, more generally, to improve the user's inhalation experience. Surprisingly, it has been found that reducing the time it takes for a heating element or heating unit to reach its operating temperature can at least partially reduce the "hot puff" phenomenon that occurs when the generated aerosol has a high water content. Thus, aerosol generating devices according to various embodiments of the present invention can provide consumers with inhalable aerosols that have better sensory properties than aerosols provided by prior art aerosol generating devices that do not include a heating unit that quickly reaches its maximum operating temperature.

[0066] In some embodiments, the device is configured such that at least one heating element within the device reaches its maximum operating temperature within 20 seconds, and the first temperature at which the at least one heating unit is held for at least 1, 2, 3, 4, 5, 10, or 20 seconds is the maximum operating temperature, i.e., in these embodiments, the heating unit is not held at a temperature that is not the maximum operating temperature before reaching the maximum operating temperature.

[0067] In some embodiments, the at least one heating unit reaches its maximum operating temperature from ambient temperature within a given period of time.

[0068] The device is configured to operate as described herein. The device may be configured to operate in this manner, at least in part, by a controller that is preferably programmed to operate the device in one or more different modes. Thus, references herein to the configuration of the device or parts thereof may refer to the controller being programmed to operate the device as disclosed herein, among other features (such as the spatial arrangement of the heating unit).

[0069] Aerosol-generating products for aerosol-generating devices (e.g., tobacco heating products) typically contain more water and / or aerosol-forming agents than combustible smoking articles to facilitate aerosol formation during use. This higher water and / or aerosol-generating agent content can increase the risk of condensation collecting within the aerosol-generating device during use, particularly at locations away from the heating unit(s). This problem can be greater in devices with enclosed heating chambers, particularly those with external heaters, than in devices with internal heaters (e.g., "blade" heaters). Without wishing to be bound by theory, it is believed that the heating assembly heats a larger proportion / surface area of ​​the aerosol-generating material, resulting in a greater aerosol release and greater condensation of the aerosol within the device than in devices that heat the aerosol-generating material internally. The inventors have discovered that the programmed heating profile of the present disclosure can be advantageously employed in devices configured to heat the aerosol-generating material externally to provide a desired amount of aerosol to the user while minimizing the amount of aerosol condensing within the device. For example, the maximum operating temperature of a heating unit can affect the amount of condensation that forms. A lower maximum operating temperature can result in less undesirable condensation. Differences in the maximum operating temperatures of heating units within a heating assembly can also affect the amount of condensation that forms. Additionally, the point in a usage session at which each heating unit reaches its maximum operating temperature can affect the amount of condensation that forms.

[0070] In some embodiments, the device is operable in at least a first (eg, base) mode and a second (eg, boost) mode.

[0071] The heating assembly may be operable in up to two modes, or may be operable in more than two modes, such as three modes, four modes, or five modes.

[0072] Each mode can be associated with a predetermined heating profile, such as a programmed heating profile, for each heating unit in the heating assembly. One or more of the programmed heating profiles can be programmed by a user. Additionally or alternatively, one or more of the programmed heating profiles may be programmed by a manufacturer. In these examples, the one or more programmed heating profiles can be fixed, preventing an end user from changing the one or more programmed heating profiles.

[0073] The operating mode may be user-selectable, for example, by a user interacting with a user interface to select a desired operating mode. Preferably, power begins to be supplied to the first heating unit substantially simultaneously with the desired operating mode being selected.

[0074] Each mode can be associated with a temperature profile that is different from the temperature profiles of the other modes. Furthermore, one or more modes may be associated with a different time point at which the device is ready for use. For example, the heating assembly may be configured such that in a first mode, the device is ready for use a first period of time after the start of a use session, and in a second mode, the device is ready for use a second period of time after the start of the session. The first period of time may be different from the second period of time. Preferably, the second period of time associated with the second mode is shorter than the first period of time associated with the second mode.

[0075] In some examples, the heating assembly is configured to render the device ready for use within 30, 25, 20, or 15 seconds of applying power to the first heating unit when operated in the first mode. The heating assembly may also be configured to render the device ready for use within a shorter period of time, such as within 25, 20, 15, or 10 seconds of applying power to the first heating unit when operated in the second mode. Preferably, the heating assembly is configured to render the device ready for use within 20 seconds of applying power to the first heating unit when operated in the first mode, and within 10 seconds of applying power to the second heating unit when operated in the second mode. The second mode of this embodiment may also advantageously be associated with the first and / or second heating units having a higher maximum operating temperature during use.

[0076] In a particularly preferred embodiment, the device is configured so that an indicator shows that the device is ready for use within 20 seconds of selecting the first (e.g., base) mode and within 10 seconds of selecting the second (e.g., boost) mode.

[0077] Providing an aerosol-generating device, such as a tobacco heating product, with a heating assembly that can operate in multiple modes (e.g., base mode and boost mode) advantageously provides consumers with more choice, especially when each mode is associated with a different maximum heater temperature. Furthermore, such devices can provide different aerosols with different characteristics because volatile components in the aerosol-generating material volatilize at different rates and concentrations at different heater temperatures. This allows users to select a particular mode based on the desired characteristics of the inhalable aerosol, such as the intensity of tobacco flavor, nicotine concentration, and aerosol temperature. For example, a mode in which the device is ready for use more quickly (e.g., second mode or "boost" mode) may provide a faster first puff, a higher nicotine content per puff, or a stronger flavor per puff. Conversely, a mode in which the device is ready for use later in a usage session (e.g., first mode or base mode) may provide a longer overall usage session, a lower nicotine content per puff, and a more sustained flavor delivery.

[0078] In embodiments in which the device is ready for use more quickly in the second (e.g., boost) mode and / or the first and / or second heating units have a higher maximum operating temperature in the second mode, the second mode may be referred to as a "boost" mode. Aspects of the present invention provide, for the first time, an aerosol generating device that can operate in a first, "normal" mode and a second, "boost" mode. Advantageously, in "boost" mode, the first puff may be delivered more quickly, or the nicotine content per puff may be higher, or the flavor per puff may be stronger.

[0079] The device may include up to two heating units. In other examples, the device may include more than two independently controllable heating units, such as three, four, or five independently controllable heating units.

[0080] Preferably, the device is configured such that each heating unit present within the device reaches a first mode maximum operating temperature in the first mode and a second mode maximum operating temperature in the second mode. For example, the second heating unit may reach a first mode maximum operating temperature in the first mode and a second mode maximum operating temperature in the second mode. The maximum operating temperatures of each heating unit in each mode may be the same or different. For example, the maximum operating temperature of the second heating unit in each mode may or may not be the same as the maximum operating temperature of the first heating unit in each mode.

[0081] As mentioned above, in some embodiments, at least one of the heating units provided in the heating assembly preferably includes an induction heating unit. In these embodiments, the heating unit preferably includes an inductor (e.g., one or more inductor coils), and the device is preferably arranged to pass a varying current, such as an alternating current, through the inductor. The varying current in the inductor generates a varying magnetic field. When the inductor and heating element are appropriately positioned relative to one another so that the varying magnetic field generated by the inductor penetrates the heating element, one or more eddy currents are generated in the heating element. Because the heating element has a resistance to the flow of current, when such eddy currents are generated in the object, their flow against the object's electrical resistance heats the object by Joule heating. Supplying a varying magnetic field to the susceptor is sometimes conveniently referred to as supplying energy to the susceptor.

[0082] The first and second heating units (which may include induction or resistance heating units) are preferably independently controllable. Heating the aerosol-generating material with independent heating units may advantageously provide more precise control of the heating of the aerosol-generating material. Independently controllable heating units may also provide different thermal energy to different portions of the aerosol-generating material, resulting in different temperature profiles between the portions of the aerosol-generating material. In certain embodiments, the first and second heating units are configured to have different temperature profiles from each other during use. This may result in asymmetric heating of the aerosol-generating material along the longitudinal plane between the mouth end and distal end of the device during use.

[0083] An object that can be inductively heated is known as a susceptor. If the susceptor contains a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., the varying orientation of magnetic dipoles in the magnetic material as a result of alignment with a varying magnetic field. Inductive heating generates heat internally within the susceptor, allowing for rapid heating compared to, for example, heating by conduction. Furthermore, the absence of physical contact between the induction heater and the susceptor allows for greater flexibility in design and application.

[0084] The heating element may include a susceptor. In a preferred embodiment, the susceptor includes multiple heating elements (at least a first induction heating element and a second induction heating element).

[0085] In other embodiments, the heating unit is not limited to an induction heating unit. For example, the first heating unit may include an electric resistance heating unit, which may be comprised of a resistive heating element. The second heating unit may additionally or alternatively be an electric resistance heating unit, which may be comprised of a resistive heating element. By "resistive heating element," we mean that when an electric current is applied to the element, the resistance within the element converts electrical energy into thermal energy that heats the aerosol-generating substrate. The heating element may be in the form of a resistive wire, mesh, coil, and / or multiple wires. The heat source may include a thin-film heater.

[0086] The heating element may comprise a metal or metal alloy. Metals are good conductors of electrical and thermal energy. Suitable metals include, but are not limited to, copper, aluminum, platinum, tungsten, gold, silver, and titanium. Suitable metal alloys include, but are not limited to, nichrome and stainless steel.

[0087] Another aspect of the present invention is an aerosol generating system comprising an aerosol generating device as described herein in combination with an aerosol generating product. In a preferred embodiment, the aerosol generating system comprises a tobacco heating product in combination with an aerosol generating product comprising tobacco. In a suitable embodiment, the tobacco heating product may comprise the heating arrangement and aerosol generating product described in connection with the following figures:

[0088] Figure 1A shows a heating assembly 100 of an aerosol generating device according to one embodiment. The heating assembly 100 is an inductive heating assembly 100. Figure 1B shows a cross section of the inductive heating assembly 100 of the device.

[0089] The heating assembly 100 has a first or proximal or mouth end 102 and a second or distal end 104. During use, a user inhales the formed aerosol through the mouth end of the aerosol generating device, which may be open-ended.

[0090] The heating assembly 100 includes a first heating unit 110 and a second heating unit 120. Both the first heating unit 110 and the second heating unit 120 are induction heating units. The first induction heating unit 110 includes a first inductor coil 112 and a first heating element 114. The second induction heating unit 120 includes a second inductor coil 122 and a second heating element 124.

[0091] The first heating unit 110 is spatially separated from the second heating unit 120. There is no overlap between the inductor coils of the heating units 110 and 120. The first heating unit 110 is closer to the mouth end than the second heating unit 120.

[0092] 1A and 1B show the aerosol-generating article 130 received within a susceptor 140 (see FIG. 1B). The susceptor 140 forms the first induction heating element 114 and the second induction heating element 124. The susceptor 140 may be formed from any material suitable for induction heating. For example, the susceptor 140 may include a metal. In some embodiments, the susceptor 140 may include a non-ferrous metal such as copper, nickel, titanium, aluminum, tin, or zinc, and / or a ferrous material such as iron, nickel, or cobalt. Additionally or alternatively, the susceptor 140 may include a semiconductor such as silicon carbide, carbon, or graphite.

[0093] Each induction heating element present in the aerosol generating device may have any suitable shape. In the embodiment shown in Figure 1B, the induction heating elements 114, 124 surround the aerosol generating product and define a receptacle for externally heating the aerosol generating product. In other embodiments (not shown), one or more induction heating elements may be substantially elongated and positioned to penetrate the aerosol generating product and heat it internally.

[0094] 1B, the first induction heating element 114 and the second induction heating element 124 may be provided together as a monolithic element 140. That is, in some embodiments, there is no physical distinction between the first heating element 114 and the second heating element 124. Rather, the different characteristics between the first heating unit 110 and the second heating unit 120 are defined by separate inductor coils 112, 122 surrounding each induction heating element 114, 124, so that they can be controlled independently of one another. In other embodiments (not shown), physically distinct induction heating elements may be employed.

[0095] The first inductor coil 112 and the second inductor coil 122 are preferably made from a conductive material. In this example, the first inductor coil 112 and the second inductor coil 122 are made from Litz wire / cable and helically wound to provide the helical inductor coils 112, 122. Litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses within the conductor. In the example of the induction heating assembly 100, the first inductor coil 124 and the second inductor coil 126 are made from copper Litz wire with a circular cross section. In other examples, the Litz wire may have other cross sections, such as a rectangular cross section.

[0096] The first inductor coil 112 is configured to generate a first varying magnetic field to heat the first induction heating element 114, and the second inductor coil 122 is configured to generate a second varying magnetic field to heat a second section of the susceptor 124. The first inductor coil 112 and the first induction heating element 114 together form the first induction heating unit 110. Similarly, the second inductor coil 122 and the second induction heating element 124 together form the second induction heating unit 120.

[0097] In this example, the first inductor coil 112 is adjacent to the second inductor coil 122 in a direction along the longitudinal axis of the device heating assembly 100 (i.e., the first inductor coil 112 and the second inductor coil 122 do not overlap). The susceptor structure 140 may include a single susceptor. Ends 150 of the first inductor coil 112 and the second inductor coil 122 may be connected to a controller, such as a PCB (not shown). In a preferred embodiment, the controller includes a PID controller (proportional-integral-derivative controller).

[0098] The varying magnetic field generates eddy currents within the first induction heating element 114, causing it to rapidly heat to its maximum operating temperature within a short time, for example, within 20, 15, 12, 10, 5, or 2 seconds, of supplying an alternative current to the coil 112. Locating the first induction heating unit 110, which is configured to rapidly reach its maximum operating temperature, closer to the mouth end 102 of the heating assembly 100 than the second induction heating unit 120 can mean that an acceptable aerosol is provided to the user as soon as possible after the start of a use session.

[0099] It will be appreciated that the first inductor coil 112 and the second inductor coil 122 may have at least one different characteristic from each other in some examples. For example, the first inductor coil 112 may have at least one different characteristic from the second inductor coil 122. More specifically, in one example, the first inductor coil 112 may have a different inductance value than the second inductor coil 122. In FIGS. 1A and 1B, the first inductor coil 112 and the second inductor coil 122 have different lengths, such that the first inductor coil 112 is wound on a smaller section of the susceptor 140 than the second inductor coil 122. Thus, the first inductor coil 112 may include a different number of turns than the second inductor coil 122 (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 112 may be made of a different material than the second inductor coil 122. In some examples, the first inductor coil 112 and the second inductor coil 122 may be substantially identical.

[0100] In this example, the first inductor coil 112 and the second inductor coil 122 are wound in the same direction. However, in another embodiment, the inductor coils 112, 122 may be wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, the first inductor coil 112 can initially operate to heat the first induction heating element 114, and the second inductor coil 122 can later operate to heat the second induction heating element 124. Winding the coils in opposite directions can help reduce current induced in inactive coils when used in conjunction with certain types of control circuitry. In one example, the first inductor coil 112 can be a right-handed spiral and the second inductor coil 122 can be a left-handed spiral. In another example, the first inductor coil 112 can be a left-handed spiral and the second inductor coil 122 can be a right-handed spiral.

[0101] The coils 112, 122 may be of any suitable shape. Without wishing to be bound by theory, configuring the induction heating element to be smaller (e.g., a spiral with a smaller pitch, fewer turns within the spiral, or a shorter overall spiral length) may increase the speed at which the induction heating element reaches its maximum operating temperature. In some embodiments, the first coil 112 may have a length of less than about 20 mm, less than 18 mm, less than 16 mm, or about 14 mm along the length of the heating assembly 100. Preferably, the first coil 112 may have a shorter length along the length of the heating assembly 100 than the second coil 124. Such a configuration may provide asymmetric heating of the aerosol-generated product along the length of the aerosol-generated product.

[0102] The susceptor 140 in this example is hollow and therefore defines a receptacle in which the aerosol-generating material is received. For example, the item 130 can be inserted into the susceptor 140. In this example, the susceptor 140 is tubular with a circular cross section.

[0103] The induction heating elements 114 and 124 surround the aerosol-generating article 130 and are positioned to heat the aerosol-generating article 130 from the outside. The aerosol-generating device is configured such that when the aerosol-generating article 130 is received within the susceptor 140, the outer surface of the article 130 abuts the inner surface of the susceptor 140. This ensures that heating is most efficient. The article 130 in this example includes an aerosol-generating material. The aerosol-generating material is disposed within the susceptor 140. The article 130 may also include other components, such as a filter, a winding material, and / or a cooling structure.

[0104] The heating assembly 100 is not limited to two heating units. In some examples, the heating assembly 100 may include three, four, five, six, or more than six heating units. Each of these heating units may be controllable independently of the other heating units present in the heating assembly 100.

[0105] 2A and 2B, there are shown a partially cut-away cross-sectional view and a perspective view of an example of an aerosol generating article 200. The aerosol generating article 200 shown in Figures 2A and 2B corresponds to the aerosol generating article 130 shown in Figure 1.

[0106] The aerosol-generating article 200 may be in any shape suitable for use with an aerosol-generating device. The aerosol-generating article 130 may be in the form of, or provided as part of, a cartridge, cassette, or rod that can be inserted into the device. In the embodiment shown in FIGS. 1A and 1B and 2 , the aerosol-generating article 130 is in the form of a substantially cylindrical rod and includes a body of smoking material 202 and a rod-shaped filter assembly 204. The filter assembly 204 includes three segments: a cooling segment 206, a filter segment 208, and a mouth-end segment 210. The article 200 has a first end 212, also known as the mouth end or proximal end, and a second end 214, also known as the distal end. The body of the aerosol-generating material 202 is disposed toward the distal end 214 of the article 200. In one example, the cooling segment 206 is positioned adjacent to the body of aerosol-generating material 202 between the body of aerosol-generating material 202 and the filter segment 208, such that the cooling segment 206 is in abutting relationship with the aerosol-generating material 202 and the filter segment 208. In other examples, there may be a separation between the body of aerosol-generating material 202 and the cooling segment 206, and between the body of aerosol-generating material 202 and the filter segment 208. The filter segment 208 is positioned between the cooling segment 206 and the mouth end segment 210. The mouth end segment 210 is positioned adjacent to the filter segment 208 toward the proximal end 212 of the article 200. In one example, the filter segment 208 is in abutting relationship with the mouth end segment 210. In one embodiment, the overall length of the filter assembly 204 is between 37 mm and 45 mm, and more preferably, the overall length of the filter assembly 204 is 41 mm.

[0107] In use, portions 202a and 202b of the body of aerosol-forming material 202 may correspond to first induction heating element 114 and second induction heating element 124, respectively, of portion 100 shown in FIG. 1B.

[0108] The body of smokable material may have multiple portions 202a, 202b corresponding to multiple induction heating elements present in the aerosol generating device. For example, the aerosol generating article 200 may have a first portion 202a corresponding to the first induction heating element 114 and a second portion 202b corresponding to the second induction heating element 124. These portions 202a, 202b may exhibit different temperature profiles during a use session, and the temperature profiles of the portions 202a, 202b may be derived from the temperature profiles of the first induction heating element 114 and the second induction heating element 124, respectively.

[0109] When there are multiple portions 202a, 202b of the body of aerosol-forming material 202, any number of the substrate portions 202a, 202b can have substantially the same composition. In certain instances, all of the substrate portions 202a, 202b have substantially the same composition. In one embodiment, the body of aerosol-forming material 202 is a unitary, continuous body, with no physical separation between the first portion 202a and the second portion 202b, and the first and second portions have substantially the same composition.

[0110] In one embodiment, the body of aerosol-forming material 202 comprises tobacco. However, in each of the other embodiments, the body of smoking material 202 may consist of tobacco, consist essentially of tobacco, contain tobacco and aerosol-forming materials other than tobacco, contain aerosol-forming materials other than tobacco, or contain no tobacco. The aerosol-forming material may include an aerosol-forming agent, such as glycerol.

[0111] In certain embodiments, the aerosol-forming material may include one or more tobacco components, filler components, binders, and aerosol-forming agents.

[0112] The filler component can be any suitable inorganic filler material. Suitable inorganic filler materials include, but are not limited to, calcium carbonate (i.e., chalk), perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. Calcium carbonate is particularly suitable. In some cases, the filler includes organic materials such as wood pulp, cellulose, and cellulose derivatives.

[0113] The binder can be any suitable binder, hi some embodiments, the binder comprises one or more of alginate, cellulose or modified cellulose, polysaccharides, starch or modified starch, and natural gum.

[0114] Suitable binders include, but are not limited to, alginates containing any suitable cation, such as sodium alginate, calcium alginate, and potassium alginate; celluloses or modified celluloses, such as hydroxypropyl cellulose and carboxymethyl cellulose; starches or modified starches; polysaccharides, such as pectins containing any suitable cation, such as sodium, potassium, calcium, or magnesium pectate; xanthan gum, guar gum, and any other suitable natural gum.

[0115] The binder may be included in the aerosol-forming material in any suitable amount and concentration.

[0116] An "aerosol-generating agent" is an agent that enhances the generation of an aerosol. An aerosol-generating agent may enhance the generation of an aerosol by facilitating the initial evaporation and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, an aerosol-generating agent may enhance the delivery of flavor from an aerosol product.

[0117] Generally, any suitable aerosol-generating agent or agents may be included in the aerosol-generating material, including, but not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols, high-boiling hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristates including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate.

[0118] In certain embodiments, the aerosol-forming material comprises a tobacco component in an amount of 60-90% by weight of the tobacco composition, a filler component in an amount of 0-20% by weight of the tobacco composition, and an aerosol-generating agent in an amount of 10-20% by weight of the tobacco composition. The tobacco component may comprise reconstituted tobacco in an amount of 70-100% by weight of the tobacco component.

[0119] In one example, the length of the body of aerosol-generating material 202 is between 34 mm and 50 mm, more preferably, the length of the body of aerosol-generating material 202 is between 38 mm and 46 mm, and even more preferably, the length of the body of aerosol-generating material 202 is 42 mm.

[0120] In one example, the total length of the article 200 is between 71 mm and 95 mm, more preferably, the total length of the article 200 is between 79 mm and 87 mm, and even more preferably, the total length of the article 200 is 83 mm.

[0121] The axial end of the body of aerosol-generating material 202 is visible at the distal end 214 of the article 200. However, in other embodiments, the distal end 214 of the article 200 may include an end member (not shown) that covers the axial end of the body of aerosol-generating material 202.

[0122] The body of aerosol-generating material 202 is disposed substantially around the periphery of filter assembly 204 so as to surround it, and is joined to filter assembly 204 by an annular piece of tipping paper (not shown) that extends partially along the length of the body of aerosol-generating material 202. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the length is between 42 mm and 50 mm, and more preferably, the length of the tipping paper is 46 mm.

[0123] In one example, cooling segment 206 is an annular tube that surrounds and defines a cavity within the cooling segment. The cavity provides a chamber for the flow of heated volatile components generated from the body of aerosol-generating material 202. Cooling segment 206 is hollow, providing a chamber for aerosol accumulation, yet rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use when article 200 is inserted into device 100. In one example, the wall thickness of cooling segment 206 is approximately 0.29 mm.

[0124] The cooling segment 206 provides a physical displacement between the aerosol-generating material 202 and the filter segment 208. The physical displacement provided by the cooling segment 206 provides a thermal gradient across the length of the cooling segment 206. In one example, the cooling segment 206 is configured to provide a temperature difference of at least 40° C. between the heated volatile components entering the first end of the cooling segment 206 and the heated volatile components exiting the second end of the cooling segment 206. In one example, the cooling segment 206 is configured to provide a temperature difference of at least 60° C. between the heated volatile components entering the first end of the cooling segment 206 and the heated volatile components exiting the second end of the cooling segment 206. This temperature difference across the length of the cooling segment 206 protects the temperature-sensitive filter segment 208 from the high temperatures of the aerosol-generating material 202 when heated by the heating assembly 100 of the aerosol-generating device. If no physical displacement is provided between the filter segment 208 and the body of the aerosol-generating material 202 and between the heating elements 114, 124 of the heating assembly 100, the temperature-sensitive filter segment 208 may be damaged during use, thereby causing the filter segment 208 to not effectively perform its required function.

[0125] In one example, the length of the cooling segment 206 is at least 15 mm. In one example, the length of the cooling segment 206 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, more specifically between 25 mm and 27 mm, and more specifically 25 mm.

[0126] The cooling segment 206 is made of paper, meaning that it is constructed of a material that does not produce compounds of concern, such as toxic compounds, when used adjacent to the heater assembly 100 of the aerosol generating device. In one example, the cooling segment 206 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

[0127] In another example, cooling segment 206 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and in use when article 200 is inserted into device 100.

[0128] For each example of cooling segment 206, the dimensional accuracy of the cooling segment is sufficient to meet the dimensional accuracy requirements of high speed manufacturing processes.

[0129] The filter segment 208 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatiles from the smoking material. In one example, the filter segment 208 is made from a monoacetate material, such as cellulose acetate. The filter segment 208 provides cooling and reduces irritation from the heated volatiles without depleting the amount of the heated volatiles to a level that is unsatisfactory for the user.

[0130] The density of the cellulose acetate tow material of filter segment 208 controls the pressure drop across filter segment 208, which in turn controls the draw resistance of article 200. Therefore, the selection of material for filter segment 208 is important in controlling the draw resistance of article 200. Additionally, filter segment 208 performs the filtration function of article 200.

[0131] In one example, the filter segment 208 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatile material while reducing the size of condensed aerosol droplets resulting from the heated volatile material, thereby satisfactorily reducing the irritation and throat impact of the heated volatile material.

[0132] The presence of filter segment 208 provides an insulating effect by providing additional cooling to the heated volatiles exiting cooling segment 206. This additional cooling effect reduces the contact temperature of the surface of filter segment 208 with the user's lips.

[0133] One or more flavors can be added to the filter segment 208 by either injecting a flavored liquid directly into the filter segment 208 or by embedding or disposing one or more flavored degradable capsules or other flavor carriers within the cellulose acetate tow of the filter segment 208.

[0134] In one example, the length of the filter segment 208 is between 6 mm and 10 mm, and more preferably 8 mm.

[0135] The mouth end segment 210 is an annular tube that is disposed around and defines a cavity within the mouth end segment 210. The cavity provides a chamber for heated volatile components that flow from the filter segment 208. The mouth end segment 210 is hollow, providing a chamber for aerosol accumulation, yet rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use when an item is inserted into the device 100. In one example, the wall thickness of the mouth end segment 210 is approximately 0.29 mm.

[0136] In one example, the mouth end segment 210 has a length of 6 mm to 10 mm, more preferably 8 mm. In one example, the mouth end segment has a thickness of 0.29 mm.

[0137] The mouth end segment 210 may be manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

[0138] The mouth end segment 210 serves the function of preventing any liquid condensate that accumulates at the outlet of the filter segment 208 from coming into direct contact with the user.

[0139] It should be understood that in one example, the mouth end segment 210 and the cooling segment 206 may be in the form of a single tube, with the filter segment 208 positioned within the tube to separate the mouth end segment 210 and the cooling segment 206.

[0140] Article 200 is provided with a ventilation region 216 to allow air to flow from the exterior of article 200 to the interior of article 200. In one example, ventilation region 216 takes the form of one or more ventilation holes 216 formed through an outer layer of article 200. The ventilation holes may be disposed in cooling segment 206 to aid in cooling article 200. In one example, ventilation region 216 includes one or more rows of holes, preferably with the holes in each row disposed circumferentially around article 200 in a cross section substantially perpendicular to the longitudinal axis of article 200.

[0141] In one example, there are 1 to 4 rows of ventilation holes to ventilate article 200. Each row of ventilation holes can have 12 to 36 ventilation holes 216. For example, the diameter of ventilation holes 216 can be 100 to 500 μm. In one example, the axial separation between rows of ventilation holes 216 is 0.25 mm to 0.75 mm, and more preferably, the axial separation between rows of ventilation holes 216 is 0.5 mm.

[0142] In one example, ventilation holes 216 are uniformly sized. In another example, ventilation holes 216 are varying sizes. The ventilation holes can be made using any suitable technique, such as one or more of the following techniques: laser techniques, mechanically drilling cooling segment 206, or pre-drilling cooling segment 206 before it is formed in article 200. Ventilation holes 216 are positioned to effectively cool article 200.

[0143] In one example, the row of ventilation holes 216 is positioned at least 11 mm from the proximal end 212 of the article, and more preferably, the ventilation holes are positioned 17 mm to 20 mm from the proximal end 212 of the article 200. The ventilation holes 216 are positioned such that the user does not block the ventilation holes 216 when the article 200 is in use.

[0144] 1 , providing a row of ventilation holes 17 mm to 20 mm from the proximal end 212 of the article 200 advantageously allows the ventilation holes 216 to be located on the exterior of the device 100 when the article 200 is fully inserted into the device 100. Locating the ventilation holes on the exterior of the apparatus allows unheated air to enter the article 200 from outside the device 100 through the ventilation holes to help cool the article 200.

[0145] The length of cooling segment 206 is such that when article 200 is fully inserted into device 100, cooling segment 206 is partially inserted into device 100. The length of cooling segment 206 serves two functions: first, to provide a physical gap between the heater arrangement and heat-sensitive filter arrangement 208 of device 100; and second, to allow ventilation holes 216 to be located in the cooling segment while remaining outside of device 100 when article 200 is fully inserted into device 100. As can be seen in FIG. 1 , the majority of cooling element 206 is located within device 100. However, there is a portion of cooling element 206 that extends from device 100. Ventilation holes 216 are located in this portion of cooling element 206 that extends from device 100.

[0146] 3 shows a first temperature profile 300 and a second temperature profile 400 that form a first heating mode 250 of the aerosol delivery device. The first heating mode 250 is a base heating mode.

[0147] The first temperature profile 300 indicates the temperature to which the first heating unit 110 is controlled over an aerosol-generating session 302, also referred to herein as a "use session" or a "smoking session."

[0148] The temperature of the first heating element 114 is measured by a suitable temperature sensor disposed within the first heating element 114. Suitable temperature sensors include a thermocouple, a thermopile, or a resistance temperature detector (RTD, also known as a resistance thermometer). In certain embodiments, the device includes at least one RTD. In a preferred embodiment, the device includes a thermocouple disposed within each heating element 114, 124 present within the aerosol generating device. Temperature data measured by each temperature sensor can be communicated to the controller. Furthermore, when the heating element 114, 124 reaches a predetermined temperature, the temperature data is communicated to the controller so that the controller can accordingly modify the power supply to the elements within the aerosol generating device. Preferably, the controller includes a PID controller that uses a control loop feedback mechanism to control the temperature of the heating element based on data provided by one or more temperature sensors disposed within the device. In a preferred embodiment, the controller includes a PID controller configured to control the temperature of each heating element based on temperature data provided by a thermocouple disposed within each heating element.

[0149] A use session 302 begins when the device is activated (304), with the controller controlling the device to supply energy to at least the first heating unit 110. The device may be activated by a user activating a push button or by inhaling from the device. In the context of a heater assembly including induction heating means, a use session begins when the controller directs the supply of a varying current to the inductors (such as the first coil 112 and the second coil 122), and thus a varying magnetic field to the induction heating elements, causing the temperature of the induction heating elements to increase. This is sometimes conveniently referred to as "energizing the heating units."

[0150] The end 306 of the use session 302 occurs when the controller instructs elements within the device to stop supplying energy to all heating units present within the aerosol generating device at time tbase after the smoking session begins. Time tbase is 260 seconds. In the context of a heater assembly including an induction heating unit, the use session ends when any of the induction heating elements provided within the heating assembly no longer receives a varying current, and therefore no longer receives a varying magnetic field.

[0151] At the beginning of the smoking session 302, the temperature of the first heating unit 110 is controlled to a first target operating temperature T1 308.

[0152] This is achieved by supplying power to and controlling via a controller the first heating unit 110. The controller controls the first heating unit 110 to the target temperature shown in Figure 3, although it will be appreciated that the actual temperature of the first heating unit 110 in practice will differ slightly from the temperatures shown in Figures 3 and 4 (e.g., due to external factors or the time it takes the heating unit to heat up).

[0153] T1 is the maximum operating temperature of the first unit and is the maximum temperature to which the first heating unit 110 is controlled during the use session 302. In the first heating mode 250, T1 is less than 260 degrees Celsius (°C). In the first heating mode 250, T1 is less than 250°C. In the first heating mode 250, T1 is 240°C.

[0154] The first heating unit 110 is controlled to maintain its temperature at the first target operating temperature T1 308 until time t4 310. In the first heating mode 250, time t4 is 185 seconds. All times referenced in Figures 3 and 4 are measured after the session start 302, i.e., the time elapsed since the start of the session.

[0155] At time t4, the first heating unit 110 is controlled to reduce its temperature to a first heating unit step-down temperature T5 312. In the first heating mode 250, T5 is 210°C.

[0156] The first heating unit 110 is controlled to maintain its temperature at the first unit step-down temperature T5 until the end of the session 306. The end of the session 306 occurs at time tbase, which is 260 seconds.

[0157] The second temperature profile 400 shows the temperature to which the second heating unit 120 is controlled throughout the aerosol generation session 302 in the first heating mode.

[0158] In the second temperature profile 400, the second heating unit 120 is controlled to an initial second unit temperature, T. During this time, the controller does not supply energy to the second heating unit 120, resulting in T being a non-heating temperature. Nevertheless, the temperature at the second induction heating element may increase somewhat due to thermal "bleed-through," i.e., conduction, convection, and / or radiation of thermal energy from the first heating element 114 to the second heating element 124.

[0159] At time t1 402, the controller begins supplying power to the second heating unit 120. The second heating unit 120 is controlled to a second target operating temperature T2 404.

[0160] In the first heating mode 250, the second target operating temperature T2 is less than 160°C. In the first heating mode 250, the second target operating temperature T2 is 150°C.

[0161] In the first heating mode 250, time t1 > 85. In the first heating mode 250, time t1 > 90. In the first heating mode 250, time t1 > 95. In the first heating mode 250, T1 is 100 seconds.

[0162] The second heating unit 120 is controlled to a second target operating temperature T2 404 until time t3 406. In the first heating mode 250, time t3 is 170 seconds. At time t3, the second heating unit 120 is controlled to increase its temperature to a third target operating temperature T4 409.

[0163] In the first heating mode 250, the third target operating temperature T4 is less than 240° C. In the first heating mode 250, the third target operating temperature T4 is less than 230° C. In the first heating mode 250, the third target operating temperature T4 is 220° C.

[0164] In the first heating mode 250, t3>t1 and T4>T2.

[0165] The second heating unit 120 is controlled to the third target operating temperature T4 409 until time t2 408. In the first heating mode 250, time t2 is 225 seconds.

[0166] At time t2, the second heating unit 120 is controlled to lower its temperature to the second heating unit step-down temperature T3 410. In the first heating mode 250, time t2 is before 30 seconds of the end 306 of session 302, and more specifically 35 seconds before the end 306 of the session.

[0167] In the first heating mode 250, the second heating unit step-down temperature 410 is less than 220 °C, more specifically less than 210 °C, and more specifically 200 °C.

[0168] In the first heating mode 250, t2 > t1. In the first heating mode, T3 > T2. In the first heating mode 250, T3 < T5. In the first heating mode, t3 < t4 < t2.

[0169] The second heating unit 120 is controlled to maintain its temperature at the second unit step-down temperature T3 until the end 306 of the session.

[0170] In addition to being shown in FIG. 3, the first heating mode 250 is specified in Table 1. Table 1 shows the cumulative temperature up to the specified time of the first and second heating units. For each heating unit, each temperature shown in the table is the temperature at which the specific heating unit is controlled up to the time specified by the corresponding time value. For example, in the first heating mode, the first heating unit is controlled to 240 °C from 0 to 185 seconds and to 210 °C from 185 to 260 seconds. The last time entry indicates the end of the usage session.

Table 1

[0171] FIG. 4 shows a third temperature profile 600 and a fourth temperature profile 700 that form a second heating mode 500. The second heating mode 500 is a boost heating mode. Compared to the base heating mode, in the boost heating mode, the aerosol supply device is configured to generate aerosol at a higher rate for a shorter usage session 502. This is achieved by generally controlling the first heating unit 110 and the second heating unit 120 to a higher temperature, and both heating units 110 and 120 heating for a larger proportion of the usage session 502 simultaneously. During use, the user selects either the first heating mode 250 or the second heating mode 500 to use for a particular article 200, for example, by providing an input via a button.

[0172] The third temperature profile 600 shows the temperature at which the first heating unit 110 is controlled over the usage session 502. The usage session 502 starts when the device is activated (504), and the controller controls the device to supply energy to at least the first heating unit 110.

[0173] The end 506 of the usage session 502 occurs at time tboost when the controller instructs the elements within the device to stop supplying energy to all heating units present within the aerosol generation device. Time tboost < tbase. In this example, time tboost is 195 seconds.

[0174] At the start of the usage session 502, the temperature of the first heating unit 110 is controlled to the first target operating temperature T1 608.

[0175] T1 is the maximum operating temperature of the first unit and the maximum temperature at which the first heating unit 110 is controlled during the usage session 502. In the second heating mode 500, T1 is 260 °C.

[0176] The first heating unit 110 is controlled to maintain its temperature at the first target operating temperature T1 608 until time t4 610. In the second heating mode 500, time t4 is 30 seconds.

[0177] At time t4, the first heating unit 110 is controlled to reduce its temperature to the first heating unit step-down temperature T5 612. In the second heating mode 500, T5 is 210°C.

[0178] The first heating unit 110 is controlled to maintain its temperature at the first heating unit step-down temperature T5 until time t5 614. In the second heating mode 500, time t5 is 135 seconds.

[0179] At time t5, the first heating unit 110 is controlled to reduce its temperature to an additional first heating unit step-down temperature T6 616. In the second heating mode, T6 is 210°C.

[0180] The first heating unit 110 is controlled to maintain its temperature at the additional first unit step-down temperature T6 until the end of the session 506. The end of the session 506 occurs at time tboost.

[0181] The fourth temperature profile 500 shows the temperature to which the second heating unit 120 is controlled throughout the aerosol generation session 502 in the second heating mode 500 .

[0182] In the second temperature profile 400, the second heating unit 120 is controlled to an initial second unit temperature, T. During this time, the controller does not supply energy to the second heating unit 120, resulting in T being a non-heating temperature. Nevertheless, the temperature at the second induction heating element may increase somewhat due to thermal "bleed-through," i.e., conduction, convection, and / or radiation of thermal energy from the first heating element 114 to the second heating element 124.

[0183] At time t1 702, the controller begins supplying power to the second heating unit 120. The second heating unit 120 is controlled to a second target operating temperature T2 704. In the second heating mode 500, the second target operating temperature T2 is 160° C. In the second heating mode 500, the time t1 is 25 seconds.

[0184] The second heating unit 120 is controlled to a second target operating temperature T2 704 until time t3 706. In the second heating mode 500, time t3 is 80 seconds. At time t3, the second heating unit 120 is controlled to increase its temperature to a third target operating temperature T4 708. In the second heating mode 500, the third target operating temperature T4 is less than 260°C. In the second heating mode 500, the third target operating temperature T4 is 250°C.

[0185] The second heating unit 120 is controlled to a third target operating temperature T4 708 until time t2 710. In the second heating mode 500, time t2 is 225 seconds. At time t2, the second heating unit 120 is controlled to reduce its temperature to a second heating unit step-down temperature T3 712. In the second heating mode 500, the second heating unit step-down temperature 410 is 200°C.

[0186] The second heating unit 120 is controlled to maintain its temperature at the second unit step-down temperature T3 until the end 506 of the session.

[0187] In the second heating mode 500, the third target operating temperature T4 is equal to the first heating unit step-down temperature T5. In the second heating mode 500, time t2 710 is equal to time t5 614. In the second heating mode 500, the second heating unit step-down temperature T3 712 is equal to the additional first heating unit step-down temperature T6 616.

[0188] In addition to what is shown in Figure 5, the second heating mode 500 is specified in Table 2. Table 2 shows the cumulative temperatures up to the specified time for the first and second heating units. As in Table 1, for each heating unit, the temperature shown is the temperature that the particular heating unit will be controlled to up to the time specified in the corresponding time column. [Table 2] [Table 3]

[0189] The exemplary device was tested according to the first heating mode 250 compared to a device operating according to an example comparative heating mode. The example comparative heating mode is summarized below in Table 3. As before, Table 3 shows the accumulated temperatures over a specified time for the first and second heating units.

[0190] Devices operated according to the first heating mode 250 and the comparative heating mode example were evaluated for the device's external body temperature and the user's sensory experience. Generally, it is desirable to reduce the device's external body temperature as much as possible for user comfort. It is also desirable to improve or maintain the user's sensory experience.

[0191] In tests conducted at room temperature, the first heating mode 250 was found to significantly reduce the external device body temperature compared to the comparative heating mode example, which was found to be unacceptable in terms of external device body temperature (often exceeding temperatures of 55° C.). In particular, towards the end of a usage session, the external device body temperature was found to be too high under the first comparative example.

[0192] Without wishing to be bound by theory, the decrease in external device temperature in the first heating mode 250 may be due to the fact that some target temperatures (e.g., the first target operating temperature T1, the second target operating temperature T2, the third target operating temperature T4, and the first heating unit step-down temperature T5) are decreased in the first heating mode 250, the second heating unit temperature is reduced (to the second heating unit step-down temperature T3) in the first heating mode 250, and / or the second heating unit begins heating later in the session in the first heating mode 250.

[0193] The sensory experience of the device operating according to the example first heating mode 250 and the comparative heating mode was evaluated by a user panel according to a continuous single product testing methodology. The panel included 15 users with two replicates, providing 30 data points.

[0194] The results of the user sensory experience are summarized below in Table 4 for several user sensory attributes. The First Heating Mode column indicates the performance of the first heating mode compared to the comparison heating mode example, with "Low" indicating a poor performance score and "NSD" indicating no significant difference in results. "FP" indicates the results for the first two puffs of the usage session, and "D" indicates the results for the remaining, later puffs of the usage session. [Table 4]

[0195] The results in Table 4 surprisingly show that (due to the significant drop in device body temperature for the first heating mode compared to the comparative heating mode example) devices operating according to the first heating mode 250 and the first comparative heating mode provide very similar user sensory experiences.

[0196] In particular, it was surprising to find that controlling the second heating unit (as in first heating mode 250 and second heating mode 500) to reduce its temperature to a second unit step-down temperature T3 at time t2 after the start of the aerosol generation session (but not in the comparative heating mode example) did not adversely affect the user's sensory experience during the latter puffs of the sensory test ("D"). Reducing the temperature of the second heating unit in this manner has been found to significantly reduce the external device temperature during a session, which typically peaks at the end of the session.

[0197] Additionally, it was surprising to find that controlling the second heating unit (as in the first heating mode 250) to begin heating to the second target operating temperature T2 at time t1 (where t1 > 85 seconds) (but not in the comparative heating mode example where the second heating unit began heating at 82 seconds) did not adversely affect the user's sensory experience during the later puffs of the sensory test ("D"). Initiating heating with the second heating unit in this manner later in the session was found to significantly reduce the external device temperature due to the cumulative effect of the longer heating with both heating units on the external device temperature.

[0198] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not intended to be limitations on the scope of the invention as defined by the appended claims or equivalents thereof, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions not currently claimed but that may be claimed in the future.

Claims

1. 1. An aerosol delivery device configured to receive at least a portion of an article including an aerosol-generating material, a first heating unit arranged to, in use, heat the aerosol-forming material to form an aerosol; a second heating unit arranged to heat the aerosol-forming material to form an aerosol during use; and a controller configured to control the first and second heating units according to a heating mode during an aerosol generation session; Equipped with During the heating mode, the controller: at the beginning of the session, controlling the first heating unit to begin heating to a first target operating temperature T1; at a time t1 after the start of the aerosol generation session, controlling the second heating unit to begin heating to a second target operating temperature T2; An aerosol delivery device wherein t1 > 85 seconds.

2. 2. The aerosol delivery device of claim 1, wherein during the heating mode, the controller is configured to control the second heating unit to heat to a third target operating temperature T4 at time t3 after the start of the aerosol generation session, where t3 > t1 and T4 > T2.

3. 3. The aerosol delivery device of claim 1, wherein during the heating mode, the controller is configured to control the second heating unit to reduce the temperature of the second heating unit to a second heating unit step-down temperature T3 at a time t2 after the start of the aerosol generation session.

4. 4. The aerosol delivery device of claim 1, wherein during the heating mode, the controller is configured to control the first heating unit to reduce the temperature of the first heating unit to a first heating unit step-down temperature T5 at a time t4 after the start of the aerosol generation session.

5. During the heating mode, the controller: controlling the first heating unit to heat to a first unit maximum operating temperature during the aerosol-generating session; configured to control the second heating unit to heat to a second unit maximum operating temperature during the aerosol generation session; The aerosol delivery device of any one of claims 1 to 4, wherein the first unit maximum operating temperature is higher than the second unit maximum operating temperature.

6. The aerosol delivery device of any one of claims 1 to 5, wherein the first heating unit and the second heating unit are configured to heat different portions of the aerosol-forming material.

7. The aerosol delivery device of any one of claims 1 to 6, wherein the first heating unit and the second heating unit are spatially separated.

8. 8. The aerosol delivery device of claim 1, wherein the aerosol delivery device has a mouth end and the first heating unit is positioned closer to the mouth end than the second heating unit.

9. The aerosol delivery device of any one of claims 1 to 8, wherein the first and second heating units comprise induction heating units.

10. 10. The aerosol delivery device of claim 1, wherein the heating mode is a base heating mode and the controller is further configured to heat according to a boost heating mode, wherein in the boost heating mode the device is configured to generate aerosol at a higher rate for a shorter duration than in the base heating mode.

11. The aerosol delivery device of any one of claims 1 to 10, wherein during the heating mode, the controller is configured to control the second heating unit to not heat until time t1.

12. The aerosol delivery device of any one of claims 1 to 11, wherein t1 > 90 seconds.

13. 13. The aerosol delivery device of any one of claims 1 to 12, wherein t1 > 95 seconds, and optionally t1 is substantially 100 seconds.

14. An aerosol delivery system comprising the aerosol delivery device according to any one of claims 1 to 12 and the article.

15. 1. A method of controlling an aerosol delivery device according to a heating mode, the aerosol delivery device configured to receive at least a portion of an article including an aerosol-generating material, the method comprising: At the beginning of an aerosol generation session, controlling a first heating unit of the aerosol delivery device to begin heating to a first target operating temperature T1; at a time t1 after the start of the aerosol generation session, controlling a second heating unit of the aerosol delivery device to begin heating to a second target operating temperature T2; Including, The method wherein t1>85 seconds.

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