aerosol generator

Abstract

An aerosol generating apparatus (100, 300, 400) is disclosed, the apparatus comprising: a cavity (102, 302, 408) configured to receive an aerosol-forming consumable; a heater (106, 306, 414) configured to heat, but not combust, an aerosol-forming consumable (104, 304, 410) received in the cavity, thereby generating an aerosol; and a gas supply device (108, 308, 404) including a separator, the gas supply device (108, 308, 404) configured to generate a gas having a reduced oxygen concentration compared to air, removing oxygen from the air by using the separator, and supplying the gas to the cavity.

Description

[Technical Field]

[0001] The present invention relates to an aerosol generating device that supplies a low-oxygen or oxygen-free gas to a heatable cavity or oven of the device. [Background technology]

[0002] Known heated tobacco ovens in aerosol generating devices, particularly non-combustion heated systems, are often limited to heating temperatures that prevent or reduce the risk of combustion of tobacco consumables placed within the oven. Tobacco combustion can occur when residual combustion-causing oxygen is present within the oven or cavity space, resulting in an aerosol that is highly toxic for inhalation by a user. In many cases, the burned tobacco consumables can also undesirably create an unpleasant odor or taste in the generated aerosol. Summary of the Invention [Problem to be solved by the invention]

[0003] It is an object of the present invention to provide a high temperature environment for heating an aerosol-forming consumable that has a lower risk of burning the consumable. [Means for solving the problem]

[0004] According to an aspect of the present invention, an aerosol generation apparatus is provided, comprising: a cavity configured to receive an aerosol-forming consumable; a heater configured to heat but not combust the aerosol-forming consumable received in the cavity, thereby generating an aerosol; and a gas supply device including a separator, the gas supply device configured to remove oxygen from air using the separator and supply gas to the cavity to produce a gas having a reduced oxygen concentration relative to air.

[0005] In this manner, a low-oxygen or oxygen-free gas can be supplied to the cavity of the aerosol-generating device. Advantageously, the low-oxygen or oxygen-free gas allows for an increased temperature of the heater within the cavity while avoiding or reducing combustion of the aerosol-forming consumables received within the cavity. Heating the aerosol-forming consumables at higher temperatures can result in more efficient use of the consumables (i.e., reduced waste of the consumables) and can produce a more desirable aerosol with more finely dispersed particles. For example, nicotine disperses into smaller particles at higher temperatures and can be better absorbed by the user's lungs into their bloodstream, resulting in more efficient nicotine delivery. Additionally, it has been found that tobacco-based consumables can be more effectively consumed when heated at higher temperatures.

[0006] Combustion or burning of aerosol-forming consumables can result in higher toxicity of the burned material and unpleasant odors to the user, which can unnecessarily increase the risk of health-related problems for the user and detract from the user experience.

[0007] The separator of the gas supply device may be configured to use a gas separation technique such as pressure swing adsorption or membrane gas separation or any other suitable gas separation technique, as will be apparent to those skilled in the art. The separator may also be an oxygen removal device, also known as an oxygen concentrator device. It will be understood that the separator actively removes oxygen from the air (before it is delivered to the cavity) so that an oxygen-depleted gas is supplied to the cavity to prevent combustion or the risk of combustion within the cavity.

[0008] In known oxygen removal and oxygen concentration devices, the oxygen removed from the air is typically the desired gas, with the nitrogen and / or other gases in the remaining air often discarded as unwanted by-products. In the present invention, a non-oxygen gas product is advantageously used to provide a low-oxygen or oxygen-free environment within the cavity of the device. The removed oxygen can be re-inserted into the air flow path of the device, away from the heater and cavity.

[0009] Preferably, the gas is substantially oxygen-free, in this way the risk of combustion or residual combustion of the aerosol-forming consumable within the cavity is significantly reduced and optimal aerosol can be produced.

[0010] Preferably, the aerosol generating device further comprises a gas tank connectable to the gas supply device for receiving gas with a reduced oxygen concentration relative to air. In this way, gas can be stored in the gas tank and released into the cavity as needed. Advantageously, the stored gas tank allows for greater variability in the delivery rate of gas to the cavity. For example, a higher delivery rate may involve the gas supply device or oxygen removal device operating in conjunction with the supply of gas from the gas tank. In another example, the gas supply device can accumulate the amount of gas stored in the gas tank, for gas supplied solely from the gas tank (i.e., without active or continuous supply from the gas supply device) for one or more uses (i.e., vaping sessions) of the device. It has also been found that the gas tank and gas supply device can be housed in different separable parts of the overall aerosol generating device to improve the ease of use of the device.

[0011] Preferably, the aerosol generating device further comprises a second gas tank connectable to the gas supply device to receive the removed oxygen. In this way, the removed oxygen can be stored in the second gas tank for release as needed. For example, oxygen can be added to the generated aerosol before it is inhaled by the user.

[0012] Preferably, the aerosol generating device further comprises an oxygen supply conduit configured to supply the removed oxygen to an airflow channel extending away from the heater within the cavity. In this way, oxygen removed by the gas supply device can be directed away from the heater and / or the cavity to reduce the risk of residual combustion. Preferably, the oxygen supply conduit is configured to supply the removed oxygen to an airflow channel within the mouthpiece. In this way, the removed oxygen can be directed to the airflow channel for inhalation by the user. In another example, the mouthpiece may comprise one or more holes to allow additional air to be combined with the generated aerosol prior to inhalation by the user.

[0013] Preferably, the aerosol generating device further comprises an additional gas supply configured to supply the cavity with a second gas having a reduced oxygen concentration compared to air. Preferably, the second gas is nitrogen. In this manner, the amount of oxygen in the cavity can be further reduced. The second gas may be combined with the gas supplied by the gas supply device before being supplied to the cavity, or in another example, the additional gas supply may provide an alternative low-oxygen or oxygen-free gas supply independent of the gas supply device. The additional gas supply may include a pressurized cylinder or gas tank of low-oxygen gas. Alternatively, the additional gas supply may include a solid, liquid, and / or solid-liquid material configured to generate a non-oxygen gas that can be supplied to the cavity.

[0014] Preferably, the aerosol generating device further comprises a puffing sensor connected to the actuator, the actuator configured to supply gas to the cavity during inhalation as detected by the puffing sensor. In this way, the supply of gas to the cavity can be controlled to occur only when the user takes a puff from the device. This provides for more efficient use of the gas supply device and may extend the use time of the device. Preferably, the aerosol generating device is further configured to supply oxygen removed during inhalation to the airflow channel as detected by the puffing sensor. A similar technique can also be used, with the removed oxygen providing oxygen to the generated aerosol when a puffing action of the user is detected. Preferably, the actuator comprises a solenoid valve.

[0015] Preferably, the aerosol generating apparatus further includes an aerosol generating device and a case capable of housing the aerosol generating device. In this manner, the functions of the entire aerosol generating apparatus can be separated to optimize the user experience. For example, the aerosol generating device may be used for user inhalation, with the gas supply device and / or other components of the apparatus being separate from the device. The aerosol generating device can be removed from the case when the user wants to take a puff and returned to the case when finished. The case may hold the gas supply device and / or other components that may not be particularly useful for the user inhalation mode provided by the device. Preferably, the case includes the gas supply device. As an example, the gas supply device in the case may recharge one or more gas tanks provided in the aerosol generating device, providing a device that is lighter for the user to handle and inhale. In a further example, the aerosol generating device may be returned to the aerosol generating apparatus case to charge the device's battery.

[0016] Preferably, the aerosol generating device further comprises an aerosol-forming consumable received in the cavity and positioned adjacent to the heater, such that the aerosol-forming consumable can be effectively heated by the heater when disposed within the cavity to generate the aerosol.

[0017] According to another aspect of the present invention, there is provided a method of generating an aerosol for user inhalation, the method comprising: receiving an aerosol-forming consumable into a cavity of an aerosol generation device; receiving air into a gas supply device of the aerosol generation device; using a separator in the gas supply device to remove oxygen from the received air to produce a gas having a reduced oxygen concentration relative to the air; supplying the gas to the cavity; and heating, but not combusting, the aerosol-forming consumable by a heater of the aerosol generation device to generate an aerosol.

[0018] Embodiments of the invention will now be described, by way of example, with reference to the drawings, in which: [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 1 is a schematic flow diagram of an aerosol generating apparatus according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a schematic diagram of a gas supply device. [Figure 3] FIG. 3 is a schematic flow diagram of an aerosol generating apparatus according to a second embodiment of the present invention. [Figure 4] FIG. 4 is a schematic flow diagram of an aerosol generating apparatus according to a third embodiment of the present invention. [Figure 5] 5A and 5B are schematic diagrams of different actuator systems. DETAILED DESCRIPTION OF THE INVENTION

[0020] 1 shows a schematic diagram of the controls and airflow through an aerosol generating device 100, according to one embodiment of the present invention. The aerosol generating device 100 includes a cavity 102 into which a consumable item 104, such as a tobacco portion or a SIM card, may be inserted and which may be heated by a heater 106 of the device 100. The cavity 102 and heater 106 together may be considered the oven of the aerosol generating device 100.

[0021] The aerosol generating apparatus 100 also includes a gas supply device 108, which functions as an oxygen removal device or oxygen concentrator by supplying a gas having a lower amount of oxygen than ambient air to the cavity 102 through a gas conduit 110. In this particular example, the gas supply device 108 is an oxygen concentrator device, which will be described in more detail with reference to FIG. 2. However, as will be apparent to those skilled in the art, alternative gas supply techniques may be used to supply low-oxygen or oxygen-free gas to the oven. For example, a supply of non-oxygen gas, such as nitrogen, may be stored in a pressurized cylinder, allowing the gas to be released into the oven as needed. In another example, a solid and / or liquid material may be used that generates a non-oxygen gas when heated. Supplying low-oxygen or oxygen-free gas to the cavity 102 allows the inserted consumables 104 to be heated in a low-oxygen or oxygen-free environment, thereby reducing the likelihood of combustion or burning of the consumables 104.

[0022] When the consumable 104 received in the cavity 102 is heated, an aerosol is formed and directed to a user through a vapor conduit 112 of the aerosol generating device 100. The vapor conduit 112 may optionally be connected to a mouthpiece 114 through which the user inhales the generated aerosol. The vapor conduit 112 may also optionally include one or more holes 115 that allow air from outside the vapor conduit 112 of the aerosol generating device 100 to combine with the generated aerosol prior to inhalation by the user.

[0023] In this particular example, the aerosol-generating apparatus 100 also includes an oxygen supply conduit 116 that delivers oxygen removed from the ambient air by the gas supply device 108 to the vapor conduit 112. In another example, the oxygen supply conduit 116 may be connected to a refillable gas tank (not shown), or alternatively, the removed oxygen may simply be released by the gas supply device 108 back into the ambient air of the apparatus 100.

[0024] The aerosol generating device 100 further includes a control system including a microcontroller 118 connected to the puffing sensor 120, the heater 106, and the gas delivery device 108. The microcontroller 118 is configured to receive a signal from the puffing sensor 120 that a user is puffing through the mouthpiece 114. The microcontroller 118 is then further configured to send instructions to the gas delivery device 108 to deliver hypoxic or anoxic gas to the cavity 102 and to the heater 106 to generate heat to heat a consumable inserted into the cavity 102. The control system and the gas delivery device 108 should be sufficiently responsive to generate an appropriate amount of gas on demand and as needed when a user inhales or takes a puff from the device 100. In some examples, the control system may further include a puffing prediction algorithm that predicts and controls the generation and delivery of gas from the gas delivery device 108. In a further example, the control system may further include an accelerometer configured to send a trigger signal to the microcontroller 118 to initiate the gas delivery device 108 prior to (and as a result of) a user's puffing action, thereby advantageously minimizing the time lag between the user performing a puffing action and the gas delivery device 108 supplying gas to the cavity 102.

[0025] As will be appreciated by those skilled in the art, the heater 106, gas delivery device 108, and control system are powered by one or more power sources (not shown), such as batteries. The different components may all be powered from a single power source or may have several shared or separate power sources.

[0026] Figure 2 shows a schematic diagram of a gas supply device 200 according to the present invention. The gas supply device 200 is described below with reference to the aerosol generation apparatus 100 of Figure 1, although it will be understood that the same gas supply device 200 can be used in the other aerosol generation apparatuses 300, 400 described herein.

[0027] Oxygen concentrators for concentrating oxygen from received air by selectively removing nitrogen and providing an oxygen-enriched gas to a user are known in the art, typically in the medical field. Essentially, such devices (oxygen removers or oxygen concentrators) separate various gases in the air, such as oxygen or nitrogen, and direct them along various paths. The gas delivery device 200 of the present invention separates oxygen from received air, directs the remaining gases, and delivers the gas to the oven cavity 102 of the aerosol generating device 100.

[0028] The gas supply device 200 includes a separator 202, which may use pressure swing adsorption technology or membrane gas separation technology or other suitable gas separation technology, as will be apparent to those skilled in the art. The gas supply device 200 also includes an air inlet 204 and a first outlet 206, where the air inlet 204 receives air from outside the aerosol-generating device and directs it to the separator 202. The separator 202 removes oxygen from the received air to produce gas having a reduced oxygen concentration compared to the outside air / received air, and delivers the produced gas to the cavity 102 of the aerosol-generating device via a gas pipe 110.

[0029] The gas supply device 200 includes a second outlet 208 that directs oxygen removed from the received air along the oxygen supply pipe to the vapor pipe 112 of the aerosol generating apparatus 100, where the removed oxygen can be combined with the aerosol generated from the heated consumable 104 within the cavity 102 of the vapor pipe 112 before the combined aerosol and oxygen are inhaled by the user.

[0030] Figure 3 shows a schematic flow diagram of an aerosol generation device 300 according to another embodiment of the present invention. The aerosol generation device 300, similar to that described with reference to Figure 1, comprises a cavity 302 for an aerosol-forming consumable 304, a heater 306, and a gas supply device 308. The aerosol generation device 300 also includes a gas conduit 310 extending from the gas supply device 308 to the cavity 302, and a vapor conduit 312 extending from the cavity 302 to a mouthpiece 314, from which a user can inhale the aerosol generated from the heated consumable 304 in the cavity 302.

[0031] The aerosol generating device 300 also includes a gas tank 316 and an actuator 318 disposed along the gas conduit 310 between the gas supply device 308 and the cavity 302. The gas tank 316 stores the gas with a reduced concentration of oxygen or an oxygen-free gas produced by the gas supply device 308. The gas tank 316 may have a capacity for one or multiple vaping sessions of the aerosol generating device 300 according to design requirements.

[0032] The actuator 318 serves as a release mechanism for the gas tank 316 to control the flow of generated gas from the gas tank 316 to the cavity 302. As an example, the actuator 318 is a solenoid valve controlled by a microcontroller 320 of the aerosol generating device 300. The microcontroller 320 is also configured to control the heater 306 and to receive a signal from a puff sensor 322 when a user puffs from the device 300. In other words, when a user puffs from the mouthpiece 314, the puff sensor 322 disposed along the vapor conduit 312 detects the user's puffing and sends a signal to the microcontroller 320. The microcontroller 320 then operates the heater 306 and the actuator 318 to allow the low- or no-oxygen gas in the gas tank 316 to flow along the gas conduit 310, through the actuator 318 or valve, and into the cavity 302. Cavity 302 is heated by heater 306 such that consumable 304 received within cavity 302 generates an aerosol that is delivered to the user through vapor conduit 312 and mouthpiece 314. Microcontroller 320 can control heater 306 and actuator 318 simultaneously or sequentially according to design requirements. As will be appreciated by those skilled in the art, the temperature of heater 306 and cavity 302 may not reach a flammable temperature of the aerosol-forming consumable in the time it takes for low / oxygen-free gas to be supplied to cavity 302. In other words, the heating time of heater 306 may be shorter than the delivery time of gas from gas tank 316 to cavity 302, and sequential operation of actuator 318 and heater 306 may not be necessary.

[0033] The aerosol generating apparatus 300 also includes an oxygen supply tube 324 that delivers oxygen separated by the gas supply device 308 to the vapor tube 312. In another example, the oxygen supply tube 324 can be connected to a second gas tank (not shown), and oxygen can be supplied to the vapor tube 312 by a second actuator (not shown) in a manner similar to that described above. The vapor tube 312 can also have one or more holes 326 to allow outside air to enter the tube and mix with the aerosol generated from the cavity 302.

[0034] In this particular example of FIG. 3 , the aerosol generating device 300 is a single device. However, in another example, the device 300 may be divided into an aerosol generating device and a case (not shown), with the gas supply device 308 provided within the case and the aerosol generating device being a removable component from the case. In a removable device, the gas tank 316, control system, oven, and mouthpiece are part of the device, which can be reinserted into the case to recharge the gas tank. As will be apparent to those skilled in the art, a separate device and case system requires a different power supply configuration, where the gas supply device 308 within the case separately powers the components within the removable device. The device may also be configured to recharge the power supply of the removable device when the removable device is inserted into the case. An example of a two-component system is described below with reference to FIG. 4 .

[0035] 4 shows a schematic diagram of the control and airflow through an aerosol generation apparatus 400 according to another embodiment of the present invention. The apparatus 400 includes an aerosol generation device 402 and a gas supply device 404. The gas supply device 404 is housed in a case (not shown), into which the aerosol generation device 402 can be removably inserted. When the aerosol generation device 402 is inserted into the case, the aerosol generation device 402 is connected to the gas supply device 404 to receive the low / oxygen-free gas generated by the gas supply device 404.

[0036] The aerosol generation device 402 includes a gas tank 406 for receiving gas generated from a gas supply device 404 and a cavity 408 for receiving an aerosol-forming consumable 410. Gas stored in the gas tank 406 is supplied to the cavity 408 through a gas conduit 412, and the aerosol generation device 402 also includes a heater 414 for providing heat to the cavity 408 and the consumable 410 received within the cavity. The aerosol formed from heating the consumable 410 is delivered to a user through a vapor conduit 416. The vapor conduit 416 may optionally include one or more holes 415 to allow ambient air to combine with the generated aerosol before the generated aerosol is inhaled by the user through a mouthpiece 417.

[0037] The aerosol generating device 402 also includes a control system comprising a puffing sensor 418, a microcontroller 420, and an actuator 422, such as a solenoid valve. The control system operates in a manner similar to that described with reference to Figure 3, with the microcontroller 420 configured to receive a signal from the puffing sensor 418 that a user is performing a puffing action and to send one or more signals to operate the actuator 422 and the heater 414 to release gas from the gas tank 406 into the cavity 408 and heat the consumable product 410 inserted in the cavity 408, respectively. In this particular example, the aerosol generating device 402 does not include an oxygen delivery line, although it will be apparent to those skilled in the art that an oxygen storage and delivery system can also be incorporated into the aerosol generating device 402 in a manner similar to a low / no oxygen gas system.

[0038] 5A and 5B are schematic diagrams of different actuator systems that can be used in the aerosol generation system of the present invention.

[0039] 5A shows a mechanical pressure regulator system 500 having a diaphragm section 502 with an inlet 504 and an outlet 506. The inlet 504 is configured to draw generated gas from a gas tank of the aerosol generation system described above, and the outlet 506 is configured to deliver generated gas to a cavity of the aerosol generation system. The inlet 504 and the outlet 506 optionally have respective pressure gauges 508, 510.

[0040] The diaphragm section 502 includes an aperture 512, a screw handle 516 connected to a plug 518, and a pressure adjustment handle 514 including a spring 520 disposed between the handle 516 and the plug 518 and between the plug and the wall opposite the handle 516. The two springs 520 suspend the plug 518 through the aperture 512, with a first end 522 of the plug 518 configured to prevent airflow through the aperture 512 (and thus prevent generated gas from moving from the inlet 504 to the outlet 506 when the device is not in use / the user is not blowing). A second end 524 of the plug 518 is connected to a flexible diaphragm 526 within the diaphragm section 502, such that when the user blows, the diaphragm 526 and connecting plug 518 are displaced, allowing generated gas to flow from the inlet 504 to the outlet 506 (and into the cavity).

[0041] As will be appreciated by those skilled in the art, the screw handle 516 can adjust the height of the plug 518 to ensure that the plug 518 blocks the aperture 512 when the device is not in use and to set a desired user inhalation pressure for sufficient displacement of the plug 518.

[0042] FIG. 5B illustrates a solenoid valve actuator system 550, a type of electromechanical valve system. As described above, when a puff sensor sends a signal to a microcontroller, the microcontroller can operate the solenoid valve by drawing power from a power source 552 and generating an electromagnetic field across a solenoid coil 554. The electromagnetic field then moves a valve plunger 556 from a first, sealed position to a second, released position. When the plunger 556 is in the first position, generated gas is prevented from passing through the actuator system 550. When the plunger 556 is in the second position, generated gas flows from a gas tank within the aerosol generating device toward a cavity from a system inlet 558 to a system outlet 560.

Claims

1. 1. An aerosol generating device, comprising: a cavity configured to receive an aerosol-forming consumable; a heater configured to heat but not combust an aerosol-forming consumable received in the cavity, thereby generating an aerosol; a gas supply device including a separator, the gas supply device configured to remove oxygen from air using the separator to produce a gas having a reduced oxygen concentration compared to air and to supply the gas to the cavity; An aerosol generating device comprising:

2. 10. The aerosol generating device of claim 1, wherein the gas is substantially free of oxygen.

3. 3. The aerosol generating apparatus according to claim 1, further comprising a gas tank connectable to the gas supply device for receiving the gas having a reduced oxygen concentration compared to air.

4. 4. The aerosol generating apparatus according to claim 1, further comprising a second gas tank connectable to the gas supply device for receiving the removed oxygen.

5. 5. An aerosol generating device according to claim 1, further comprising an oxygen supply conduit configured to supply the removed oxygen to an airflow channel extending away from the heater within the cavity.

6. 6. The aerosol generating device of claim 5, wherein the oxygen supply conduit is configured to supply the removed oxygen to the airflow channel in the mouthpiece.

7. 7. The aerosol generating device of claim 1, further comprising an additional gas supply configured to supply a second gas having a reduced oxygen concentration compared to air to the cavity.

8. 8. The aerosol generating device of claim 7, wherein the second gas is nitrogen.

9. An aerosol generating device as described in any one of claims 1 to 8, further comprising a puffing action sensor connected to an actuator, the actuator configured to supply the gas to the cavity during inhalation as detected by the puffing action sensor.

10. 10. The aerosol generating device of claim 9, further configured to supply the removed oxygen to the airflow channel during inhalation as detected by the puffing action sensor.

11. 11. The aerosol generating device according to claim 9 or 10, wherein the actuator comprises a solenoid valve.

12. 12. The aerosol generating apparatus according to claim 1, further comprising an aerosol generating device and a case in which the aerosol generating device can be housed.

13. The aerosol generating device according to claim 12 , wherein the case contains the gas supply device.

14. 14. The aerosol generating device of any one of claims 1 to 13, further comprising an aerosol-forming consumable received in the cavity and positioned adjacent the heater.

15. 1. A method of generating an aerosol for user inhalation, comprising: receiving an aerosol-forming consumable within a cavity of an aerosol generating device; receiving air into a gas supply device of the aerosol generating apparatus; removing oxygen from the received air using a separator in the gas supply device to produce a gas having a reduced oxygen concentration relative to air; supplying the gas into the cavity; heating, but not burning, the aerosol-forming consumable by a heater in the aerosol generating device so as to generate the aerosol; A method comprising:

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