Aerosol Delivery Device

Abstract

The aerosol delivery device comprises a heater element having an outer diameter Dp, a volume Vp, and an outer surface area Sp, the heater element being configured to be inserted into an article, the article comprising a first cylindrical portion containing an aerosol-generating material, the first cylindrical portion having an outer diameter Dc, a volume Vc, and an outer surface area Sc, and Sc / Sp being at least 3.4.

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device, an aerosol delivery system, and a method for generating an aerosol. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these items by creating products that release compounds without burning. Examples of such products include so-called "heat-and-burn" products or tobacco heating devices or products that release compounds by heating rather than burning a material. The material can be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] Aerosol delivery systems, including the devices or products described above, are well known. Typical systems use a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. In many cases, the medium used must be replaced or changed to deliver a different aerosol for inhalation. It is known to use resistive heating systems as heaters to generate an aerosol from a suitable medium. Alternatively, it is known to use induction heating systems as heaters. Summary of the Invention

[0004] According to one aspect, a heater element having an outer diameter Dp, a volume Vp, and an outer surface area Sp, the heater element being configured to be inserted into an article, the article having a first cylindrical portion containing an aerosol-generating material, the first cylindrical portion having an outer diameter Dc, a volume Vc, and an outer surface area Sc; An aerosol delivery device is provided in which Sc / Sp is at least 3.4.

[0005] Optionally, the heater element comprises a pin-shaped heater element.

[0006] Optionally, the pin-shaped heater element comprises a cylindrical body and a conical tip.

[0007] Optionally, the pin-shaped heater element comprises an elongate body having a cavity and one or more heater coils disposed within the cavity.

[0008] Optionally, the heater element comprises a blade heater element.

[0009] Optionally, the blade heater element comprises one or more conductive or resistive tracks, which may comprise nichrome (Ni20Cr80).

[0010] Optionally, the heater element comprises a resistive heater element.

[0011] Optionally, the heater element comprises an induction heater element.

[0012] Optionally, Sc / Sp is in the range of 3.4 to 9.0.

[0013] Optionally, Sc / Sp is in the range of 5.0 to 9.0.

[0014] Optionally, Sc / Sp is in the range of 7.5 to 8.5.

[0015] Optionally, Vc / Vp is at least 31.0.

[0016] Optionally, Vc / Vp is in the range of 31.0 to 131.0.

[0017] Optionally, Vc / Vp is in the range of 81.0 to 131.0.

[0018] Optionally, Vc / Vp is in the range of 101.0 to 131.0.

[0019] Optionally, Vc / Vp,total is in the range of 11.0 to 16.0.

[0020] Optionally, Vc / Vp,total is in the range of 12.0 to 15.0.

[0021] Optionally, Vc / Vp,total is in the range of 13.0 to 14.0.

[0022] Optionally, Dc / Dp is at least 2.6.

[0023] Optionally, Dc / Dp is in the range of 2.6 to 6.0.

[0024] Optionally, Dc / Dp is in the range of 4.0 to 5.8.

[0025] Optionally, Dc / Dp is in the range of 4.5 to 5.5.

[0026] The aerosol supply device can further comprise a controller configured to control the heater element during a use session. During the use session, the controller is configured to control the heater element to heat to a first target operating temperature T1 during a first time period t0 - t1, to heat to a second target operating temperature T2 during a second time period t1 - t2, to heat to a third target operating temperature T3 during a third time period t2 - t3, and to heat to a fourth target operating temperature T4 during a fourth time period t3 - t4. Optionally, the times are t0 < t1 < t2 < t3 < t4 and the temperatures are T1 > T2 > T3 > T4. Optionally, T4 ≥ 300°C.

[0027] According to another aspect, the above-described aerosol supply device, and an article containing an aerosol-generating material comprise an aerosol supply system is provided.

[0028] Optionally, the article comprising the aerosol-forming material may comprise band-cast reconstituted tobacco.

[0029] According to another aspect, there is provided a method of generating an aerosol, comprising the steps of: providing an aerosol delivery device as described above; at least partially inserting an article including an aerosol-generating material into a receiving portion of a heating chamber of an aerosol delivery device; activating the aerosol delivery device to generate an aerosol from the article; A method is provided which includes:

[0030] The aerosol delivery device can include a controller configured to set a target operating temperature for the heater element according to a heating profile. The heating profile can include an initial first target operating temperature, which can then be gradually decreased over the course of a use session or aerosol generation session. In particular, the heating profile can have a profile that can be configured to decrease the desired operating temperature set for the heater element in a series of steps, for example, four steps, over the course of a use session or aerosol generation session. A heating profile with, for example, four steps of decrease over time can correspond to a first standard or regular operating mode known as a “base” operating mode. When the aerosol delivery device is operating in the first or base operating mode, the aerosol generation session can be configured to last, for example, 300 seconds (5 minutes).

[0031] According to various embodiments, a use session can begin at time t0 and can end at time t4, when the controller can switch the heater element OFF. After a use session begins at time t0, there can be a rise time or time to first puff before aerosol can be generated. The rise time or time to first puff can end at time t_start. An aerosol generation session can be considered to begin at time t_start and end at time t4, when, for example, the heater element can be switched OFF.

[0032] The aerosol delivery device can be operated in a second operating mode known as a "boost" operating mode. When the aerosol delivery device operates in the second or boost operating mode, the use session and corresponding aerosol generation session duration can be shorter. For example, the length of the aerosol generation session can be shortened, for example, to 180 seconds (3 minutes). According to various embodiments, during the first and / or second operating modes, the temperature set for the heater element can remain ≥ 300°C throughout the use session (and thus throughout the aerosol generation session). The maximum operating temperature of the heater element during the use session (and thus during the aerosol generation session) can be higher when the aerosol delivery device operates in the second or boost operating mode compared to the maximum operating temperature of the heater element when operating in the first or base operating mode. According to various embodiments, the maximum operating temperature can be approximately 350°C. According to various embodiments, the controller can be configured to attempt to maintain the temperature of the heater element in the range of 300-350°C during the use session.

[0033] The heater element may be configured to heat the aerosol product internally, or alternatively, the heater element may be configured to heat the aerosol product externally.

[0034] The aerosol delivery device can include a power source, a controller, and a heating chamber in which the aerosol product article is removably received. The aerosol delivery device can be configured for wireless charging.

[0035] The aerosol delivery device can include one or more indicating or notifying devices to instruct or notify a user, for example, after an initial rise time, when the heater element has reached a desired operating temperature, and / or when the aerosol delivery device is ready for use. For example, the one or more indicating or notifying devices can be configured to be activated or change state at time t_start, i.e., after the initial rise time or time to first puff.

[0036] An aerosol delivery system can be provided that includes the aerosol delivery device described above in combination with a charging unit. The charging unit can include a cavity for removably receiving the aerosol delivery device. The charging unit can include a movable cover configured to cover the aerosol delivery device in a closed configuration. The charging unit can include a user display. The user display can be visible to a user when the movable cover is in a closed position and can be partially or completely hidden or obscured from view by the cover when the cover is in an open position.

[0037] The aerosol delivery device can include a controller and a user interface. The user interface can be activated by a user to operate the aerosol delivery device in a first (e.g., base) operating mode, the controller being configured to control the heater element such that the heater element is heated to a series of target operating temperatures according to a first heating profile as a function of time. The user interface can also be activated by a user to operate the aerosol delivery device in a second (e.g., boost) operating mode, the controller being configured to control the heater element such that the heater element is heated to a series of target operating temperatures according to a second, different heating profile as a function of time. The first heating profile is a heating profile for a total duration t 1total and the heater element can be associated with a usage session having a minimum target operating temperature T 1min and maximum target operating temperature T 1max The second heating profile can be set for a total duration of t 2total and the heater element can be associated with a usage session having a minimum target operating temperature T 2min and maximum target operating temperature T 2max The target operating temperature can be set between t_start and t_start. The duration of the aerosol generation session can correspond to the time period after the initial time (or rise time) to the first puff, i.e., from time t_start onwards, until the time corresponding to the end of the aerosol generation session, at which no aerosol is intended to be generated. At the end of the aerosol generation session, the controller can set the heater element to a target operating temperature, e.g., 20°C, that is too low to generate aerosol. At the end of the aerosol generation session, the heater element can be switched OFF, i.e., zero current can be supplied to the heater element. According to various embodiments, t 1total >t 2total , and / or T 2max >T 1max , and / or T 2min >T 1min According to various embodiments, T1min ≧300℃, and / or T 2min ≧300°C.

[0038] The aerosol delivery device may further include a temperature sensor for monitoring or sensing the temperature of the heater element during a use session or an aerosol generation session. The temperature sensor may include a thermocouple, a thermopile, or a resistance temperature detector (“RTD”), which may also be referred to as a resistance thermometer. Temperature data measured by the temperature sensor may be communicated to a controller. In particular, the controller may be configured to vary the supply of power to the heater element when the temperature sensor determines that the heater element has reached a target operating temperature (e.g., T1, T2, T3, or T4) at some point during the use session. The controller may be configured as a proportional-integral-derivative (“PID”) controller that controls the temperature of the heater element based on data, information, or signal(s) provided by one or more temperature sensors using a control feedback loop mechanism.

[0039] The article containing the aerosol-generating material may include a capsule that can be broken to introduce additional flavorings or other agents into the aerosol generated in the aerosol-generating portion of the article. The article may include one or more filters, which may comprise, for example, cellulose acetate. The article may include one or more vent holes formed through the outer layer of the article to assist in cooling the article. The vent hole or holes may be located less than 5 mm from the proximal (mouth) end of the article.

[0040] Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings. [Brief explanation of the drawings]

[0041] [Figure 1]FIG. 1 is a perspective view of an aerosol delivery system including an aerosol delivery device located within a charging unit, the aerosol delivery device including a heater element. [Figure 2] 2 is a schematic cross-sectional view of a portion of the aerosol delivery device shown in FIG. 1, wherein the aerosol delivery device includes a pin-shaped heater element. [Figure 3] 2 is a schematic cross-sectional view of a portion of the aerosol delivery device and aerosol product shown in FIG. 1, with a pin-shaped heater element shown inserted into the distal end of the aerosol product. [Figure 4] FIG. 10 is a perspective view of another embodiment of a stand-alone aerosol delivery device in which the aerosol delivery device can be charged directly rather than being charged by an inserted charging unit. [Figure 5] FIG. 5 is a schematic cross-sectional view of the aerosol delivery device shown in FIG. 4, illustrating that the aerosol delivery device can be equipped with a pin-shaped heater element, which can be inserted into the distal end of the aerosol product during use. [Figure 6] 1 is a schematic cross-sectional view of a pin-shaped heater element that can be used to heat an aerosol product according to various embodiments. FIG. [Figure 7A] FIG. 1 illustrates a stand-alone or integrated aerosol delivery device according to one embodiment, showing an aerosol product article partially inserted into the heating chamber of the aerosol delivery device. [Figure 7B] A cross-sectional view of the internal details of the aerosol delivery device shown in Figure 7A, showing a pin-shaped heater element inserted into the distal end of a cylindrical aerosol product product, the aerosol product having a first portion and a further portion, with the pin-shaped heater element shown inserted into the first portion of the aerosol product product. [Figure 8A] FIG. 1 shows a first computer-aided design (“CAD”) model of a pin-shaped heater element surrounded by a first cylindrical portion of an aerosol production article. [Figure 8B]FIG. 1 shows a simplified second CAD model utilized in computational fluid dynamics ("CFD") simulations, in which the consumables are modeled as being held in a consumable holder, and are equipped with pin-shaped heater elements, with multiple air inlets provided in the base portion of the consumable holder. [Figure 9] FIG. 1 shows the heating profile utilized in various computational fluid dynamics (CFD) simulations, where the heating profile shows the temperature modeled as attained by a pin-shaped heater element over the course of a simulation modeled to last 300 seconds (5 minutes), and where the heating profile includes four stages of temperature reduction over the course of the simulation. [Figure 10] FIG. 1 shows a pin heater element modeled in CAD to enable various CFD simulations to be performed, with a coil heater element modeled as being located within the pin heater element, the pin heater element having a diameter Dp and a wall thickness Tp, the length of the pin modeled as Lp with the coil heater element displaced a distance Lh from a reference point, and a cylindrical consumable portion modeled as surrounding the pin heater element, the cylindrical consumable portion modeled as having a length Lc and a diameter Dc. [Figure 11] 11 is a table showing various parameters of the pin heater element shown in FIG. 10 along with the minimum and maximum values ​​of the parameters used in various CFD simulations. [Figure 12] FIG. 12 shows images from CFD simulations of a pin heater element and consumables modeled with reference to the parameters shown in FIGS. 10 and 11, from which the thermal efficiency ε for the consumables can be determined. [Figure 13A] FIG. 10 shows how CFD simulations determined that the thermal efficiency ε for the consumable, based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable, varies as a function of the ratio of the diameter of the consumable (Dc) to the diameter of the pin-shaped heater element (Dp). [Figure 13B] FIG. 10 shows how CFD simulations determined that the thermal efficiency ε for the consumable varies as a function of the ratio of the volume of the consumable (Vc) to the volume of the pin-shaped heater element (Vp), based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable. [Figure 13C] FIG. 10 shows how CFD simulations determined that the heating efficiency ε for the consumable, based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable, varies as a function of the ratio of the surface area of ​​the consumable (Sc) to the surface area of ​​the pin-shaped heater element (Vp). [Figure 13D] FIG. 10 shows how CFD simulations determined that the thermal efficiency ε for the consumable varies as a function of the ratio of the volume of the consumable (V) to the volume of the pin heater element (V,total), based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable. [Figure 14] 10A-10C are side cross-sectional views of an aerosol product article partially inserted into a receiving portion or recess of an aerosol delivery device according to various embodiments, wherein the aerosol delivery device includes a pin-shaped heater element. [Figure 15] 15 is a cross-sectional view of the aerosol product shown in FIG. 14 taken along line AA' shown in FIG. 14. DETAILED DESCRIPTION OF THE INVENTION

[0042] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the component aerosol-generating materials of the aerosol delivery system (or its components) are not burned or combusted to facilitate delivery of at least one substance to a user.

[0043] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0044] In some embodiments, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0045] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0046] In some embodiments, the non-combustible aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0047] Typically, a non-combustible aerosol delivery system can include a non-combustible aerosol delivery device and a consumable item for use with the non-combustible aerosol delivery device.

[0048] In some embodiments, the non-combustible aerosol delivery device can include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0049] In some embodiments, a consumable for use with a non-flammable aerosol delivery device can include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material delivery component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0050] As used herein, the term "aerosol-forming material" refers to a material capable of generating an aerosol when, for example, heated, irradiated, or activated in any other way. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (such as a gel) form, and may or may not contain active substances and / or flavorings.

[0051] The aerosol-generating material may include one or more active agents and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0052] The aerosol-generating material may include an adhesive, such as a gelling agent, and an aerosol-forming material. Optionally, a substance to be delivered and / or a filler material may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0053] The aerosol-generating material can include or be in the form of an aerosol-generating film. The aerosol-generating film can include an adhesive, such as a gelling agent, and an aerosol-forming material. Optionally, a substance to be delivered and / or a filler material can be present. The aerosol-generating film can be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0054] The aerosol-generating film can have a thickness of from about 0.015 mm to about 1 mm. For example, the thickness can range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0055] The aerosol-generating film can be continuous. For example, the film can include or be a continuous sheet of material. The sheet can be in the form of a wrapper, can be pleated to form a pleated sheet, or can be chopped to form a chopped sheet. The chopped sheet can include one or more strands or strips of aerosol-generating material.

[0056] The aerosol-generating film can also be discontinuous. For example, the aerosol-generating film can include one or more discrete portions or regions of aerosol-generating material, such as dots, strips, or lines, which can be supported on a support. In such embodiments, the support can be planar or non-planar.

[0057] The aerosol-generating film can be formed by combining an adhesive, such as a gelling agent, with one or more other components, such as a solvent, such as water, an aerosol-forming material, and one or more substances to be delivered, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent and form the aerosol-generating film.

[0058] The aerosol delivery device can receive an article containing an aerosol-forming material for heating. In this context, an "article" is a component that, when used, contains or contains the aerosol-forming material, and, when heated, volatilizes the aerosol-forming material and optionally other components. A user can insert the article into or onto the aerosol delivery device, which is then heated to generate an aerosol that the user then inhales. The article can be, for example, of a predetermined or specific size configured to be placed in or on the heater of the device, sized to receive the article.

[0059] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator can be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0060] A consumable is an article containing or consisting of an aerosol-generating material, where some or all of the aerosol-generating material is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that releases heat during use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0061] The susceptor is a heating material that can be heated by immersion in a varying magnetic field, such as an alternating magnetic field. The susceptor can be a conductive material, such that immersion of the susceptor in the varying magnetic field causes induction heating of the heating material. The heating material can be a magnetic material, such that immersion of the heating material in the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor can be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. The susceptor can also be solely magnetic or solely conductive. An aerosol delivery device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0062] The non-combustible aerosol delivery system can comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some implementations, the non-combustible aerosol delivery device can comprise a power source and a controller (or control circuitry). The power source can include, for example, a power source such as a battery or a rechargeable battery. In some implementations, the non-combustible aerosol delivery device can also comprise the aerosol generating components. However, in other implementations, the aerosol product article can comprise, in part or entirely, the aerosol generating components.

[0063] The present disclosure relates to an aerosol delivery device, described below with reference to FIGS. 1-6 . The aerosol delivery device can include a controller and a heater element, such as a pin-shaped heater element. The controller can be configured to set a series of different target operating temperatures for the heater element according to a heating profile, such as the heating profile shown in FIG. 9 . According to various embodiments, the aerosol delivery device includes a heater element having an outer diameter Dp, a volume Vp, and an outer surface area Sp, the heater element configured to be inserted into an article, the article including a first cylindrical portion containing an aerosol-generating material, the first cylindrical portion having an outer diameter Dc, a volume Vc, and an outer surface area Sc. It has been recognized that various optimal ratios for the above parameters exist. For example, according to various embodiments, CFD simulations have shown that when Dc / Dp is at least 2.6, the heating efficiency ε for the consumable is 0.05 to 0.05. c It is shown that optimal performance is achieved in terms of Vc / Vp. Similarly, it has been found to be optimal that Vc / Vp should be at least 31.0. Additionally, it has been found to be optimal that Sc / Sp should be at least 3.4.

[0064] 1 shows an aerosol delivery system 10 comprising an aerosol delivery device 100 and a charging unit 101. The device is shown positioned within a cavity of the charging unit 101. The aerosol delivery device 100 is configured to generate an aerosol from an aerosol-producing article that can be inserted into the aerosol delivery device 100 during use. The aerosol delivery device 100 and the article can together form part of the aerosol delivery system 10.

[0065] As discussed in more detail below, aerosol delivery device 100 includes a heater element. For example, aerosol delivery device 100 can include a pin-type heater element, as described in more detail below. The aerosol delivery device can further include a controller that can be configured to control the heater element during a use session. During a use session, the controller can be configured to control the heater element to a first target operating temperature T1 during a first time period t0-t1, a second target operating temperature T2 during a second time period t1-t2, a third target operating temperature T3 during a third time period t2-t3, and a fourth target operating temperature T4 during a fourth time period t3-t4. According to various embodiments, the controller can be configured to decrease the target operating temperature during a use session. For example, temperatures T1 > T2 > T3 > T4. According to embodiments, T4 ≧ 300°C. Thus, the controller can be configured to cause the heater element to heat to a series of target operating temperatures during a use session, with the target operating temperatures decreasing progressively over time. For example, the heater element may be controlled by the controller to follow a heating profile in which the target operating temperature is reduced four times during a use session. According to an embodiment, the target operating temperature of the heater element during a use session may always be ≧300° C.

[0066] At an initial time t0, the aerosol delivery device 100 and heater element may be at ambient temperature, for example, 20° C. Other embodiments are contemplated in which a previous aerosol generation session has been performed and the temperature of the heater element has decreased to a temperature <50° C. Thus, at the initial time t0, the heater element may be at a temperature <50° C.

[0067] Aerosol delivery device 100 can have an elongated structure extending along a longitudinal axis. Aerosol delivery device 100 has a proximal end that is closest to a user (e.g., a user's mouth) when used by the user to inhale the aerosol generated by aerosol delivery device 100. Aerosol delivery device 100 also has a distal end that is farthest from a user when in use. The proximal end may also be referred to as the "mouth end." Aerosol delivery device 100 has an opening that leads to a heating chamber.

[0068] Aerosol delivery device 100 can be removably inserted into charging unit 101 for charging. However, as discussed in more detail below, aerosol delivery device can also include a stand-alone aerosol delivery device that can be charged directly without requiring charging unit 101 to recharge the aerosol delivery device.

[0069] Charging unit 101 includes a cavity for receiving aerosol delivery device 100. Aerosol delivery device 100 can be inserted into the cavity of charging unit 101 through an opening. The cavity of charging unit 101 can include a longitudinal opening. A portion of aerosol delivery device 100 can include a first side. One or more user-operable controls, such as buttons 106, can be provided on the first side of aerosol delivery device 100 that can be activated to operate aerosol delivery device 100 (particularly to select a desired mode of operation). The first side of aerosol delivery device 100 can be received in the longitudinal opening provided in charging unit 101.

[0070] The cavity of the charging unit 101 can have a cross-sectional profile that only allows the aerosol delivery device 100 to be inserted into the charging unit 101 in a single orientation. The outer profile of the aerosol delivery device 100 can include an arcuate portion and a linear portion. The cross-sectional profile of the cavity in the charging unit 101 can also include similar arcuate and linear portions. The linear portion of the cross-sectional profile of the cavity can correspond to the longitudinal opening. The charging unit 101 can include a slidable cover 103. When the aerosol delivery device 100 is inserted into the charging unit 101 for recharging, the slidable cover 103 can close to cover the opening to the aerosol delivery device 100. In other embodiments, the charging unit 101 can have an alternative cover configuration, such as a hinged or pivoting cover, or can be provided without a cover. The charging unit 101 can include a user interface, such as a display 108, which can be provided in any convenient location, such as the location shown in FIG. 1 .

[0071] FIG. 2 shows a cross-sectional view of a portion of an aerosol delivery device 100 according to various embodiments. The aerosol delivery device 100 includes a main housing 200. The main housing 200 defines a device body of the device 100. The aerosol delivery device 100 defines a heating chamber 201. A receptacle 205 defining the heating chamber 201 can be provided. An opening 203 can be provided to provide access to the heating chamber 201. The receptacle 205 can include a receptacle sidewall 205a and a receptacle base 205b. The receptacle base 205b can be provided at a distal end of the receptacle 205. A heating region 201a configured to receive at least a portion of the aerosol product can be provided. A heater element 301 can be provided in a portion of the main housing 200, and the heater element 301 can extend or protrude into the heating chamber 201. Heater element 301 can include a base portion 301 a that can be positioned within a recess in a portion of the body of aerosol delivery device 100 .

[0072] The heater element 301 may comprise an elongated heater element, such as a pin-shaped heater element 301. The pin-shaped heater element 301 may comprise a metal, such as stainless steel or aluminum. Alternatively, the pin-shaped heater element 301 may comprise a ceramic material. Other embodiments are also contemplated in which the heater element may comprise a blade-shaped heater element (not shown). In use, the heater element 301 may be inserted into the distal end of the aerosol product article, which is received within the heating chamber 201 for heating the aerosol product article therein.

[0073] The housing 200 may include a housing wall 200a. The housing wall 200a may extend along a longitudinal axis of the aerosol delivery device 100 and may surround the heating chamber 201. The housing wall 200a may at least partially define a receiving chamber of the aerosol delivery device 100 as a volume enclosed within the wall 200a. The housing 200 may include a housing base 200b at a distal end of the housing wall 200a. The heater element 301 may be configured to stand upright from the housing base 200b. The heater element 301 may be configured to protrude through the receptacle base 205b. An opening 206 may be formed in the receptacle base 205b, and the heater element 301 may protrude through the opening 206. The heater element 301 may be attached to the receptacle base 205b.

[0074] The aerosol delivery device 100 may optionally include a removal mechanism 204 that may be removably retained on the main housing 200 of the aerosol delivery device 100. However, according to other embodiments, the removal mechanism 204 may be omitted. The removal mechanism 204 may include a tubular wall portion 207a and a base wall portion 207b. After an aerosol generation session is completed, the removal mechanism 204 may be removed from the main housing 200 of the aerosol delivery device 100. When the removal mechanism 204 is removed, the base wall portion 207b of the removal mechanism 204 may be configured to engage the distal end of an article located on the pin-shaped heater element 301, such that when the removal mechanism is removed, the base wall portion 207b of the removal mechanism removes the used aerosol product article from the heater element 301. As a result, the removal mechanism 204 may assist in removing the used aerosol product article from a heater element, such as the pin-shaped heater element 301.

[0075] FIG. 3 shows the distal end of an article 50 containing aerosol-forming material positioned on a pin-shaped heater element 301 of an aerosol delivery device 100 .

[0076] FIG. 4 illustrates an integrated aerosol delivery device 400 for generating an aerosol from an article 50 containing an aerosol-generating material. The aerosol delivery device 400 includes an elongated housing 500 that surrounds and houses various components of the aerosol delivery device 400. The aerosol delivery device 400 has an opening 504 at one end through which the article 50 can be inserted for heating by the aerosol delivery device 400. The article 50 can be fully or partially inserted into the aerosol delivery device 400 for heating by the aerosol delivery device 400. The aerosol delivery device 400 can include a user-operable control element 506, such as a button or switch, to operate the aerosol delivery device 400. For example, a user depresses the user-operable control element 506 to place the aerosol delivery device 400 in a first operating mode or a second operating mode. Aerosol delivery device 400 defines a longitudinal axis 509 along which article 50 can extend when inserted into aerosol delivery device 400. Opening 504 is aligned with longitudinal axis 509.

[0077] As discussed in more detail below, the aerosol delivery device 400 can be operated in a first or base operating mode, in which the desired operating temperature of the heater element can be configured to decrease in a series of steps, e.g., four steps, over the course of an aerosol generation session, which can last, e.g., 300 seconds (5 minutes). The aerosol delivery device 400 can also be operated in a second or boost operating mode, in which the desired operating temperature of the heater element can also be configured to decrease in a series of steps, e.g., four steps, over a shorter period of time. For example, an aerosol generation session can be configured to last, e.g., 180 seconds (3 minutes) in the second or boost operating mode. The maximum operating temperature of the heater element during a use session or aerosol generation session can be higher when the aerosol delivery device operates in the second or boost operating mode.

[0078] FIG. 5 shows a schematic cross-sectional view of an aerosol supply device 400, in which an aerosol generating article 50 is received in a heating chamber of the aerosol supply device 400. The aerosol supply device 400 includes a power source 410, a controller 420, and a heating chamber 401, and the aerosol generating article 50 is removably received in the heating chamber 401. The aerosol supply device 400 further includes a heater element. The heater element can include a heater element 301. The controller 420 is configured to control the heater element 301 to heat to a first target operating temperature T1 during a first time period t0-t1, to heat to a second target operating temperature T2 during a second time period t1-t2, to heat to a third target operating temperature T3 during a third time period t2-t3, and to heat to a fourth target operating temperature T4 during a fourth time period t3-t4. The temperature is T1>T2>T3>T4, and the time is t0<t1<t2<t3<t4. The heater element 301 can be inserted into the distal end of the aerosol generating article 50 during use, and the aerosol generating article 50 is received in the heating chamber 401 to heat the aerosol generating article 50 internally.

[0079] The aerosol delivery device 400 can include a resistive heater element, such as a resistive heating coil, configured to be activated to heat the heater element 301. An electric current can be applied directly to the resistive heater element, causing the resulting current flow through the heater element to heat the heater element by Joule heating. The resistive heater element can include a resistive material configured to generate heat when a suitable electric current passes through it. The aerosol delivery device 400 can further include electrical contacts for supplying electric current to the resistive material. The resistive heater element can be configured to transfer thermal energy to the heater element 301 by conduction. Similarly, the heater element 301 can transfer thermal energy to a portion of the aerosol product article 50 by conduction. Providing a resistive heating component can enable a compact component, thereby facilitating miniaturization of the device. Furthermore, using a resistive heater element, such as the pin-shaped heater element 301 inserted into the distal end of the aerosol product article 50, to heat a portion of the aerosol product article can minimize heat loss and therefore achieve high energy efficiency.

[0080] FIG. 6 illustrates a heater element 301 in more detail according to various embodiments. The heater element 301 includes an elongated housing 302 having an internal void 308 or cavity and a resistive heater element 350 located within the internal void 308 or cavity. The elongated housing 302 can be formed from a thermally conductive material such as aluminum or stainless steel. The elongated housing 302 can include a coating on its exterior surface. The elongated housing 302 is configured to transfer heat from the resistive heater element 350 to the aerosol product. The elongated housing 302 has a base end 303 and a free end 304. The base end 303 can be attached to the heating chamber. The base end 303 can include a mount 305 for securing the heater element 301. The elongated housing 302 can include a groove 302a or a region of reduced cross-sectional diameter toward the base end 303 of the elongated housing 302. The grooves 302a or areas of reduced cross-sectional diameter can act as a thermal barrier to reduce heat radiation from the heater element 301 into the mount 305, or more generally to the attachment point. The inner void 308 can be at least partially filled, for example with a filler material.

[0081] The filling material can include one or more of (i) a potting compound, (ii) an adhesive, (iii) a thermosetting plastic, or (iv) an epoxy resin. For example, the inner cavity can be at least partially filled with an insulating material. The insulating material can be a potting compound, an adhesive, a thermosetting plastic, or an epoxy resin. The potting compound can include an epoxy resin. For example, a two-part epoxy can be used, consisting of a polymer resin and a hardener, which, when mixed together, causes a chemical reaction that crosslinks chemical bonds within the polymer chains to produce a tough, rigid, and strong compound. The potting compound can alternatively include polyurethane ("PU"), e.g., a thermosetting plastic. This can include a two-part compound consisting of a base resin with an isocyanate curing agent. Alternatively, the potting compound can include a silicone. For example, a silicone rubber can be utilized, which includes a synthetic polysiloxane polymer that uses an added catalyst (e.g., platinum) to transition from a liquid to a solid state.

[0082] The heater element 311 has a tip 311 that extends to an apex 312. The resistive heater element 350 may include a heating coil 351. The heating coil 351 may include an electrically insulating coating, such as a ceramic, to electrically insulate the heating coil 351 from the elongated housing 302. Electrical connection paths may extend from each end of the heater element 350. A base electrical connection path 352 may extend from the distal end of the heater element 350. A return electrical connection path 353 may extend from the proximal end of the heater element 350. The heating coil 351 may be formed from a resistive material such as a nickel / chromium alloy, such as Nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0083] 7A illustrates a stand-alone or integrated aerosol delivery device 400 according to one embodiment. An aerosol product item 50 is shown partially inserted into the heating chamber of the aerosol delivery device 400.

[0084] FIG. 7B shows a cross-sectional view of the internal details of the aerosol delivery device 400 shown in FIG. 7A, illustrating a pin-shaped heater element 801 inserted into the distal end of a cylindrical aerosol product article. As discussed in more detail below with reference to FIGS. 14 and 15, the aerosol product article can comprise multiple portions, i.e., the aerosol product article can comprise a first portion, a second portion, and optionally a third portion. The aerosol product article can also comprise a fourth portion. The first portion can be located at the distal end of the aerosol product article. The second portion, and the optional third and fourth portions, can be located upstream of the first portion. According to various embodiments, the aerosol product article can comprise a first (distal) portion, a second (middle) portion, a third (intermediate) portion, and a fourth (proximal) portion. At least one of the second, third, or fourth portions can include a filter. At least one of the second, third, or fourth portions can include a vent. At least one of the second, third, or fourth portions can include a breakable capsule that can be broken to introduce additional flavoring or other agents into the aerosol generated in the aerosol-generating portion of the aerosol product, e.g., the first portion of the aerosol product. The fourth portion can include a mouth end through which a user can inhale the aerosol. A pin-shaped heater element 301 is shown inserted into the first portion of the aerosol product. The first portion of the aerosol product can include an aerosol-generating material 801.

[0085] FIG. 8A shows a first computer-aided design (“CAD”) model of a pin-shaped heater element 301, which was modeled as being hollow and having a coil-shaped heater element 802 located within the cavity formed by the pin-shaped heater element 301. The pin-shaped heater element 301 was modeled as having a hollow body with a first cylindrical body portion and a tip portion. The coil-shaped heater element 802 was modeled as being located within the cylindrical body portion of the pin-shaped heater element 301. The cylindrical body portion of the pin-shaped heater element 301 was modeled as having a wall thickness of 200 μm. The interior of the pin-shaped heater element 301 was modeled as being filled with a filter material. According to the first CAD model, the pin-shaped heater element 301 was modeled as being surrounded by the first cylindrical portion of the aerosol product.

[0086] 8B shows a simplified second CAD model utilized in various computational fluid dynamics ("CFD") simulations. The second simplified second CAD model was modeled as including a consumable held in a consumable holder 803. The pin-type heater element 301 was modeled as including a coil heater element 802. Multiple air inlets 805 were modeled as being provided in the base portion of the consumable holder 803.

[0087] It is understood that computational fluid dynamics (CFD) is a scientific simulation technique capable of providing spatially and temporally resolved predictions of complex physical problems involving fluid dynamics. A preprocessing step can be performed, and a computer-aided design (CAD)-created model can be used to define the geometry and physical boundaries of the problem. After the initial CAD model is created, the data can be suitably processed (i.e., cleaned up), and fluid volume data (or fluid domain) can be extracted. The volume occupied by the fluid can be divided into individual cells, which can be referred to as a mesh. A mesh can be uniform or non-uniform. A mesh can be structured or unstructured. A mesh can include a combination of hexahedral, tetrahedral, prismatic, pyramidal, or polyhedral elements. Physical modeling can then be defined, for example, by inputting various equations of fluid motion and other equations, for example, related to heat flow, and various boundary conditions can be defined. The process of establishing boundary conditions can involve specifying fluid behavior and properties at all boundary surfaces of the fluid domain. Initial conditions can also be defined for transient problems. A simulation can then be initiated, and various physical modeling equations can be iteratively solved, either steady-state or transient. The simulation data can then be post-processed to aid in the analysis and visualization of the resulting solutions.

[0088] FIG. 9 shows the heating profile established for the heater element modeled in FIG. 8B above, and a series of computational fluid dynamics ("CFD") simulations involving dynamic modeling of the heater element and consumables were performed. The overall session time for the heater profile shown in FIG. 9 used in the CFD simulations was 300 seconds (i.e., 5 minutes). The heating profile was modeled as having four gradual decreases in time during the use session, while the temperature was maintained at ≧300° C. during the use session.

[0089] According to this model, the heater element can be modeled as taking several seconds to acquire a first desired target operating temperature (e.g., 350° C.) At the end of the simulation, the heater element was modeled to assume a temperature of 0° C.

[0090] Time t0 can correspond to the time the model assumes the heater element is switched ON. According to the heating profile shown in FIG. 8, the heater element acquires a first operating temperature T1 over time period t0-t1. The heater element is then modeled as being set to a second, lower operating temperature T2 over time period t1-t2. The heater element is then modeled as being set to a third, lower operating temperature T3 over time period t2-t3. Finally, the heater element is modeled as being set to a fourth and final operating temperature T4 over time period t3-t4. The entire time period t0-t4 was modeled as 300 seconds (5 minutes). The heating profile shown in FIG. 8 can be considered to comprise a base heating profile, in which the heater element is modeled assuming a temperature ≧300°C throughout the entire simulated use session.

[0091] While FIG. 9 illustrates a heating profile used for simulation purposes, it will be understood that aerosol delivery devices according to various embodiments can be activated by a user at time t0 to cause the controller to set the heater element to a desired heating profile. For example, a user can activate a user interface (e.g., see user interface 106 shown in FIG. 1 ) provided on the aerosol delivery device to cause the heater element to follow the desired heating profile during a use session. After the user interacts with the user interface and the controller sets the desired heating profile for the heater element, there may be a short time delay before the heater element reaches the desired operating temperature and is capable of generating sufficient aerosol from an aerosol product article at least partially inserted into the aerosol delivery device. This time delay may be referred to as the rise time or time to first puff and may be approximately 10 to 20 seconds.

[0092] FIG. 10 shows how the pin-type heater element 301 was modeled in CAD to enable various CFD simulations to be performed. According to the CAD model, the coil heater element was modeled as being located within the pin-type heater element. The pin-type heater element was modeled as having a diameter Dp and a wall thickness Tp. The length of the pin-type heater element was modeled as being Lp. The coil heater element was modeled as being displaced a distance Lh from a reference point. A cylindrical consumable portion was modeled as surrounding the pin-type heater element 301. The cylindrical consumable portion was modeled as having a length Lc and a diameter Dc.

[0093] FIG. 11 shows a table illustrating various parameters of the pin-type heater element shown in the CAD model illustrated and described above with reference to FIG. 10. The parameter table includes, in the penultimate column, the minimum value of the parameter used in the various CFD simulations. The parameter table also includes, in the final column, the maximum value of the parameter used in the various CFD simulations. For example, in the various CFD simulations performed, the diameter of the pin-type heater element was varied in the different CAD models used in the CFD simulations. For example, CFD simulations were performed where the pin-type heater element diameter was modeled as being in the range of 1.5 to 2.6 mm.

[0094] FIG. 12 shows images from CFD simulations of the pin heater element 301 and consumable 801 modeled with reference to the parameters shown in FIGS. 10 and 11, and the thermal efficiency ε for the consumable from these CFD simulations. c It is shown that the thermal efficiency of consumables ε can be determined. c is the sensible heat stored within the consumable material (e.g., cigarette) h c and the total amount of sensible heat that is distributed in the system before and after the initial heating phase, h total This is reflected by the following equation:

[0095]

number

number

[0096] Therefore, the appreciable heat applied to the consumable material (eg, tobacco) during the initial heating phase leading up to the first puff was modeled as follows:

number

[0097] The total sensible heat added to the system during the initial heating phase was modeled as follows:

number

[0098] FIG. 13A shows the thermal efficiency ε for the consumable based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable. c It is shown how it was determined from CFD simulations that varies as a function of the ratio of the consumable diameter (Dc) to the pin heater element diameter (Dp).

[0099] FIG. 13B shows the thermal efficiency ε for the consumable based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable. cIt is shown how it was determined from CFD simulations that V varies as a function of the ratio of the consumable volume (Vc) to the pin heater element volume (Vp).

[0100] FIG. 13C shows the heating efficiency ε for the consumable based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable. c It is shown how it was determined from CFD simulations that varies as a function of the ratio of the surface area of ​​the consumable (Sc) to the surface area of ​​the pin heater element (Sp).

[0101] FIG. 13D shows the thermal efficiency ε for the consumable based on the thermal energy input to the consumable during the initial heating phase up to the time of the first puff from the consumable. c It is shown how it has been determined from CFD simulations that V varies as a function of the ratio of the consumable volume (Vc) to the pin heater element volume (Vp,total).

[0102] As shown in FIG. 13C, performed CFD simulations indicate that a heater element having a surface area Sp configured to heat a consumable having a surface area Sc can achieve a desired thermal efficiency ε for the consumable of at least about 50% when the ratio Sc / Sp is at least 3.4. c It was established that the thermal efficiency ε for the optimized consumables c By having a thermal efficiency ε , the amount of energy consumed in producing a given amount of aerosol from the consumable can be reduced. Aerosol delivery devices of the claimed type are typically battery-powered devices. Therefore, the thermal efficiency ε cOptimizing the heating efficiency during the initial heating phase can increase the amount of aerosol the device can produce before the battery needs to be replaced or recharged. Advantageously, this can therefore increase the number of puffs a user can get from the device. Additionally, optimizing the heating efficiency during the initial heating phase can decrease the "time to puff," i.e., the time it takes to heat the consumable to a point where a user can take a puff from it and experience a desired sensory effect, which may be desirable. In particular, CFD simulations have been performed in which a heater element having an outer diameter Dp, a volume Vp, and an outer surface area Sp is modeled in a CAD design, the heater element being surrounded by a first cylindrical portion modeled as containing an aerosol-generating material, and the first cylindrical portion having an outer diameter Dc, a volume Vc, and an outer surface area Sc, such that a ratio Sc / Sp of at least 3.4 can be achieved to achieve a desired thermal efficiency ε for the consumable of at least about 50% during the initial heating phase until the first puff. c It has been established that this is found to result in

[0103] Therefore, the CFD simulations carried out show that for a heater element with surface area Sp used to heat a cylindrical consumable with surface area Sc, the heating efficiency of the consumable, ε c It has been established that there is an optimum ratio of Sc / Sp that can be selected to provide the desired optimum performance with respect to ε. In particular, the ratio Sc / Sp can be selected to be at least 3.4. According to various embodiments, the ratio Sc / Sp is related to the heating efficiency ε of the consumable. c According to a further embodiment, the ratio Sc / Sp can be selected to be in the range of 3.4 to 9.0 to provide the desired optimum performance with respect to the heating efficiency ε c In a further embodiment, the ratio Sc / Sp can be selected to be in the range of 5.0 to 9.0 to provide the desired optimum performance with respect to the heating efficiency of the consumable, ε ccan be selected to be in the range of 7.5 to 8.5 to provide the desired optimum performance. Sp is the surface area of ​​the heater element facing the consumable. This includes the tip, the portion surrounding the heater coil, and the portion leading to the coil heater, as shown in Figure 10.

[0104] The thermal efficiency ε for the above and desired consumables c While other ratios have been established to be particularly beneficial relative to the optimal ratio Sc / Sp, which can be selected to be at least 3.4 to provide a desired consumable thermal efficiency ε of at least about 50%, as shown in FIG. 13A, according to various embodiments, the ratio Dc / Dp can be selected to provide a desired consumable thermal efficiency ε of at least about 50%. c In particular, Dc / Dp may be selected to be in the range of 2.6 to 6.0. According to other embodiments, Dc / Dp may be selected to be in the range of 4.0 to 5.8. According to further embodiments, Dc / Dp may be selected to be in the range of 4.5 to 5.5.

[0105] Similarly, in addition to the optimal ratio Sc / Sp, which may be selected to be at least 2.6, according to various embodiments, the ratio Vc / Vp may be selected to achieve a desired consumable thermal efficiency ε of at least about 50%, as shown in FIG. 13B. cTo achieve this, Vc / Vp can be selected to be at least 31.0. In particular, Vc / Vp can be selected to be in the range of 31.0 to 131.0. According to other embodiments, Vc / Vp can be selected to be in the range of 81.0 to 131.0. According to further embodiments, Vc / Vp can be selected to be in the range of 101.0 to 131.0. The volume Vp of the heater element is the volume of the outer shell of the heater element and does not include the volume of the cavity defined by the outer shell. In the simulations and other tests described herein, this includes the volume of the entire outer shell, including the tip of the outer shell. Referring to FIG. 8A, heater element 301 can comprise heater element 802 disposed within outer shell 807. Thus, volume Vp can be the volume defined by the material forming outer shell 807.

[0106] Similarly, as shown in FIG. 13D, the performed CFD simulations showed that for a heater element with volume Vp,total used to heat a cylindrical consumable with volume Vc, the heating efficiency of the consumable, ε c It has been established that there is an optimum ratio of Vc / Vp,total that can be selected to provide the desired optimum performance with respect to . In particular, the ratio Vc / Vp,total can be selected to be at least 11.0. According to various embodiments, the ratio Vc / Vp,total is determined by the heating efficiency ε of the consumable. c According to a further embodiment, the ratio Vc / Vp,total can be selected to be in the range of 11.0 to 16.0 to provide the desired optimum performance with respect to the heating efficiency ε c In a further embodiment, the ratio Vc / Vp,total can be selected to be in the range of 12.0 to 15.0 to provide the desired optimum performance with respect to the heating efficiency of the consumable, ε c can be selected to be in the range of 13.0 to 14.0 to provide the desired optimum performance.

[0107] The volume Vp,total is the volume that the heater element occupies within the consumable. In the simulations and other tests described herein, this includes the volume of heater element material and the interior volume of the heater element, both of which cover the tip, the portion of the heater element surrounding the coil heater, and the portion of the heater element connected to the coil heater, as shown in FIG.

[0108] According to various embodiments of an aerosol delivery device having a heater element with a surface area Sp, when used with a consumable product having a surface area Sc, the ratio Sc / Sp is configured to be within a range of 5.0 to 8.0. After the ramp-up time t_start and / or when the heater element reaches a first target operating temperature T1, one or more indicator devices can indicate to a user that the aerosol delivery device is ready for use. For example, the indicator device can include one or more light-emitting diodes (LEDs) disposed on a user interface of the aerosol delivery device. The number of illuminated LEDs and / or the color of the illuminated LED(s) and / or the intensity of the illuminated LED(s) can indicate to a user when the aerosol delivery device is ready for use. Additionally or alternatively, the indicator device can include a tactile feedback device. Embodiments are also contemplated in which the indicator device can additionally or alternatively include an audible indicator. The one or more indicator devices described above can also indicate to a user when an aerosol generation session is complete.

[0109] As discussed in more detail below with reference to FIG. 14 , embodiments are contemplated in which the aerosol delivery device can be utilized with an aerosol product having a fragrance capsule. The aerosol delivery device can be operated in either a first or base heating mode of operation or a second or boost heating mode of operation. The first heating mode of operation can provide an optimal sensory experience when the fragrance capsule is unbroken, and the second heating mode of operation can provide an optimal sensory experience when the fragrance capsule is broken. Other embodiments are also contemplated in which the first heating mode can provide an optimal sensory experience when the fragrance capsule is broken, and the second heating mode can provide an optimal sensory experience when the fragrance capsule is unbroken.

[0110] According to embodiments, the aerosol delivery device can include a first heater element and a second heater element, where the first heater element can be configured to form a first heating zone configured to heat a portion of the aerosol product article, and the second heater element can be configured to form a second heating zone configured to heat a different portion of the aerosol product article.

[0111] According to various embodiments, an aerosol delivery device is provided that includes a controller. The controller can be configured to set a heating profile for the heater element, which can include a pin-shaped heater element (or a blade-shaped heater element). The heater element is configured to heat an aerosol product article that includes multiple distinct zones or portions. The aerosol product article can include, among other things, a cylindrical article, for example, including a cylindrical portion of aerosol-generating material disposed at a distal portion of the article. The cylindrical portion of aerosol-generating material can have a diameter of approximately 7.0 mm and a length of 12.0 mm. A first tubular element can be disposed upstream of the cylindrical portion of aerosol-generating material, having a length of approximately 7 mm and an outer diameter of approximately 7.0 mm. A second tubular element can be disposed upstream of the first tubular element, having a length of approximately 17 mm and an outer diameter of approximately 7 mm. The cylindrical portion of aerosol-generating material, the first tubular element, and the second tubular element can be wrapped in one or more outer wrapping materials, which can have an overall thickness of approximately 200 μm.

[0112] FIG. 14 shows a side cross-sectional view of an aerosol product 1001 that can be utilized with an aerosol delivery device 1003 including a pin-shaped heater element 1002a, as discussed in more detail above, according to various embodiments. The pin-shaped heater element 1002a can be controlled by a controller (not shown), and according to various embodiments, a heating profile, such as the heating profile shown and described above in connection with FIG. 9, can be set for the heater element 1002a. In particular, the heater element 1002a can be operated in a first or base operating mode; thus, according to one embodiment, the heating profile shown in FIG. 9 can be set for the pin-shaped heater element 1002a. As discussed above, the heating profile can have a profile that includes a series of four-stage declines over the course of a use session. The temperature set for the heater element 1002a can be maintained at ≧300° C. throughout the use session. According to other embodiments, the heater element 1002a can be operated in a second or boost operating mode; thus, a different heating profile can be set for the pin-shaped heater element 1002a. As discussed above, the heating profile can have a profile including a series of four-stage declines over the course of a use session. The temperature set for the heater element 1002a can be maintained at ≥ 300°C throughout the use session. Note that the first or base operating mode can enable a user to experience an aerosol generation session that lasts approximately 300 seconds after the initial time to the first puff (t_start), while the second or base operating mode can enable a user to experience a different sensory experience, where the aerosol generation session lasts for a shorter period of time, e.g., 180 seconds, after the initial time to the first puff (t_start). The different sensory experience can be achieved, in part, by ensuring that the average temperature set for the heater element 1002a during the second or boost operating mode is higher than the average temperature set for the heater element 1002a during the first or base operating mode.

[0113] According to various embodiments, the aerosol delivery device 1003 can, more generally, comprise a heater element having an outer diameter Dp, a volume Vp, and an outer surface area Sp. The heater element can be configured to be inserted into an article 1001, which comprises a first cylindrical portion containing an aerosol-generating material. The first cylindrical portion has an outer diameter Dc, a volume Vc, and an outer surface area Sc. The heater element can be configured with an outer surface area such that Sc / Sp is at least 3.4.

[0114] The aerosol product article 1001 can include an aerosol-generation region 1004 that can be inserted into a receiving portion 1002 of an aerosol delivery device 1003 during use. The receiving portion 1002 can include a recess in the aerosol delivery device 1003. The aerosol delivery device 1003 can include a heater element, such as a pin-type heater 1002a. The pin-type heater 1002a can be located within the receiving portion 1002 of the aerosol delivery device 1003, and the pin-type heater can be configured to penetrate into the aerosol-generation region 1004 of the aerosol product article 1001 as the aerosol product article 1001 is inserted into the aerosol delivery device 1003 during use. The pin-type heater 1002a can be resistively heated and can include a resistive heater element. However, alternative embodiments are contemplated in which the heater element 1002a can include a blade-type heater element. Further embodiments are contemplated in which the heater element can include a heater element formed from a heating material that can be inductively heated and can include a susceptor element. A magnetic field generator may be provided that is configured to induce an alternating current in the susceptor element, thereby causing heating of the susceptor element.

[0115] The article 1001 may include a downstream section 1005 downstream of the aerosol-generating section 1004. The downstream section 1005 may include or comprise a mouthpiece designed to be inserted into a user's mouth during use. The downstream section 1005 may include an upstream end 1005a and a downstream end 1005b. The aerosol-generating section 1004 may include a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material. In another example, the aerosol-generating section 1004 may include a cavity for receiving the source of aerosol-generating material. The aerosol-generating material may include at least 5% aerosol-forming material by weight of the aerosol-generating material, calculated on a dry weight basis. The aerosol-forming material may include, for example, glycerol or propylene glycol.

[0116] The mouthpiece or downstream portion 1005 may include a first tubular element 1008a disposed immediately downstream of the aerosol-generation zone 1004. The first tubular element 1008a may define a first hollow cavity. The first tubular element 1008a may be in abutting relationship with the aerosol-generation zone 1004. The first tubular element 1008a may have a first tubular wall. The mouthpiece or downstream portion 1005 may also include a second tubular element 1008b immediately downstream of the first tubular element 1008a. The second tubular element 1008b may be in abutting relationship with the first tubular element 1008a. The second tubular element 1008b may have a second tubular wall having a wall thickness of less than about 320 μm. The second tubular element 1008b may have an axial length of 15 to 25 mm, for example, 17 mm. The downstream section 1005 may include a body of material 1006 at its downstream end 1005b. The first and second tubular elements 1008a and 1008b and the body of material 1006 may each define a cylindrical outer shape and may be arranged end-to-end about a common axis. The first and second tubular elements 1008a and 1008b, the aerosol-generation section 1004, and the body of material 1006 may be configured to have approximately the same outer diameter.

[0117] The first tubular element 1008a and the second tubular element 1008b together can define a chamber into which the aerosol formed in the aerosol-generation zone 1004 is drawn, expanded, and cooled. Providing separate first tubular element 1008a and second tubular element 1008b allows these components to be designed to achieve different functional effects. For example, the first tubular element 1008a can be effective in reducing the movement of the aerosol-generating material when the article 1001 is inserted into the recess 1002 over the pin-shaped heater element 1002a. To this end, the first tubular element 1008a can have a wall thickness of 1.0 to 3.5 mm, e.g., 1.5 to 2.5 mm. The first tubular element 1008a can assist by providing rigidity to the article 1001. The first tubular element 1008a can also be configured to urge the aerosol to flow primarily through an axial region of the second tubular element 1008b to aid in the formation of the aerosol. In contrast, the second tubular element 1008b can be configured to define a relatively larger chamber compared to the first tubular element 1008a, thereby providing more space into which the aerosol formed in the aerosol-generation zone 1004 can be drawn so that the aerosol can expand and cool.

[0118] The aerosol product article 1001 may have a circumference of 22.1 mm, corresponding to a diameter of 7.0 mm. The aerosol-generation zone 1004 may have a length of 12.0 mm, the first tubular element 1008a may have a length of 7.0 mm, and the second tubular element may have a length of 17.0 mm. According to various embodiments, the aerosol-generating material provided to the aerosol-generation zone 1004 may include multiple strands or strips of aerosol-generating material. The strands or strips of aerosol-generating material may be arranged such that their longitudinal dimension is substantially parallel to the longitudinal axis of the aerosol product article 1003. The aerosol-generating material may be in the form of a reconstituted sheet tobacco material, such as band-cast reconstituted tobacco. The wall of the second tubular element 1008b may comprise first and second overlapping paper layers, each extending substantially around the entire circumference of the second tubular element 1008b. The first and second overlapping paper layers can each have a thickness of 30 to 150 μm. The aerosol delivery device 1003 can include a housing 1009 and an opening 1010 in the housing 1009 through which the article 1001 can be inserted during use. When the article 1001 is fully inserted into the aerosol delivery device 1003, the second tubular element 1008b can extend at least about 5 mm into the housing 1009 and can extend at least 8 mm beyond the housing 1009. The article 1001 can be inserted into the aerosol delivery device 1003 to an insertion depth of about 25 mm, as shown by arrow "B" in FIG. 14.

[0119] Those skilled in the art will appreciate that band-cast reconstituted tobacco has a relatively high density. Note that the heating profile disclosed above with reference to Figure 9 has a relatively high maximum target operating temperature, e.g., 350°C, and also has a relatively high minimum target operating temperature, e.g., 300°C. Over the course of a use session, a heating profile such as that discussed above with reference to Figure 9 may have an average target operating temperature > 300°C. The relatively high target operating temperature is particularly well-suited for generating aerosol from articles comprising band-cast reconstituted tobacco.

[0120] Article 1001 can include one or more vent openings 1012 that extend through second tubular element 1008b to a location on the exterior of housing 1009 when article 1001 is fully inserted into aerosol delivery device 1003. One or more vent openings 1012 can be provided as one or more rows of openings, such as laser- or machine-formed perforations, circumscribing article 1001.

[0121] The cylindrical rod of aerosol-generating material can include multiple strands and / or strips of aerosol-generating material circumscribed by a wrapper 1015. The wrapper 1015 can be a moisture-impermeable wrapper. The multiple strands or strips of aerosol-generating material can be aligned within the aerosol-generation zone 1004 with their longitudinal dimensions aligned parallel to the longitudinal axis X-X' of the article 1001. Alternatively, the strands or strips can be generally positioned with their aligned longitudinal dimensions transverse to the longitudinal axis of the article 1001. When the majority of the strands or strips are positioned in the aerosol-generation zone 1004 with their longitudinal axes parallel to the longitudinal axis of the aerosol-generation zone 1004 of the article 1001, a relatively small force can be required to insert a heater element, such as heater element 1002a, into the aerosol-generating material. This can result in an article 1001 that is easier to use.

[0122] The rod of aerosol-generating material may have a circumference of approximately 22.1 mm (corresponding to a diameter of 7.0 mm). The first tubular element 1008a may be formed from a filament tow, such as plasticized cellulose acetate tow. The wall of the first tubular element 1008a may be relatively non-porous, such that at least 80% of the aerosol generated by the aerosol-generating material passes longitudinally through the hollow channel through the tube, rather than through the wall material itself. The first tubular element 1008a and the second tubular element 1008b may be configured to provide a temperature difference of at least 40°C between the heated volatilized components entering the first upstream ends of the first tubular element 1008a and the second tubular element 1008b and the heated volatilized components exiting the second downstream ends of the first tubular element 1008a and the second tubular element 1008b. This temperature difference across the length of the first tubular element 1008a and the second tubular element 1008b can protect the temperature-sensitive body of material 1006 from the high temperatures of the aerosol-generating material when heated.

[0123] The non-permeable wrapper 1015 circumscribing the rod of aerosol-generating material can comprise aluminum foil. The body of material 1006 can be wrapped in a first plug wrap 1007. A second plug wrap 1013 can be provided to connect the body of material 1006, the first tubular element 1008a, and the second tubular element 1008b. The length of the body of material 1006 can be less than about 15 mm, for example, 12 mm. The body of material 1006 can be formed from filament tow. For example, the tow can comprise plasticized cellulose acetate tow or polylactic acid (PLA).

[0124] As shown in FIG. 15 , tipping paper 1016 can be wrapped around the entire length of the downstream portion 1005 and a portion of the rod of aerosol-generating material. The tipping paper 1016 can have an adhesive on its inner surface to connect the downstream portion 1005 and the rod of aerosol-generating material. The rod of aerosol-generating material can be wrapped in a wrapper 1015, which forms a first packaging material, and the tipping paper 1016 can form an outer packaging material that extends at least partially over the rod of aerosol-generating material to connect the downstream portion 1005 and the rod of aerosol-generating material. The tipping paper 1016 can extend 5 mm over the rod of aerosol-generating material to provide a secure attachment. The article 1001 can have a ventilation level of approximately 25% of the aerosol drawn through the article 1001. The article 1001 can include a vent opening provided in the second tubular element 1008b. The second hollow cavity defined by the second tubular element 1008b may have a diameter of about 6.6 mm and a radius "r" shown in FIG. 11 of about 3.3 mm.

[0125] The aerosol modifier can be provided within the body of material 1006 in the form of an additive release component. As shown in FIG. 14 , the additive release component can include a capsule 1011. However, it should be understood that the capsule 1011 is optional and can be omitted in various embodiments. When the article 1003 includes the capsule 1011, the first plug wrap 1007 can include an oil-resistant first plug wrap 1007. The capsule 1011 can include a frangible capsule, i.e., a solid, frangible shell surrounding a liquid payload. The capsule 1011 can include a shell encapsulating a liquid agent, such as a flavoring, or other agent. A user can break the capsule shell to release the flavoring or other agent into the body of material 1006. The capsule 1011 can be spherical and have a diameter of approximately 3 mm. The aerosol-generating material can include an aerosol-forming material. The aerosol-forming material can include, for example, glycerol or propylene glycol. The aerosol-generating material can include an aerosol-modifying agent, such as menthol.

[0126] 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 exhaustive and / or exclusive. It is understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations on the scope of the invention, as defined by the claims, or limitations on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. The 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 which may be claimed in the future.

Claims

1. a heater element having an outer diameter Dp, a volume Vp, and an outer surface area Sp, the heater element being configured to be inserted into an article, the article having a first cylindrical portion containing an aerosol-generating material, the first cylindrical portion having an outer diameter Dc, a volume Vc, and an outer surface area Sc; An aerosol delivery device having an Sc / Sp of at least 3.

4.

2. The aerosol delivery device of claim 1 , wherein the heater element comprises a pin-type heater element.

3. 3. The aerosol delivery device of claim 2, wherein the pin-shaped heater element comprises a cylindrical body and a conical tip.

4. 4. The aerosol delivery device of claim 2 or 3, wherein the pin-shaped heater element comprises an elongated body having a cavity and one or more heater coils disposed within the cavity.

5. The aerosol delivery device of claim 1 , wherein the heater element comprises a blade-shaped heater element.

6. The aerosol delivery device of claim 5 , wherein the blade-shaped heater element comprises one or more conductive tracks.

7. The aerosol delivery device of any one of claims 1 to 6, wherein the heater element comprises a resistive heating element.

8. The aerosol delivery device of any one of claims 1 to 3 or 5, wherein the heater element comprises an induction heating element.

9. The aerosol delivery device according to any one of claims 1 to 8, wherein Sc / Sp is in the range of 3.4 to 9.

0.

10. 10. The aerosol delivery device of claim 9, wherein Sc / Sp is in the range of 5.0 to 9.

0.

11. 11. The aerosol delivery device of claim 10, wherein Sc / Sp is in the range of 7.5 to 8.

5.

12. 12. The aerosol delivery device of claim 1, wherein Vc / Vp is at least 31.

0.

13. 13. The aerosol delivery device of claim 12, wherein Vc / Vp is in the range of 31.0 to 131.

0.

14. 14. The aerosol delivery device of claim 13, wherein Vc / Vp is in the range of 81.0 to 131.

0.

15. 15. The aerosol delivery device of claim 14, wherein Vc / Vp is in the range of 101.0 to 131.

0.

16. 16. The aerosol delivery device of any one of claims 1 to 15, wherein Dc / Dp is at least 2.

6.

17. 17. The aerosol delivery device of claim 16, wherein Dc / Dp is in the range of 2.6 to 6.

0.

18. 18. The aerosol delivery device of claim 17, wherein Dc / Dp is in the range of 4.0 to 5.

8.

19. 19. The aerosol delivery device of claim 18, wherein Dc / Dp is in the range of 4.5 to 5.

5.

20. The aerosol delivery device further comprises a controller configured to control the heater element during a use session, the controller comprising: (i) heating to a first target operating temperature T1 during a first time period t0-t1; (ii) heating to a second target operating temperature T2 during a second time period t1-t2; (iii) heating to a third target operating temperature T3 during a third time period t2-t3; and (iv) heating to a fourth target operating temperature T4 during a fourth time period t3-t4; configured to control the heater element; The temperatures are T1>T2>T3>T4, and the times are t0<t1<t2<t3<t4, The aerosol delivery device of any one of claims 1 to 19, wherein T4 > 300°C.

21. An aerosol delivery device according to any one of claims 1 to 20; an article containing an aerosol-forming material; An aerosol delivery system comprising:

22. 22. The aerosol delivery system of claim 21, wherein the article comprising an aerosol-forming material comprises band-cast reconstituted tobacco.

23. 1. A method for generating an aerosol, comprising: Providing an aerosol delivery device according to any one of claims 1 to 20; at least partially inserting an article including an aerosol-forming material into a receiving portion of a heating chamber of the aerosol delivery device; activating the aerosol delivery device to generate an aerosol from the article; A method comprising:

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