Aerosol Delivery Device

Abstract

1. An aerosol delivery device configured to receive at least a portion of an article comprising an aerosol-generating material, the aerosol delivery device comprising: one or more aerosol generators arranged to generate an aerosol from the aerosol-generating material; and a controller configured to control the one or more aerosol generators during a session of use, wherein during the session of use, the controller is configured to control the one or more aerosol generators to (i) heat to a first target operating temperature T1 during a first time period t0-t1, (ii) heat to a second target operating temperature T2 during a second time period t1-t2, (iii) heat to a third target operating temperature T3 during a third time period t2-t3, and (iv) heat to a fourth target operating temperature T4 during a fourth time period t3-t4, wherein temperatures T1>T2>T3>T4 and time t0 <t1<t2<t3<t4であり、T4> It is 300°C.

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 articles by creating products that release compounds without combustion. Examples of such products are so-called "non-combustion heating" products or tobacco heating devices or products that release compounds by heating but not burning a material. The material may be, for example, tobacco or other non-tobacco products that may or may not contain nicotine.

[0003] Aerosol delivery systems are known that cover the above-mentioned devices or products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. Often, the medium used must be replaced or changed to provide a different aerosol for inhalation. It is known to use a resistance heating system as a heater to generate an aerosol from a suitable medium. Separately, it is known to use an induction heating system as a heater. Summary of the Invention

[0004] According to one aspect, there is provided an aerosol delivery device configured to receive at least a portion of an article comprising an aerosol-generating material, the aerosol delivery device comprising: one or more aerosol generators arranged to generate an aerosol from the aerosol-generating material; a controller configured to control the one or more aerosol generators during a session of use, wherein during a session of use, the controller controls the one or more aerosol generators to: (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; (iv) configured to control heating to a fourth target operating temperature T4 during a fourth time period t3-t4; Temperature T1>T2>T3>T4 and time t0 <t1<t2<t3<t4であり、 T4>300℃.

[0005] According to another aspect, there is provided an aerosol delivery device configured to receive at least a portion of an article comprising an aerosol-generating material, the aerosol delivery device comprising: one or more aerosol generators arranged to generate an aerosol from the aerosol-generating material; a controller configured to control the one or more aerosol generators during a session of use, wherein during a session or use, the controller is configured to control the one or more aerosol generators to a sequence of temperatures T1, T2, T3 to Tn, over periods t1, t2, t3 to tn, where T1 > T2 > T3 > Tn and at time t0 <t1<t2<t3<tnである。

[0006] According to another aspect, there is provided an aerosol delivery device configured to receive at least a portion of an article comprising an aerosol-generating material, the aerosol delivery device comprising: one or more aerosol generators arranged to generate an aerosol from the aerosol-generating material; a controller configured to control the one or more aerosol generators during a session of use, wherein during a session or use, the controller is configured to control the one or more aerosol generators to a series of target operating temperatures T1, T2, T3 to Tn, over periods t1, t2, t3 to tn, the series of target operating temperatures being progressively decreasing.

[0007] According to various embodiments, an aerosol delivery device is provided that includes a controller configured to set a target operating temperature of one or more aerosol generators according to a heating profile. The heating profile includes an initial first target operating temperature, which is then gradually decreased over the course of an aerosol generation session. In particular, the heating profile may be configured to gradually decrease the desired operating temperature of the aerosol generator in a series of steps, e.g., four steps, during an aerosol generation session. A heating profile having, e.g., four step-downs over time, may correspond to a first standard or normal operating mode, known as a "basic" operating mode. When the aerosol delivery device is operating in the first or basic operating mode, an aerosol generation session may be configured to last, e.g., 300 seconds (5 minutes).

[0008] It will be appreciated that a use session begins at time t0 and, according to various embodiments, ends at a time (such as t4) at which the controller may switch one or more aerosol generators off. When a use session begins at time t0, there is a ramp-up time or time to the first puff before aerosol may be generated. The ramp-up time or time to the first puff may end at time t_start. An aerosol generation session may be considered to begin at time t_start and, according to various embodiments, to end at time t4 at which one or more aerosol generators may be switched off.

[0009] According to other embodiments, a heating profile having, for example, four step-downs as a function of time can correspond to a second operating mode known as a "boost" operating mode. When the aerosol delivery device is operating in the second or boost operating mode, the use session and the aerosol generation session may be shorter. For example, the length of the aerosol generation session may be shortened to, for example, 180 seconds (3 minutes). A common feature of both the first and second operating modes is that the temperature set for the aerosol generator may be >300°C throughout the use session (and thus throughout the aerosol generation session). Furthermore, the maximum operating temperature of the aerosol generator during the use session (and thus throughout the aerosol generation session) may be higher when the aerosol delivery device is operating in the second or boost operating mode compared to the maximum operating temperature of the aerosol generator when operating in the first or base operating mode. According to various embodiments, the maximum operating temperature in the second or boost operating mode may be, for example, 380°C or 390°C. In contrast, the maximum operating temperature in the first or base mode of operation may be lower, such as 350° C. In other embodiments, the maximum operating temperature in the second or boost mode of operation may be, for example, 430° C., and the maximum operating temperature in the first or base mode of operation may be lower, such as 400° C.

[0010] According to various embodiments, when the aerosol delivery device is operating in the first operating mode or the basic operating mode, the controller may be configured to achieve a fourth target operating temperature T4>305°C, T4>310°C, or T4>315°C during the fourth period t3-t4.

[0011] In other embodiments, when the aerosol delivery device is operating in the first operating mode or the basic operating mode, the controller may be configured to achieve a fourth target operating temperature T4>360°C, T4>370°C, or T4>380°C during the fourth period t3-t4.

[0012] In other embodiments, when the aerosol delivery device is operating in the first operating mode or the basic operating mode, the controller may be configured to achieve a final target operating temperature Tn>360°C, Tn>370°C, or Tn>380°C during the final period tn.

[0013] According to various embodiments, when the aerosol delivery device is operating in the second operating mode or the boost operating mode, the controller may be configured to achieve a fourth target operating temperature T4>305°C, T4>310°C, T4>315°C, T4>320°C, T4>325°C, T4>330°C, T4>335°C, T4>340°C, T4>345°C, T4>350°C, or T4>355°C during the fourth period t3-t4.

[0014] In other embodiments, when the aerosol delivery device is operating in the second operating mode or the boost operating mode, the controller may be configured to achieve a fourth target operating temperature T4>395°C, T4>400°C, T4>405°C, T4>410°C, T4>415°C, or T4>420°C during the fourth period t3-t4.

[0015] In other embodiments, when the aerosol delivery device is operating in the first operating mode or the basic operating mode, the controller may be configured to achieve a final target operating temperature Tn>360°C, Tn>370°C, or Tn>380°C during the final period tn.

[0016] More generally, embodiments are contemplated in which the controller may be configured to control one or more aerosol generators such that, during a use session, T4>305°C, T4>310°C, T4>315°C, T4>320°C, T4>325°C, T4>330°C, T4>335°C, T4>340°C, T4>345°C, T4>350°C, T4>355°C, T4>360°C, T4>370°C, T4>380°C, T4>390°C, T4>400°C, or T4>410°C during a fourth period t3-t4.

[0017] The one or more aerosol generators may be arranged to heat the aerosol product article internally. According to other embodiments, the one or more aerosol generators may be arranged to heat the aerosol product article externally.

[0018] In some embodiments, (i) T1 = 350 ± 10°C, (ii) T2 = 340 ± 10°C, (iii) T3 = 330 ± 10°C, and (iv) T4 = 320 ± 10°C.

[0019] In some embodiments, (i) T1 = 400 ± 10°C, (ii) T2 = 390 ± 10°C, (iii) T3 = 380 ± 10°C, and (iv) T4 = 370 ± 10°C.

[0020] Optionally, (i) t0-t1=90±10 seconds, (ii) t1-t2=85±10 seconds, (iii) t2-t3=85±10 seconds, and (iv) t3-t4=60±10 seconds.

[0021] In some embodiments, (i) T1 = 380 ± 10°C, (ii) T2 = 370 ± 10°C, (iii) T3 = 365 ± 10°C, and (iv) T4 = 360 ± 10°C.

[0022] In some embodiments, (i) T1 = 430 ± 10°C, (ii) T2 = 420 ± 10°C, (iii) T3 = 415 ± 10°C, and (iv) T4 = 410 ± 10°C.

[0023] Optionally, (i) t0-t1=40±10 seconds, (ii) t1-t2=40±10 seconds, (iii) t2-t3=40±10 seconds, and (iv) t3-t4=75±10 seconds.

[0024] In some embodiments, (i) T1 = 390 ± 10°C, (ii) T2 = 380 ± 10°C, (iii) T3 = 370 ± 10°C, and (iv) T4 = 360 ± 10°C.

[0025] In some embodiments, (i) T1 = 440 ± 10 °C, (ii) T2 = 430 ± 10 °C, (iii) T3 = 320 ± 10 °C, and (iv) T4 = 410 ± 10 °C.

[0026] Optionally, (i) t0 - t1 = 20 ± 10 seconds, (ii) t1 - t2 = 40 ± 10 seconds, (iii) t2 - t3 = 40 ± 10 seconds, and (iv) t3 - t4 = 90 ± 10 seconds.

[0027] During a usage session, the controller may be further configured to control one or more aerosol generators to heat to a fifth target operating temperature T5 during a fifth period t4 - t5, where temperature T4 > T5 and time t4 < t5.

[0028] During a usage session, the controller may be configured to control one or more aerosol generators to heat to a sixth target operating temperature T6 during a sixth period t5 - t6, where temperature T6 > T5 and time t5 < t6.

[0029] During a usage session, the controller may be configured to control one or more aerosol generators to heat to a seventh target operating temperature T7 during a seventh period t6 - t7, where temperature T7 > T6 and time t6 < t7.

[0030] During a usage session, the controller may be configured to control one or more aerosol generators to heat to an eighth target operating temperature T8 during an eighth period t7 - t8, where temperature T8 > T7 and time t7 < t8. Optionally, During a usage session, the controller may be configured to control one or more aerosol generators to heat to a ninth target operating temperature T9 during a ninth period t8 - t9, where temperature T9 > T8 and time t8 < t9.

[0031] In some embodiments, (i) T1 = 400 ± 10°C, (ii) T2 = 396 ± 10°C, (iii) T3 = 394 ± 10°C, (iv) T4 = 392 ± 10°C, (v) T5 = 390 ± 10°C, (vi) T6 = 386 ± 10°C, (vii) T7 = 384 ± 10°C, (viii) T8 = 382 ± 10°C, and (ix) T9 = 380 ± 10°C.

[0032] In some embodiments, (i) t0-t1 = 20 ± 10 seconds, (ii) t1-t2 = 20 ± 10 seconds, (iii) t2-t3 = 20 ± 10 seconds, (iv) t3-t4 = 20 ± 10 seconds, (v) t4-t5 = 20 ± 10 seconds, (vi) t5-t6 = 20 ± 10 seconds, (vii) t6-t7 = 20 ± 10 seconds, (viii) t7-t8 = 20 ± 10 seconds, and (ix) t8-t9 = 20 ± 10 seconds.

[0033] In some embodiments, when the aerosol delivery device is operating in the first or basic operating mode, the controller may be configured to control the one or more aerosol generators in n steps, the final step being (n) an nth period t n-1 -t n During step (m), the temperature is heated to the nth target operating temperature Tn, where n>4, T1=400±10°C and Tn≧370°C. In step (m), Tm-1>Tm and n≧m≧2.

[0034] In some embodiments, when the aerosol delivery device is operating in the second or boost mode of operation, the controller may be configured to control the one or more aerosol generators in n steps, the final step being (n) the nth period t n-1 -t n The target operating temperature is Tn, where Tn is the temperature at which the nth temperature is reached, and Tn is 430±10°C for n>4. n ≧410° C. In step (m), Tm−1>Tm and n≧m≧2.

[0035] According to a further aspect, there is provided an aerosol delivery device configured to receive at least a portion of an article comprising an aerosol-generating material, the aerosol delivery device comprising: one or more aerosol generators arranged to generate an aerosol from the aerosol-generating material; a controller configured to control the one or more aerosol generators during a session of use, wherein during a session of use, the controller controls the one or more aerosol generators to: (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; (iv) configured to control heating to a fourth target operating temperature T4 during a fourth time period t3-t4; Temperature T1>T2>T3>T4 and time t0 <t1<t2<t3<t4であり、 the one or more aerosol generators are operable in at least a first mode and a second mode; In a first mode, the controller is configured to control one or more aerosol generators such that T1>380°C or 390°C and T4>360°C.

[0036] In a second mode, the controller is configured to control the one or more aerosol generators such that T1>350°C and T4>305°C.

[0037] The first mode may be a base mode, and the second mode may be a boost mode.

[0038] In a first mode, the controller may be configured to control the one or more aerosol generators such that T1 > 430°C and T4 > 305°C.

[0039] In a second mode, the controller may be configured to control one or more aerosol generators such that T1 > 400°C and T4 > 360°C.

[0040] In the second mode, the controller may be further configured to (v) control the one or more aerosol generators to be heated to a fifth target operating temperature T5 during a fifth time period t4-t5, where temperature T4>T5 and time t4 <t5である。

[0041] In the second mode, the controller may be further configured to (vi) control the one or more aerosol generators to be heated to a sixth target operating temperature T6 during a sixth time period t5-t6, where temperature T6>T5 and time t5 <t6である。

[0042] In the second mode, the controller may be further configured to (vii) control the one or more aerosol generators to be heated to a seventh target operating temperature T7 during a seventh time period t6-t7, where temperature T7>T6 and time t6 <t7である。

[0043] In the second mode, the controller may be further configured to control the one or more aerosol generators to be heated to an eighth target operating temperature T8 during an eighth time period t7-t8, where temperature T8>T7 and time t7 <t8である。

[0044] In the second mode, the controller may be further configured to control the one or more aerosol generators to be heated to a ninth target operating temperature T9 during (ix) a ninth time period t8-t9, where temperature T9>T8 and time t8 <t9である。

[0045] Optionally, (i) T1 = 400 ± 10°C, (ii) T2 = 396 ± 10°C, (iii) T3 = 394 ± 10°C, (iv) T4 = 392 ± 10°C, (v) T5 = 390 ± 10°C, (vi) T6 = 386 ± 10°C, (vii) T7 = 384 ± 10°C, (viii) T8 = 382 ± 10°C, and (ix) T9 = 380 ± 10°C.

[0046] Optionally, (i) t0-t1 = 20 ± 10 seconds, (ii) t1-t2 = 20 ± 10 seconds, (iii) t2-t3 = 20 ± 10 seconds, (iv) t3-t4 = 20 ± 10 seconds, (v) t4-t5 = 20 ± 10 seconds, (vi) t5-t6 = 20 ± 10 seconds, (vii) t6-t7 = 20 ± 10 seconds, (viii) t7-t8 = 20 ± 10 seconds, and (ix) t8-t9 = 20 ± 10 seconds.

[0047] One or more of the aerosol generators may comprise a pin-shaped heater element.

[0048] The pin-shaped heater element may include a cylindrical body and a conical tip.

[0049] The pin-shaped heater element may include an elongated body having a cavity and one or more heater coils disposed within the cavity.

[0050] One or more of the aerosol generators may comprise a blade-shaped heater element.

[0051] The blade-shaped heater element may include one or more conductive or resistive tracks, which may include nichrome (Ni20Cr80).

[0052] One or more of the aerosol generators may include a resistive heater element.

[0053] One or more of the aerosol generators may include an induction heater element.

[0054] The aerosol delivery device may include a power source, a controller, and a heating chamber in which the aerosol product article is removably received. The aerosol delivery device may be configured for wireless charging.

[0055] The aerosol delivery device may include one or more indicator or signaling devices to indicate to a user when the aerosol generator has reached a desired operating temperature and / or when the aerosol delivery device is ready for use, for example, after an initial ramp-up time. For example, the one or more indicator or signaling devices may be arranged to be activated or change state at time t_start, i.e., after the initial ramp-up time or time to first puff.

[0056] According to another aspect, the aerosol delivery device described above; An aerosol delivery system is provided that includes an article comprising an aerosol-generating material.

[0057] The article comprising the aerosol-forming material may include band-cast reconstituted tobacco.

[0058] The aerosol delivery system may include a charging unit having a cavity for removably receiving the aerosol delivery device. The charging unit may include a movable cover configured to cover the aerosol delivery device in a closed configuration. The charging unit may include a user display. The user display may be visible to a user when the movable cover is in the closed position and may be partially or completely hidden or obscured from view by the cover when the cover is in the open position.

[0059] The aerosol delivery device may include a controller and a user interface. The user interface may be activated by a user to operate the aerosol delivery device in a first (e.g., base) operating mode, with the controller configured to control the one or more aerosol generators to heat to a series of target operating temperatures according to a first heating profile as a function of time. The user interface may also be activated by a user to operate the aerosol delivery device in a second (e.g., boost) operating mode, with the controller configured to control the one or more aerosol generators to heat to a series of target operating temperatures according to a second, different heating profile as a function of time. The first heating profile is configured to control the one or more aerosol generators to heat to a series of target operating temperatures according to a second, different heating profile as a function of time. The first heating profile is configured to control the one or more aerosol generators to heat to a series of target operating temperatures according to a second, different heating profile as a function of time. The first heating profile is configured to control the one or more aerosol generators to heat to a series of target operating temperatures according to a first ... first, different heating profile as a function of time. The first heating profile is configured to control the one or more aerosol generators to heat to a series of target operating temperatures according to a second, different heating profile as a function of time 1total and the aerosol generator may be associated with a use session having a minimum target operating temperature T 1min and maximum target operating temperature T 1max The second heating profile may be set to a target operating temperature between t 2total and the aerosol generator may be associated with a use session having a minimum target operating temperature T 2min and maximum target operating temperature T 2max The duration of the aerosol generation session may correspond to a period following the initial time (or ramp-up time) until the first puff, i.e., from time t_start~ forward, up to a time corresponding to the end of the aerosol generation session during which no aerosol is intended to be generated. At the end of the aerosol generation session, the controller may set a target operating temperature for the aerosol generator that is too low to generate aerosol, e.g., 20°C. At the end of the aerosol generation session, the aerosol generator may be switched off, i.e., zero current may be supplied to the aerosol generator. According to various embodiments, t 1total >t 2total and / or T 2max >T 1max and / or T 2min >T 1minAccording to various embodiments, T 1min ≥ 320°C and / or T 2min ≧360°C.

[0060] The aerosol delivery device may further include a temperature sensor for monitoring or sensing the temperature of the aerosol generator (or heater element) over the course of a use session or aerosol generation session. The temperature sensor may include a resistance temperature detector (“RTD”), which may also be referred to as a thermocouple, thermopile, or resistance thermometer. Temperature data measured by the temperature sensor may be communicated to the controller. In particular, the controller may be configured to modify the power supply to the aerosol generator or heater element when the temperature sensor determines that the aerosol generator or heater element has reached a target operating temperature (e.g., T1, T2, T3, or T4). The controller may include a proportional-integral-derivative (“PID”) controller that uses a control feedback loop mechanism to control the temperature of the aerosol generator or heater element based on data, information, or signal(s) provided by one or more temperature sensors.

[0061] Articles comprising aerosol-generating materials may include capsules that can be fragmented to introduce additional flavorings or other agents into the aerosol generated within the aerosol-generating portion of the article. The articles may include one or more filters, which may include, for example, cellulose acetate. The articles may also include one or more vent holes formed through the outer layer of the article to aid in cooling the article. The one or more vent holes may be provided >5 mm from the proximal (mouth) end of the article.

[0062] 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 comprising an aerosol-generating material into a receiving portion of a heating chamber of an aerosol delivery device; and actuating the aerosol delivery device to generate an aerosol from the article.

[0063] According to another aspect, an aerosol delivery device configured to receive at least a portion of an article comprising an aerosol-generating material, the aerosol delivery device comprising one or more RF generators (resonant frequency generators) arranged to generate a varying magnetic field, and a controller configured to control the one or more RF generators during a use session; an article comprising a heating material inductively heated by one or more RF generators; During a use session, the controller is configured to control the one or more RF generators to (i) heat the heating material to a first target operating temperature T1 during a first time period t0-t1, (ii) heat the heating material to a second target operating temperature T2 during a second time period t1-t2, (iii) heat the heating material to a third target operating temperature T3 during a third time period t2-t3, and (iv) heat the heating material to a fourth target operating temperature T4 during a fourth time period t3-t4, wherein temperatures T1>T2>T3>T4 and time t0 <t1<t2<t3<t4であり、T4> It is 300°C.

[0064] Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings. [Brief explanation of the drawings]

[0065] [Figure 1] FIG. 1 is a perspective view of an aerosol delivery system including an aerosol delivery device disposed within a charging unit, the aerosol delivery device optionally including a controller configured to heat one or more aerosol generators to a series of different target operating temperatures during a usage session. [Figure 2] 2 shows a schematic cross-sectional view of a portion of the aerosol delivery device shown in FIG. 1, the aerosol delivery device comprising a pin-shaped heater element. [Figure 3] 2 shows 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] 1 illustrates a perspective view of a stand-alone aerosol delivery device according to another embodiment, where the stand-alone aerosol delivery device may be charged directly rather than being charged by a charging unit into which the aerosol delivery device is inserted. [Figure 5] 5 shows a schematic cross-sectional view of the aerosol delivery device shown in FIG. 4, illustrating that the aerosol delivery device may include a pin-shaped heater element that may be inserted into the distal end of the aerosol product article during use. [Figure 6] 1 shows a schematic cross-sectional view of a pin-shaped heater element that may be used to heat an aerosol product according to various embodiments, the heater element may be controlled by a controller to heat to a series of target operating temperatures according to a heating profile, the target operating temperatures progressively decreasing over time during the course of a usage session. [Figure 7] 1 illustrates a heating profile according to one embodiment that may be set by a controller for one or more aerosol generators when the aerosol delivery device operates in a first or basic operating mode having an aerosol generation session time of 300 seconds, the heating profile having four gradual step-downs during which the target operating temperature of the one or more aerosol generators is maintained at ≧320°C during the use session. [Figure 8] 1 illustrates a heating profile according to one embodiment that may be set by the controller for one or more aerosol generators when the aerosol delivery device operates in a second operating mode or boost operating mode having a shortened aerosol generation session time of 180 seconds, the heating profile having four gradual step-downs during which the target operating temperature of the one or more aerosol generators is maintained at ≧360°C during the use session. [Figure 9]1 illustrates a heating profile according to one embodiment that may be set by the controller for one or more aerosol generators when the aerosol delivery device operates in a second operating mode or boost operating mode having a shortened aerosol generation session time of 180 seconds, the heating profile having four gradual step-downs during which the target operating temperature of the one or more aerosol generators is maintained at ≧360°C during the use session. [Figure 10] A side cross-sectional view of an aerosol product article partially inserted into a receiving portion or recess of an aerosol delivery device according to various embodiments, the aerosol delivery device including a pin-shaped heater element, the aerosol delivery device including a controller configured to set the pin-shaped heater element to a heating profile such as that shown in either FIG. 8, FIG. 9, or FIG. 10. [Figure 11] 11 is a cross-sectional view of the aerosol product shown in FIG. 10 taken along line A-A' shown in FIG. 10. [Figure 12] 1 illustrates a heating profile according to one embodiment that may be set by a controller for one or more aerosol generators when the aerosol delivery device operates in a second operating mode or boost operating mode having a shortened aerosol generation session time of 180 seconds, the heating profile having nine gradual step-downs during which the target operating temperature of the one or more aerosol generators is maintained at ≧380°C during the use session. DETAILED DESCRIPTION OF THE INVENTION

[0066] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not burned or combusted to facilitate delivery of at least one substance to a user.

[0067] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0068] 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.

[0069] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0070] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates 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.

[0071] Typically, a non-combustible aerosol delivery system may include a non-combustible aerosol delivery device and a consumable item for use with the non-combustible aerosol delivery device.

[0072] In some embodiments, the non-combustible aerosol delivery device may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0073] In some embodiments, consumables for use with non-combustible aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage regions, aerosol-generating material transfer components, aerosol generators, aerosol-generating regions, housings, wrappers, filters, mouthpieces, and / or aerosol modifiers.

[0074] As used herein, the term "aerosol-forming material" refers to a material that is capable of generating an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-forming material may be in the form of, for example, a solid, liquid, or semi-solid (such as a gel), which may or may not contain an active agent and / or flavoring.

[0075] The aerosol-forming materials may include one or more active agents and / or flavoring agents, one or more aerosol former materials, and optionally one or more other functional materials.

[0076] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol former. Optionally, a delivery substance and / or a bulking agent may also be present. Optionally, a solvent, such as water, is also 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.

[0077] The aerosol-generating material may include or be in the form of an aerosol-generating film. The aerosol-generating film may include a binder, such as a gelling agent, and an aerosol former. Optionally, a delivery substance and / or a filler may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0078] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0079] The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, which may be gathered to form a collected sheet, or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material.

[0080] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more distinct portions or regions of aerosol-generating material, such as dots, stripes, or lines, that may be supported on a substrate. In such embodiments, the substrate may be planar or non-planar.

[0081] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with one or more other components, such as a solvent, such as water, an aerosol former, 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.

[0082] The aerosol delivery device can accept an article comprising an aerosol-generating material for heating. An "article" in this context is a component that includes or contains an aerosol-generating material that is heated during use to volatilize the aerosol-generating material, and optionally other components during use. A user may insert the article into or onto the aerosol delivery device before the article is heated to generate an aerosol, and the user then inhales the aerosol. The article may be, for example, of a predetermined or specific size configured to be placed into or onto a heater of a device sized to receive the article.

[0083] An aerosol generator is a device that generates 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 may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0084] A consumable is an article comprising or consisting of an aerosol-generating material, some or all of which 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 transfer 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 upon use to generate an aerosol in the aerosol-generating material. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0085] A susceptor is a heating material that can be heated by penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration thereof by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration of the varying magnetic field into the heating material causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. The susceptor may 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.

[0086] The non-flammable aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some implementations, the non-flammable aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may include a power source, such as, for example, a battery or a rechargeable battery. In some implementations, the non-flammable aerosol delivery device may also comprise the aerosol generating components. However, in other implementations, the aerosol product article may comprise, in part or entirely, the aerosol generating components.

[0087] The present disclosure particularly relates to various heating profiles, as described below with reference to FIGS. 7-9 and 12. The aerosol delivery device is described below with particular reference to FIGS. 1-6. The aerosol delivery device may include a controller and a heater element, such as a pin-shaped heater element. The controller may be arranged to set the heater element to a series of different target operating temperatures according to the heating profiles shown in FIGS. 7-9 and 12. The heating profiles shown and described with reference to FIGS. 7-9 and 12 have been found to provide an excellent sensory experience. The aerosol delivery device disclosed with reference to FIGS. 1-6 and operable according to the heating profiles shown and disclosed with reference to FIGS. 7-9 and 12 has been found to be particularly suitable when used to generate an aerosol from the aerosol product article disclosed with reference to FIGS. 10-11.

[0088] Various different aspects of the aerosol delivery device are described herein that can operate according to various heating profiles according to various embodiments.

[0089] 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 arranged to generate an aerosol from an aerosol-producing article that may be inserted into the aerosol delivery device 100 during use. The aerosol delivery device 100 and the article may together form part of the aerosol delivery system 10.

[0090] As described in more detail below, the aerosol delivery device 100 may include one or more aerosol generators. For example, the aerosol delivery device 100 may include an aerosol generator including a pin-shaped heater element, as described in more detail below. The aerosol delivery device may further include a controller that may be configured to control the one or more aerosol generators during a use session. During a use session, the controller may be configured to control the one or more aerosol generators to heat to a first target operating temperature T1 during a first time period t0-t1, to a second target operating temperature T2 during a second time period t1-t2, to a third target operating temperature T3 during a third time period t2-t3, and to a fourth target operating temperature T4 during a fourth time period t3-t4. The temperatures are T1>T2>T3>T4, and T4>300°C. According to an embodiment, T4≧320°C.

[0091] Thus, the controller may be configured to heat one or more aerosol generators to a series of target operating temperatures during a use session, where the target operating temperatures progressively decrease as a function of time. For example, one or more aerosol generators may be controlled by the controller to follow a heating profile where the target operating temperature decreases four times during the course of a use session. According to an embodiment, at all times, the target operating temperature of the aerosol generator during a use session may be ≧320°C.

[0092] At the initial time t0, the aerosol delivery device 100 and the aerosol generator 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 aerosol generator has dropped to a temperature below 50° C. Thus, at the initial time t0, the aerosol generator may be at a temperature below 50° C.

[0093] Aerosol delivery device 100 may comprise 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 a 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 is sometimes referred to as the "mouth end." Aerosol delivery device 100 comprises an opening that leads to a heating chamber.

[0094] Aerosol delivery device 100 may be removably inserted into charging unit 101 for charging. However, as described in more detail below, the aerosol delivery device may comprise a stand-alone aerosol delivery device that can be charged directly without requiring charging unit 101 to recharge the aerosol delivery device.

[0095] Charging unit 101 includes a cavity for receiving aerosol delivery device 100. Aerosol delivery device 100 may be inserted into the cavity of charging unit 101 through an opening. The cavity of charging unit 101 may include a longitudinal opening. A portion of aerosol delivery device 100 may include a first side. One or more user-operable control elements, such as buttons 106, that can be actuated to operate aerosol delivery device 100 (particularly to select a desired mode of operation) may be provided on the first side of aerosol delivery device 100. The first side of aerosol delivery device 100 may be received in the longitudinal opening provided in charging unit 101.

[0096] The cavity of charging unit 101 may have a cross-sectional profile that only allows aerosol delivery device 100 to be inserted into charging unit 101 in a single orientation. The outer shape of aerosol delivery device 100 may include arcuate and straight portions. The cross-sectional profile of the cavity provided in charging unit 101 may also include similar arcuate and straight portions. The straight portion of the cavity's cross-sectional profile may correspond to a longitudinal opening. Charging unit 101 may include a slidable cover 103. When aerosol delivery device 100 is inserted into charging unit 101 for recharging, slidable cover 103 may close to cover the opening to aerosol delivery device 100. In other embodiments, charging unit 101 may have an alternative cover configuration, such as a hinged or pivoting cover, or no cover may be provided. Charging unit 101 may include a user interface, such as display 108, which may be provided in any convenient location, such as the location shown in FIG. 1 .

[0097] 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 may be provided. An opening 203 may be provided to allow access to the heating chamber 201. The receptacle 205 may include a receptacle sidewall 205a and a receptacle base 205b. The receptacle base 205b may be provided at a distal end of the receptacle 205. A heating zone 201a configured to receive at least a portion of the aerosol product may be provided. A heater element 301 may be provided in a portion of the main housing 200, and the heater element 301 may extend or protrude into the heating chamber 201. Heater element 301 may include a base portion 301 a that may be positioned in a recess in a portion of the body of aerosol delivery device 100 .

[0098] 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 envisioned 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 an aerosol product article received within the heating chamber 201 to heat the aerosol product article therein.

[0099] Housing 200 may include housing wall 200a. Housing wall 200a may extend along the longitudinal axis of aerosol delivery device 100 and may enclose heating chamber 201. Housing wall 200a may at least partially define a receiving chamber of aerosol delivery device 100 as a volume enclosed within wall 200a. Housing 200 may include housing base 200b at a distal end of housing wall 200a. Heater element 301 may be positioned upright from housing base 200b. Heater element 301 may be positioned to protrude through receptacle base 205b. Opening 206 may be formed in receptacle base 205b, through which heater element 301 may protrude. Heater element 301 may be attached to receptacle base 205b.

[0100] Aerosol delivery device 100 may optionally include a detachment mechanism 204 that may be removably retained on main housing 200 of aerosol delivery device 100. However, according to other embodiments, detachment mechanism 204 may be omitted. Detachment mechanism 204 may include tubular wall portion 207a and base wall portion 207b. After an aerosol generation session is completed, detachment mechanism 204 may be removed from main housing 200 of aerosol delivery device 100. When detachment mechanism 204 is removed, base wall portion 207b of detachment mechanism 204 may be positioned to engage the distal end of an article that was located on pin-shaped heater element 301, such that when detachment mechanism 204 is removed, base wall portion 207b of detachment mechanism 204 removes the used aerosol product article from heater element 301. As a result, detachment mechanism 204 may assist in the removal of the used aerosol product article from a heater element, such as pin-shaped heater element 301.

[0101] FIG. 3 shows the distal end of article 50 comprising aerosol-generating material positioned on pin-shaped heater element 301 of aerosol delivery device 100 .

[0102] FIG. 4 illustrates an integrated aerosol delivery device 400 for generating an aerosol from an article 50 comprising an aerosol-generating material. The aerosol delivery device 400 includes an elongated housing 500 that encloses 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 may be fully or partially inserted into the aerosol delivery device 400 for heating by the aerosol delivery device 400. The aerosol delivery device 400 may include a user-operable control element 506, such as a button or switch, for operating the aerosol delivery device 400. For example, the user-operable control element 506 may be pressed to cause the aerosol delivery device 400 to enter either a first operating mode or a second operating mode. The aerosol delivery device 400 defines a longitudinal axis 509, and the article 50 may extend along the longitudinal axis when inserted into the aerosol delivery device 400. Opening 504 is aligned on longitudinal axis 509 .

[0103] As described in more detail below, the aerosol delivery device 400 can operate in a first or base mode of operation, in which the desired operating temperature of the heater element can be configured to decrease in a series of, 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 operate in a second or boost mode of operation, in which the desired operating temperature of the heater element can also be configured to decrease in a series of, 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 mode of operation. The maximum operating temperature of the heater element during an aerosol generation session can be higher when the aerosol delivery device is operated in the second or boost mode of operation. According to various embodiments, the maximum operating temperature in the second or boost mode of operation can be, e.g., 380°C or 390°C. In contrast, the maximum operating temperature in the first or base mode of operation can be, e.g., 350°C.

[0104] FIG. 5 shows a schematic cross-sectional view of an aerosol supply device 400 having an aerosol generating article 50 received within 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 in which the aerosol generating article 50 is removably received. The aerosol supply device 400 further includes one or more aerosol generators. The one or more aerosol generators may 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 period t0 - t1, to a second target operating temperature T2 during a second period t1 - t2, to a third target operating temperature T3 during a third period t2 - t3, and to a fourth target operating temperature T4 during a fourth period t3 - t4. The temperatures are such that T1 > T2 > T3 > T4, and the times are such that t0 < t1 < t2 < t3 < t4. The heater element 301 may be inserted at a distal end of the aerosol generating article 50 received within the heating chamber 401 for heating the aerosol generating article 50 internally during use.

[0105] The aerosol delivery device 400 may include a resistive heater element, such as a resistive heating coil, configured to operate to heat the heater element 301. An electric current may be applied directly to the resistive heater element, and the resulting current flow within the heater element may cause the heater element to heat by Joule heating. The resistive heater element may include a resistive material configured to generate heat when an appropriate electric current is passed therethrough. The aerosol delivery device 400 may further include electrical contacts for supplying electric current to the resistive material. The resistive heater element may be positioned to transfer thermal energy to the heater element 301 by conduction. Similarly, the heater element 301 may transfer thermal energy to a portion of the aerosol product article 50 by conduction. Employing a resistive heating configuration allows a compact configuration to be achieved, thereby facilitating miniaturization of the device. Furthermore, heating a portion of the aerosol product 50 using a resistive heating element such as a pin-shaped heater element 301 (where the pin-shaped heater element 301 is inserted into the distal end of the aerosol product) allows for high energy efficiency to be achieved as heat loss can be minimized.

[0106] 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 positioned within the internal void 308 or cavity. The elongated housing 302 may be formed from a thermally conductive material such as aluminum or stainless steel. The elongated housing 302 may 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 portion 303 and a free end portion 304. The base end portion 303 can be attached to a heating chamber. A mount 305 can be provided on the base end portion 303 to secure the heater element 301. A groove 302a or a region of reduced cross-sectional diameter can be provided in the elongated housing 302 toward the base end portion 303 of the elongated housing 302. The groove 302a or region of reduced cross-sectional diameter may act as a thermal break to reduce heat flow from the heater element 301 to the mount 305, or more generally to the attachment point. The internal void 308 may be at least partially filled, for example with a filler material.

[0107] The filling material may include one or more of (i) a potting compound, (ii) an adhesive, (iii) a thermosetting plastic, or (iv) an epoxy resin. For example, the interior cavity may be at least partially filled with an insulating material. The insulating material may be a potting compound, an adhesive, a thermosetting plastic, or an epoxy resin. The potting compound may include an epoxy resin. For example, a two-component epoxy may be used, consisting of a polymer resin and a hardener, which, when mixed together, cause a chemical reaction that crosslinks the chemical bonds in the polymer chains to produce a tough, rigid, and strong compound. Alternatively, the potting compound may include polyurethane ("PU"), e.g., a thermosetting plastic. This may include a two-component compound consisting of a base resin with an isocyanate curing agent. Alternatively, the potting compound may include a silicone. For example, silicone rubber, which includes a synthetic polysiloxane polymer that uses an added catalyst (e.g., platinum) to transition from a liquid to a solid state, may be utilized.

[0108] The heater element 311 has a tip 311 that extends to an apex 312. The resistive heater element 350 may comprise 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.

[0109] Various heating profiles will now be described with reference to Figures 7-9 and 12. The controller can set a series of target operating temperatures for one or more aerosol generators (or heating elements), where target operating temperatures T1, T2, T3, and T4 are shown and described below with reference to Figures 7-9 and 12.

[0110] 7 illustrates a heating profile according to one embodiment that may be set by a controller (e.g., controller 420 shown in FIG. 5) for one or more aerosol generators (or heating element(s)) when the aerosol delivery device operates in a first or base operating mode. The first or base operating mode may be configured to have an aerosol generation session time of 300 seconds (i.e., 5 minutes). An overall use session may last 320 seconds, i.e., the overall use session may include a 20-second ramp-up period followed by a 300-second aerosol generation session.

[0111] As described in more detail below, the heating profile has four gradual step-downs during a use session, and the temperature is maintained at ≧320° C. during the use session.

[0112] According to various embodiments, the controller may be configured to cause the aerosol generator to reach a first target operating temperature as quickly as possible once a particular operating mode is selected. There may be a short delay, e.g., 10-20 seconds, during an initial period when the aerosol generator is switched on but the aerosol generator has not yet reached the desired target operating temperature and therefore cannot generate aerosol. This initial period may be known as the ramp-up time (time to first puff). According to embodiments, the aerosol generation session may be considered to begin after the ramp-up time or time to first puff ends, i.e., at time t_start. At the end of the aerosol generation session, the controller may set the target operating temperature of the aerosol generator to, e.g., 20°C, which is too low to generate aerosol. At the end of the aerosol generation session, the aerosol generator may be switched off, i.e., zero current may be supplied to the aerosol generator.

[0113] The aerosol delivery device may comprise a pin-shaped heater element or a blade-shaped heater element as described above with reference to Figures 3, 5 and 6. Alternatively, the heater element may comprise an induction heater element, i.e., the heater element may comprise a heating material that is inductively heated by an RF generator.

[0114] The pin-shaped heater element may include a cavity, and one or more resistive coils may be located within the cavity. Current may be supplied to the one or more resistive coils under the control of a controller, and the resistive coils may heat up due to resistive heating. The pin-shaped heater element may include a cylindrical body portion with a conical tip. Other embodiments are contemplated in which the heater element may include a blade-shaped heater. The blade-shaped heater may include one or more electrical, conductive, or resistive tracks, and current may be supplied to the one or more electrical, conductive, or resistive tracks, and the electrical, conductive, or resistive tracks may heat up due to resistive heating. The conductive or resistive tracks may include nichrome (Ni20Cr80).

[0115] Other embodiments are envisioned where the heater element can include an induction heater element, i.e., the heater element can include a heating material that is inductively heated by an RF generator. Thus, the heater element can form a susceptor that includes a heating material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may include a conductive material, such that its penetration by the varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that magnetic hysteresis heating of the heating material occurs when the varying magnetic field penetrates the heating material. The RF generator can include one or more induction coils.

[0116] According to various embodiments, the controller may be configured to control the heater element to heat to a first target operating temperature T1 during a first period t0 - t1, to a second target operating temperature T2 during a second period t1 - t2, to a third target operating temperature T3 during a third period t2 - t3, and to a fourth target operating temperature T4 during a fourth period t3 - t4. The temperature of the heater element may be configured to gradually decrease during the course of the use session such that T1 > T2 > T3 > T4. It will also be understood that t0 < t1 < t2 < t3 < t4.

[0117] The aerosol supply device may further include a temperature sensor for monitoring or sensing the temperature of the aerosol generator during the use session. The temperature sensor may include a resistance temperature detector ("RTD"), also referred to as a thermocouple, thermopile, or resistance thermometer. The temperature data measured by the temperature sensor may be communicated to the controller. In particular, the controller may be configured to change the power supply to the aerosol generator or heater element when the temperature sensor determines that the aerosol generator or heater element has reached a target operating temperature (e.g., T1, T2, T3, or T4). The controller may include a proportional integral derivative ("PID") controller that uses a control feedback loop mechanism to control the temperature of the aerosol generator or heater element based on data, information, or signals supplied from one or more temperature sensors.

[0118] The time t0 may correspond to the time when the controller first activates or turns on the aerosol generator, or for example supplies current to the heater element. The heater element may be set to a first target operating temperature T1, but it may take several seconds for the heater element to reach either the first target operating temperature T1 or a lower temperature sufficient to generate an aerosol. This initial time may be referred to as the ramp-up time or the time to the first puff. The aerosol generation session may be considered to start after the ramp-up time or the time to the first puff at time t_start, where t0 < t_start < t1. The time to t_start may be, for example, 10 to 20 seconds. For the heating profile shown in FIG. 7, t_start is 20 seconds after time t0. According to various embodiments, the controller may be configured to control one or more aerosol generators or heater elements such that the average operating temperature of the aerosol generator(s) or heater element(s) gradually decreases after time t_start.

[0119] The controller may be configured such that the heating mode is executed, and as the temperature gradually decreases, the desired operating temperature set for the heater element remains at ≧320°C. For example, according to an embodiment, the lowest target operating temperature T4 set for the heater element during the aerosol generation session may be configured to be ≧320°C.

[0120] The specific heating profile shown in FIG. 7 relates to a basic or standard operating mode (also referred to as the first operating mode) in which the user is given a total aerosol generation session time of about 300 seconds (i.e., 5 minutes). According to this specific embodiment, the time from t0 to t_start is 20 seconds, and the time from t_start to t4 (when the aerosol generator or heating element is switched off) is 300 seconds. [Table 1]

[0121] When the controller sets a heating profile such as the heating profile shown in FIG. 7, the controller may be configured to ensure that the first target operating temperature T1 is achieved as quickly as possible, thereby shortening the time to first puff. For example, with reference to the heating profile shown in FIG. 7, the first target operating temperature T1 set by the controller may be 350°C. Other embodiments are contemplated in which the first target operating temperature T1 may be 350±10°C. According to various embodiments, the first target operating temperature T1 may be 340-345°C, 345-350°C, 350-355°C, or 355-360°C. The controller may be configured to set the heater element to the first target operating temperature T1 during a first time period t0-t1. The first time period t0-t1 may be 90 seconds. Other embodiments are contemplated in which t0-t1 may be 90±10 seconds. According to an embodiment, t0-t1 may be 80-85 seconds, 85-90 seconds, 90-95 seconds, or 95-100 seconds.

[0122] A user may activate the aerosol delivery device at time t0 to cause the controller to set one or more aerosol generators to a desired heating profile. For example, a user may activate a user interface (e.g., see user interface 106 as shown in FIG. 1 ) provided on the aerosol delivery device to cause the controller to set one or more aerosol generators to a desired heating profile for the one or more aerosol generators. Once the user interacts with the user interface and the controller sets the desired heating profile for one or more aerosol generators, there may be a relatively short time delay (between time t0 and t_start) before the aerosol generators reach the desired operating temperature and can generate sufficient aerosol from an aerosol product item at least partially inserted into the aerosol delivery device. The time delay may be referred to as a ramp-up time or time to first puff. As shown in FIG. 7 , an aerosol generation session may be considered to have begun at the end of the ramp-up time or once the time to first puff has elapsed (e.g., at time t_start). 7, the ramp-up time or time to the first puff (i.e., time t0 to t_start) is 20 seconds. However, according to other embodiments, the ramp-up time or time to the first puff may be shorter or longer than 20 seconds, such as 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0123] With respect to the heating profile shown in FIG. 7 , the controller may set one or more aerosol generators to a first target temperature T1 for a period of, for example, 90 seconds immediately upon activation of the aerosol delivery device by a user. If the time to first puff or ramp-up time is 20 seconds, it is understood that the controller may be configured to maintain the desired first target operating temperature T1, for example, 350°C, for an additional 70 seconds after the ramp-up time or time to first puff has occurred. At the end of the first period t0-t1, the controller may be configured to set progressively lower target operating temperatures. For example, after the end of the first period t0-t1, the controller may be configured to set a second target operating temperature T2 of one or more aerosol generators. The second target operating temperature T2 may be 340°C. It will be understood that the second target operating temperature T2 is lower than the first target operating temperature T1. Other embodiments are envisioned in which T2 may be 340±10°C. According to embodiments, T2 may be 330-335°C, 335-340°C, 340-345°C, or 345-350°C. The controller may be configured to set one or more aerosol generators to a second target operating temperature T2 during a second time period t1-t2. The second time period t1-t2 may be 85 seconds. Other embodiments are envisioned in which t1-t2 may be 85±10 seconds. According to embodiments, t1-t2 may be 75-80 seconds, 80-85 seconds, 85-90 seconds, or 90-95 seconds.

[0124] After the second time period t1-t2 expires, the controller may be configured to set progressively lower target operating temperatures. For example, after the second time period t1-t2 expires, the controller may be configured to set a third target operating temperature T3 for one or more aerosol generators. The third target operating temperature T3 may be 330°C. It will be understood that the third target operating temperature T3 is lower than the second target operating temperature T2. Other embodiments are contemplated in which T3 may be 330±10°C. According to embodiments, T3 may be 320-325°C, 325-330°C, 330-335°C, or 335-340°C. The controller may be configured to set one or more aerosol generators to the third target operating temperature T3 during a third time period t2-t3. The third time period t2-t3 may be 85 seconds. Other embodiments are contemplated in which t2-t3 may be 85±10 seconds. According to an embodiment, t2-t3 may be 75-80 seconds, 80-85 seconds, 85-90 seconds, or 90-95 seconds.

[0125] At the end of the third period t2-t3, the controller may be configured to set a lower target operating temperature. For example, after the end of the third period t2-t3, the controller may be configured to set a fourth target operating temperature T4 for one or more aerosol generators. The fourth target operating temperature T4 may be 320°C. It will be understood that the fourth target operating temperature T4 is lower than the third target operating temperature T3. Other embodiments are contemplated in which T4 may be 320±10°C. According to embodiments, T4 may be 310-315°C, 315-320°C, 320-325°C, or 325-330°C. The controller may be configured to set one or more aerosol generators to the fourth target operating temperature T4 during a fourth period t3-t4. The fourth period t3-t4 may be 60 seconds. Other embodiments are contemplated in which t3-t4 may be 60±10 seconds. According to an embodiment, t3-t4 may be 50-65 seconds, 65-70 seconds, 70-75 seconds, or 75-80 seconds.

[0126] 7, as described above, the total aerosol generation session length may be 300 seconds, i.e., the use session may be configured to end after a total time of 320 seconds, and the aerosol delivery device was ready for use after a 20-second ramp-up time or time to first puff (i.e., time t0 to t_start was 20 seconds). Note that, according to an embodiment, the maximum operating temperature set for the heater element may be approximately 350°C.

[0127] According to an alternative embodiment of the first or base operating mode, the controller sets a heating profile similar to that of Figure 7. The controller may be configured such that a heating mode is performed in which the desired operating temperature set for the heater element remains ≥ 370°C as the temperature is progressively reduced. [Table 2]

[0128] The first target operating temperature T1 set by the controller may be 400° C. Other embodiments are envisioned in which the first target operating temperature T1 may be 400±10° C. According to various embodiments, the first target operating temperature T1 may be 390-395° C., 395-400° C., 400-405° C., or 405-410° C.

[0129] The second target operating temperature T2 may be 390°C. It will be appreciated that the second target operating temperature T2 is lower than the first target operating temperature T1. Other embodiments are envisioned in which T2 may be 390±10°C. According to embodiments, T2 may be 380-385°C, 385-390°C, 390-395°C, or 395-400°C.

[0130] The third target operating temperature T3 may be 380°C. It will be appreciated that the third target operating temperature T3 is lower than the second target operating temperature T2. Other embodiments are envisioned in which T3 may be 380±10°C. According to embodiments, T3 may be 370-375°C, 375-380°C, 380-385°C, or 385-390°C.

[0131] The fourth target operating temperature T4 may be 370°C. It will be appreciated that the fourth target operating temperature T4 is lower than the third target operating temperature T3. Other embodiments are envisioned in which T4 may be 370±10°C. According to embodiments, T4 may be 360-365°C, 365-370°C, 370-375°C, or 375-380°C.

[0132] The maximum operating temperature set for the heater element may be approximately 400°C.

[0133] The embodiment is otherwise the same as that described with respect to FIG.

[0134] 8 illustrates a heating profile according to one embodiment that may be set by a controller (e.g., controller 420 as shown in FIG. 5) for an aerosol generator when the aerosol delivery device operates in a second or boost mode of operation. The second or boost mode of operation may be configured to have a shorter aerosol generation session time, for example, 180 seconds (i.e., 3 minutes). An entire use session may last 195 seconds, i.e., the entire use session may include a 15-second ramp-up period followed by a 180-second aerosol generation session.

[0135] The heating profile has four progressive step - downs while the temperature is maintained at ≥ 360 °C during the usage session. The aerosol supply device may comprise a pin - shaped heater element or a blade - shaped heater element as described above with reference to FIGS. 3, 5 and 6. Alternatively, the heater element may comprise an induction heater element, i.e., the heater element may comprise a heating material that is inductively heated by an RF generator.

[0136] According to various embodiments, the controller may be configured to control the heater element to heat to a first target operating temperature T1 during a first period t0 - t1, to a second target operating temperature T2 during a second period t1 - t2, to a third target operating temperature T3 during a third period t2 - t3, and to a fourth target operating temperature T4 during a fourth period t3 - t4. The temperature of the heater element may be arranged to gradually decrease during the progression of the aerosol generation session such that T1 > T2 > T3 > T4. It will also be understood that t0 < t1 < t2 < t3 < t4.

[0137] The aerosol supply device may comprise a temperature sensor for monitoring or sensing the temperature of the aerosol generator during the aerosol generation session as described above.

[0138] The time t0 may correspond to the time when the controller first activates or turns on the aerosol generator, or for example supplies current to the heater element. The heater element may be set to the first target operating temperature T1, but it may take several seconds for the heater element to reach either the first target operating temperature T1 or a lower temperature that is sufficient to generate aerosol. This initial time may be referred to as the ramp - up time or the time to first puff. The aerosol generation session may be considered to start after the ramp - up time or the time to first puff at time t_start, where t0 < t_start < t1. The time to t_start may be, for example, 10 - 20 seconds. With respect to the heating profile shown in FIG. 8, t_start is 15 seconds after time t0.

[0139] The controller may be configured to execute a heating mode, where the desired operating temperature set remains ≧360° C. as the temperature is progressively reduced. For example, according to an embodiment, the lowest target operating temperature T4 that may be set for the heater element during a use session may be configured to be ≧360° C.

[0140] 8 is for a second or boost mode of operation that provides the user with a total aerosol generation session time of approximately 180 seconds (i.e., 3 minutes). According to this particular embodiment, the time from t0 to t_start is 15 seconds, and the time from t_start to t4 (when the aerosol generator or heating element is switched off) is 180 seconds. [Table 3]

[0141] When the controller sets a heating profile such as the heating profile shown in FIG. 8, the controller may be configured to ensure that the first target operating temperature T1 is achieved as quickly as possible, thereby shortening the time to first puff. For example, with reference to the heating profile shown in FIG. 8, the first target operating temperature T1 set by the controller may be 380°C. Other embodiments are contemplated in which the first target operating temperature T1 may be 380±10°C. According to various embodiments, the first target operating temperature T1 may be 370-375°C, 375-380°C, 380-385°C, or 385-390°C. The controller may be configured to set the heater element to the first target operating temperature T1 during a first time period t0-t1. The first time period t0-t1 may be 40 seconds. Other embodiments are contemplated in which t0-t1 may be 40±10 seconds. According to an embodiment, t0-t1 may be 30-35 seconds, 35-40 seconds, 40-45 seconds, or 45-50 seconds.

[0142] A user may activate the aerosol delivery device at time t0 to cause the controller to set one or more aerosol generators to a desired heating profile. For example, a user may activate a user interface (e.g., see user interface 106 as shown in FIG. 1 ) provided on the aerosol delivery device to cause the controller to set one or more aerosol generators to a desired heating profile for the one or more aerosol generators. Once the user interacts with the user interface and the controller sets the desired heating profile for one or more aerosol generators, there may be a relatively short time delay (between time t0 and t_start) before the aerosol generators reach the desired temperature and can generate sufficient aerosol from an aerosol product article at least partially inserted into the aerosol delivery device. The time delay may be referred to as a ramp-up time or time to first puff. As shown in FIG. 8 , an aerosol generation session may be considered to have begun at the end of the ramp-up time or time to first puff (e.g., at time t_start). In the example shown in FIG. 8 , the ramp-up time or time to first puff (i.e., time t0 and t_start) is 15 seconds. However, according to other embodiments, the ramp-up time or time to first puff may be shorter or longer than 15 seconds, for example, 5-10 seconds, 10-15 seconds, 15-20 seconds, or 20-25 seconds.

[0143] With respect to the heating profile shown in FIG. 8 , the controller may set one or more aerosol generators to a first target temperature T1 for a period of, for example, 40 seconds immediately upon activation of the aerosol delivery device by a user. If the time to first puff or ramp-up time is 15 seconds, it is understood that the controller may be configured to maintain the desired first target operating temperature T1, for example, 380° C., for an additional 25 seconds after the ramp-up time or time to first puff has occurred. At the end of the first period t0-t1, the controller may be configured to set progressively lower target operating temperatures. For example, after the end of the first period t0-t1, the controller may be configured to set a second target operating temperature T2 of one or more aerosol generators. The second target operating temperature T2 may be 370° C. It will be understood that the second target operating temperature T2 is lower than the first target operating temperature T1. Other embodiments are envisioned in which T2 may be 370±10° C. According to embodiments, T2 may be 360-365°C, 365-370°C, 370-375°C, or 375-380°C. The controller may be configured to set one or more aerosol generators to a second target operating temperature T2 during a second time period t1-t2. The second time period t1-t2 may be 40 seconds. Other embodiments are envisioned in which t1-t2 may be 40±10 seconds. According to embodiments, t1-t2 may be 30-35 seconds, 35-40 seconds, 40-45 seconds, or 45-50 seconds.

[0144] After the second time period t1-t2 expires, the controller may be configured to set progressively lower target operating temperatures. For example, after the second time period t1-t2 expires, the controller may be configured to set a third target operating temperature T3 for one or more aerosol generators. The third target operating temperature T3 may be 365°C. It will be understood that the third target operating temperature T3 is lower than the second target operating temperature T2. Other embodiments are contemplated in which T3 may be 365±10°C. According to embodiments, T3 may be 355-360°C, 360-365°C, 365-370°C, or 370-375°C. The controller may be configured to set one or more aerosol generators to the third target operating temperature T3 during a third time period t2-t3. The third time period t2-t3 may be 40 seconds. Other embodiments are contemplated in which t2-t3 may be 40±10 seconds. According to an embodiment, t2-t3 may be 30-35 seconds, 35-40 seconds, 40-45 seconds, or 45-50 seconds.

[0145] At the end of the third time period t2-t3, the controller may be configured to set a lower target operating temperature. For example, after the end of the third time period t2-t3, the controller may be configured to set a fourth target operating temperature T4 for one or more aerosol generators. The fourth target operating temperature T4 may be 360°C. It will be understood that the fourth target operating temperature T4 is lower than the third target operating temperature T3. Other embodiments are contemplated in which T4 may be 360±10°C. According to embodiments, T4 may be 350-355°C, 355-360°C, 360-365°C, or 365-370°C. The controller may be configured to set one or more aerosol generators to the fourth target operating temperature T4 during a fourth time period t3-t4. The fourth time period t3-t4 may be 75 seconds. Other embodiments are contemplated in which t3-t4 may be 75±10 seconds. According to an embodiment, t3-t4 may be 65-70 seconds, 70-75 seconds, 75-80 seconds, or 80-85 seconds.

[0146] 8, as described above, the total aerosol generation session length may be 180 seconds, i.e., the use session may be configured to end after a total use session length of 195 seconds, and the aerosol delivery device was ready for use after a 15-second ramp-up time or time to first puff (i.e., time t0 to t_start was 15 seconds). Note that, according to an embodiment, the maximum operating temperature set for the heater element may be approximately 380°C.

[0147] According to an alternative embodiment of the second or boost mode of operation, the controller sets a heating profile similar to that of Figure 8. The heating profile has four gradual step-downs during which the temperature is maintained at ≥ 410°C over the course of a use session. [Table 4]

[0148] The first target operating temperature T1 set by the controller may be 430° C. Other embodiments are envisioned in which the first target operating temperature T1 may be 430±10° C. According to various embodiments, the first target operating temperature T1 may be 420-425° C., 425-430° C., 430-435° C., or 435-440° C.

[0149] The second target operating temperature T2 may be 420°C. It will be appreciated that the second target operating temperature T2 is lower than the first target operating temperature T1. Other embodiments are envisioned in which T2 may be 420±10°C. According to embodiments, T2 may be 410-415°C, 415-320°C, 420-425°C, or 425-430°C.

[0150] The third target operating temperature T3 may be 415°C. It will be appreciated that the third target operating temperature T3 is lower than the second target operating temperature T2. Other embodiments are envisioned in which T3 may be 415±10°C. According to embodiments, T3 may be 405-410°C, 410-415°C, 415-420°C, or 420-425°C.

[0151] The fourth target operating temperature T4 may be 410°C. It will be appreciated that the fourth target operating temperature T4 is lower than the third target operating temperature T3. Other embodiments are envisioned in which T4 may be 410±10°C. According to embodiments, T4 may be 400-405°C, 405-410°C, 410-415°C, or 415-420°C.

[0152] The maximum operating temperature set for the heater element may be approximately 430°C.

[0153] The embodiment is otherwise the same as that described with respect to FIG.

[0154] 9 illustrates a heating profile according to one embodiment that may be set by a controller (e.g., controller 420 as shown in FIG. 5) for an aerosol generator when the aerosol delivery device operates in a second or boost mode of operation. The second or boost mode of operation may be configured to have a shorter session time, e.g., 180 seconds (i.e., 3 minutes). An entire use session may last 190 seconds, i.e., the entire use session may include a 10-second ramp-up period followed by a 180-second aerosol generation session.

[0155] The heating profile has four progressive step - downs while the temperature is maintained at ≥ 360 °C during the usage session. The aerosol supply device may comprise a pin - shaped heater element or a blade - shaped heater element as described above with reference to FIGS. 3, 5 or 6. Alternatively, the heater element may comprise an induction heater element, i.e., the heater element may comprise a heating material that is inductively heated by an RF generator.

[0156] According to various embodiments, the controller may be configured to control the heater element to heat to a first target operating temperature T1 during a first period t0 - t1, to a second target operating temperature T2 during a second period t1 - t2, to a third target operating temperature T3 during a third period t2 - t3, and to a fourth target operating temperature T4 during a fourth period t3 - t4. The temperature of the heater element may be configured to gradually decrease during the progress of the usage session such that T1 > T2 > T3 > T4. It will also be understood that t0 < t1 < t2 < t3 < t4.

[0157] The aerosol supply device may comprise a temperature sensor for monitoring or sensing the temperature of the aerosol generator during the usage session as described above.

[0158] The time t0 may correspond to the time when the controller first activates or turns on the aerosol generator, or for example supplies current to the heater element. The heater element may be set to the first target operating temperature T1, but it may take several seconds for the heater element to reach either the first target operating temperature T1 or a lower temperature sufficient to generate an aerosol. This initial time may be referred to as the ramp - up time or the time to the first puff. The aerosol generation session may be considered to start after the ramp - up time or the time to the first puff at time t_start, where t0 < t_start < t1. The time to t_start may be, for example, 10 - 20 seconds. For the heating profile shown in FIG. 9, t_start is 10 seconds after time t0.

[0159] The controller may be configured to perform a heating mode, where the desired operating temperature set remains ≧360° C. as the temperature is progressively reduced. For example, according to an embodiment, the minimum target operating temperature T4 set for the heater element during a use session may be configured to be ≧360° C.

[0160] 9 is for a boost mode of operation that provides the user with a total aerosol generation session time of approximately 180 seconds (i.e., 3 minutes). According to this particular embodiment, the time from t0 to t_start is 10 seconds, and the time from t_start to t4 (when the aerosol generator or heating element is switched off) is 180 seconds. [Table 5]

[0161] When the controller sets a heating profile, such as the heating profile shown in FIG. 9, the controller may be configured to ensure that the first target operating temperature T1 is achieved as quickly as possible, thereby shortening the time to first puff. For example, with reference to the heating profile shown in FIG. 9, the first target operating temperature T1 set by the controller may be 390°C. Other embodiments are contemplated in which the first target operating temperature T1 may be 390±10°C. According to various embodiments, the first target operating temperature T1 may be 380-385°C, 385-390°C, 390-395°C, or 395-400°C. The controller may be configured to set the heater element to the first target operating temperature T1 during a first time period t0-t1. The first time period t0-t1 may be 20 seconds. Other embodiments are contemplated in which t0-t1 may be 20±10 seconds. According to an embodiment, t0-t1 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0162] A user may activate the aerosol delivery device at time t0 to cause the controller to set one or more aerosol generators to a desired heating profile. For example, a user may activate a user interface (e.g., see user interface 106 as shown in FIG. 1 ) provided on the aerosol delivery device to cause the controller to set one or more aerosol generators to a desired heating profile for the one or more aerosol generators. Once the user interacts with the user interface and the controller sets the desired heating profile for one or more aerosol generators, there may be a relatively short time delay (between time t0 and t_start) before the aerosol generators reach the desired temperature and can generate sufficient aerosol from an aerosol product article at least partially inserted into the aerosol delivery device. The time delay may be referred to as a ramp-up time or time to first puff. As shown in FIG. 9 , an aerosol generation session may be considered to have begun at the end of the ramp-up time or time to first puff (e.g., at time t_start). In the example shown in FIG. 9 , the ramp-up time or time to first puff (i.e., time t0 and t_start) is 10 seconds. However, according to other embodiments, the ramp-up time or time to first puff may be shorter or longer than 10 seconds, for example, 5-10 seconds or 10-15 seconds.

[0163] With respect to the heating profile shown in FIG. 9 , the controller may set one or more aerosol generators to a first target temperature T1 for a period of, for example, 20 seconds immediately upon activation of the aerosol delivery device by a user. If the time to first puff or ramp-up time is 10 seconds, it is understood that the controller may be configured to maintain the desired first target operating temperature T1, for example, 390°C, for an additional 10 seconds after the ramp-up time or time to first puff has occurred. At the end of the first period t0-t1, the controller may be configured to set progressively lower target operating temperatures. For example, after the end of the first period t0-t1, the controller may be configured to set a second target operating temperature T2 of one or more aerosol generators. The second target operating temperature T2 may be 380°C. It will be understood that the second target operating temperature T2 is lower than the first target operating temperature T1. Other embodiments are envisioned in which T2 may be 380±10°C. According to embodiments, T2 may be 370-375°C, 375-380°C, 380-385°C, or 385-390°C. The controller may be configured to set one or more aerosol generators to a second target operating temperature T2 during a second time period t1-t2. The second time period t1-t2 may be 40 seconds. Other embodiments are envisioned in which t1-t2 may be 40±10 seconds. According to embodiments, t1-t2 may be 30-35 seconds, 35-40 seconds, 40-45 seconds, or 45-50 seconds.

[0164] After the second time period t1-t2 expires, the controller may be configured to set progressively lower target operating temperatures. For example, after the second time period t1-t2 expires, the controller may be configured to set a third target operating temperature T3 for one or more aerosol generators. The third target operating temperature T3 may be 370°C. It will be understood that the third target operating temperature T3 is lower than the second target operating temperature T2. Other embodiments are contemplated in which T3 may be 370±10°C. According to embodiments, T3 may be 360-365°C, 365-370°C, 370-375°C, or 375-380°C. The controller may be configured to set one or more aerosol generators to the third target operating temperature T3 during a third time period t2-t3. The third time period t2-t3 may be 40 seconds. Other embodiments are contemplated in which t2-t3 may be 40±10 seconds. According to an embodiment, t2-t3 may be 30-35 seconds, 35-40 seconds, 40-45 seconds, or 45-50 seconds.

[0165] At the end of the third time period t2-t3, the controller may be configured to set a lower target operating temperature. For example, after the end of the third time period t2-t3, the controller may be configured to set a fourth target operating temperature T4 for one or more aerosol generators. The fourth target operating temperature T4 may be 360°C. It will be understood that the fourth target operating temperature T4 is lower than the third target operating temperature T3. Other embodiments are contemplated in which T4 may be 360±10°C. According to embodiments, T4 may be 350-355°C, 355-360°C, 360-365°C, or 365-370°C. The controller may be configured to set one or more aerosol generators to the fourth target operating temperature T4 during a fourth time period t3-t4. The fourth time period t3-t4 may be 90 seconds. Other embodiments are contemplated in which t3-t4 may be 90±10 seconds. According to an embodiment, t3-t4 may be 80-85 seconds, 85-90 seconds, 90-95 seconds, or 95-100 seconds.

[0166] 9, as described above, the user may be given a total aerosol generation session length of 180 seconds, i.e., the use session may be configured to end after a total time of 195 seconds, and the aerosol delivery device was ready for use after a 10-second ramp-up time or time to first puff. Note that, according to an embodiment, the maximum operating temperature set for the heater element may be approximately 390°C.

[0167] According to an alternative embodiment, the controller sets a heating profile similar to that of Figure 9. The heating profile has four gradual step-downs during which the temperature is maintained at ≥ 410°C during the use session. [Table 6]

[0168] The first target operating temperature T1 set by the controller may be 440° C. Other embodiments are envisioned in which the first target operating temperature T1 may be 440±10° C. According to various embodiments, the first target operating temperature T1 may be 430-435° C., 435-340° C., 440-345° C., or 445-350° C.

[0169] The second target operating temperature T2 may be 430°C. It will be appreciated that the second target operating temperature T2 is lower than the first target operating temperature T1. Other embodiments are envisioned in which T2 may be 430±10°C. According to embodiments, T2 may be 420-425°C, 425-430°C, 430-435°C, or 435-440°C.

[0170] The third target operating temperature T3 may be 420°C. It will be appreciated that the third target operating temperature T3 is lower than the second target operating temperature T2. Other embodiments are envisioned in which T3 may be 420±10°C. According to embodiments, T3 may be 410-415°C, 415-420°C, 420-425°C, or 425-430°C.

[0171] The fourth target operating temperature T4 may be 410°C. It will be appreciated that the fourth target operating temperature T4 is lower than the third target operating temperature T3. Other embodiments are envisioned in which T4 may be 410±10°C. According to embodiments, T4 may be 400-405°C, 405-410°C, 410-415°C, or 415-420°C.

[0172] The maximum operating temperature set for the heater element may be approximately 440°C.

[0173] The embodiment is otherwise the same as that described with respect to FIG.

[0174] 12 illustrates a heating profile according to one embodiment that may be set by a controller (e.g., controller 420 as shown in FIG. 5) for an aerosol generator when the aerosol delivery device operates in a second or boost mode of operation. The second or boost mode of operation may be configured to have a shorter aerosol generation session time, for example, 180 seconds (i.e., 3 minutes). An entire use session may last 205 seconds, i.e., the entire use session may include a 15-second ramp-up period followed by a 180-second aerosol generation session.

[0175] The heating profile has nine gradual step-downs during which the temperature is maintained at ≥ 380°C over the course of a use session. The aerosol delivery device may comprise a pin-shaped or blade-shaped heater element as described above with reference to Figures 3, 5 and 6. Alternatively, the heater element may comprise an induction heater element, i.e., the heater element may comprise a heating material that is inductively heated by an RF generator.

[0176] According to various embodiments, the controller may be configured to control the heater element to heat to a first target operating temperature T1 during a first period t0 - t1, heat to a second target operating temperature T2 during a second period t1 - t2, heat to a third target operating temperature T3 during a third period t2 - t3, heat to a fourth target operating temperature T4 during a fourth period t3 - t4, heat to a fifth target operating temperature T5 during a fifth period t4 - t5, heat to a sixth target operating temperature T6 during a sixth period t5 - t6, heat to a seventh target operating temperature T7 during a seventh period t6 - t7, heat to an eighth target operating temperature T8 during an eighth period t7 - t8, and heat to a ninth target operating temperature T9 during a ninth period t8 - t9. The temperature of the heater element may be arranged to gradually decrease during the progress of the aerosol generation session such that the temperatures are T1>T2>T3>T4>T5>T6>T7>T8>T9. It will also be understood that the times are t0<t1<t2<t3<t4<t5<t6<t7<t8<t9.

[0177] The aerosol supply device may include a temperature sensor for monitoring or sensing the temperature of the aerosol generator during the aerosol generation session as described above. The time t0 may correspond to the time when the controller first activates or turns on the aerosol generator, or for example supplies current to the heater element. The heater element may be set to the first target operating temperature T1, but it may take several seconds to reach either the first target operating temperature T1 or a lower temperature sufficient to generate an aerosol. This initial time may be referred to as the ramp-up time or the time to the first puff. The aerosol generation session may be considered to start after the ramp-up time or the time to the first puff at time t_start, where t0<t_start<t1. The time to t_start may be, for example, 10 - 20 seconds. With respect to the heating profile shown in FIG. 8, t_start is 15 seconds after time t0.

[0178] The controller may be configured to execute a heating mode, where the desired operating temperature set remains ≧380° C. as the temperature is progressively reduced. For example, according to an embodiment, the lowest target operating temperature T9 that may be set for the heater element during a use session may be configured to be ≧380° C.

[0179] 12 is for a boost mode of operation that provides the user with a total aerosol generation session time of approximately 180 seconds (i.e., 3 minutes). According to this particular embodiment, the time from t0 to t_start is 15 seconds, and the time from t_start to t9 (when the aerosol generator or heating element is switched off) is 180 seconds. [Table 7]

[0180] When the controller sets a heating profile such as the heating profile shown in FIG. 12, the controller may be configured to ensure that the first target operating temperature T1 is achieved as quickly as possible, thereby shortening the time to first puff. For example, with reference to the heating profile shown in FIG. 12, the first target operating temperature T1 set by the controller is 400°C. In other embodiments, the first target operating temperature T1 may be 400±10°C. According to various embodiments, the first target operating temperature T1 may be 390-395°C, 395-400°C, 400-405°C, or 405-410°C. The controller may be configured to set the heater element to the first target operating temperature T1 during a first time period t0-t1. The first time period t0-t1 may be 20 seconds. Other embodiments are contemplated in which t0-t1 may be 20±10 seconds. According to an embodiment, t0-t1 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0181] A user may activate the aerosol delivery device at time t0 to cause the controller to set one or more aerosol generators to a desired heating profile (see, for example, user interface 106 as shown in FIG. 1). Once the user interacts with the user interface and the controller sets the desired heating profile for one or more aerosol generators, there may be a relatively short time delay (between time t0 and t_start) before the aerosol generators reach the desired temperature and can generate sufficient aerosol from an aerosol product item at least partially inserted into the aerosol delivery device. The time delay may be referred to as a ramp-up time or time to first puff. As shown in FIG. 12, an aerosol generation session may be considered to have begun at the end of the ramp-up time or time to first puff (e.g., at time t_start). For the example shown in FIG. 8, the ramp-up time or time to first puff (i.e., time t0 and t_start) is 15 seconds. However, according to other embodiments, the ramp-up time or time to first puff may be shorter or longer than 15 seconds, for example, 5-10 seconds, 10-15 seconds, 15-20 seconds, or 20-25 seconds.

[0182] With respect to the heating profile shown in FIG. 12 , the controller may set one or more aerosol generators to a first target temperature T1 for a period of, for example, 20 seconds immediately upon activation of the aerosol delivery device by a user. If the time to first puff or ramp-up time is 15 seconds, it is understood that the controller may be configured to maintain the desired first target operating temperature T1, for example, 400°C, for an additional 5 seconds after the ramp-up time or time to first puff has occurred. At the end of the first period t0-t1, the controller may be configured to set progressively lower target operating temperatures. For example, after the end of the first period t0-t1, the controller may be configured to set a second target operating temperature T2 of one or more aerosol generators. The second target operating temperature T2 may be 396°C. It will be understood that the second target operating temperature T2 is lower than the first target operating temperature T1. Other embodiments are envisioned in which T2 may be 396±10°C. According to embodiments, T2 may be 386-391°C, 391-396°C, 396-401°C, or 401-406°C. The controller may be configured to set one or more aerosol generators to a second target operating temperature T2 during a second time period t1-t2. The second time period t1-t2 may be 20 seconds. Other embodiments are envisioned in which t1-t2 may be 20±10 seconds. According to embodiments, t1-t2 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0183] After the second time period t1-t2 expires, the controller may be configured to set progressively lower target operating temperatures. For example, after the second time period t1-t2 expires, the controller may be configured to set a third target operating temperature T3 for one or more aerosol generators. The third target operating temperature T3 may be 394°C. It will be understood that the third target operating temperature T3 is lower than the second target operating temperature T2. Other embodiments are contemplated in which T3 may be 394±10°C. According to embodiments, T3 may be 384-389°C, 389-394°C, 394-399°C, or 399-404°C. The controller may be configured to set one or more aerosol generators to the third target operating temperature T3 during a third time period t2-t3. The third time period t2-t3 may be 20 seconds. Other embodiments are contemplated in which t2-t3 may be 20±10 seconds. According to an embodiment, t2-t3 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0184] At the end of the third time period t2-t3, the controller may be configured to set a lower target operating temperature. For example, after the end of the third time period t2-t3, the controller may be configured to set a fourth target operating temperature T4 for one or more aerosol generators. The fourth target operating temperature T4 may be 392°C. It will be understood that the fourth target operating temperature T4 is lower than the third target operating temperature T3. Other embodiments are contemplated in which T4 may be 392°C ± 10°C. According to embodiments, T4 may be 382-387°C, 387-392°C, 392-397°C, or 397-402°C. The controller may be configured to set one or more aerosol generators to the fourth target operating temperature T4 during a fourth time period t3-t4. The fourth time period t3-t4 may be 20 seconds. Other embodiments are contemplated in which t3-t4 may be 20°C ± 10 seconds. According to an embodiment, t3-t4 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0185] At the end of the fourth time period t3-t4, the controller may be configured to set a lower target operating temperature. For example, after the end of the fourth time period t3-t4, the controller may be configured to set a fifth target operating temperature T5 for one or more aerosol generators. The fifth target operating temperature T5 may be 390°C. It will be understood that the fifth target operating temperature T5 is lower than the fourth target operating temperature T4. Other embodiments are contemplated in which T5 may be 390±10°C. According to embodiments, T5 may be 380-385°C, 385-390°C, 390-395°C, or 395-400°C. The controller may be configured to set one or more aerosol generators to the fifth target operating temperature T5 during the fifth time period t4-t5. The fifth time period t4-t5 may be 20 seconds. Other embodiments are contemplated in which t4-t5 may be 20±10 seconds. According to an embodiment, t3-t4 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0186] At the end of the fifth time period t4-t5, the controller may be configured to set a lower target operating temperature. For example, after the end of the fifth time period t4-t5, the controller may be configured to set a sixth target operating temperature T6 for one or more aerosol generators. The sixth target operating temperature T6 may be 386°C. It will be understood that the sixth target operating temperature T6 is lower than the fifth target operating temperature T5. Other embodiments are contemplated in which T6 may be 386±10°C. According to embodiments, T6 may be 376-381°C, 381-386°C, 386-391°C, or 391-396°C. The controller may be configured to set one or more aerosol generators to the sixth target operating temperature T6 during the sixth time period t5-t6. The sixth time period t5-t6 may be 20 seconds. Other embodiments are contemplated in which t5-t6 may be 20±10 seconds. According to an embodiment, t5-t6 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0187] At the end of the sixth time period t5-t6, the controller may be configured to set a lower target operating temperature. For example, after the end of the sixth time period t5-t6, the controller may be configured to set a seventh target operating temperature T7 for one or more aerosol generators. The seventh target operating temperature T7 may be 384°C. It will be understood that the seventh target operating temperature T7 is lower than the sixth target operating temperature T6. Other embodiments are contemplated in which T7 may be 384±10°C. According to embodiments, T7 may be 374-379°C, 379-384°C, 384-389°C, or 389-404°C. The controller may be configured to set one or more aerosol generators to the seventh target operating temperature T7 during the seventh time period t6-t7. The seventh time period t6-t7 may be 20 seconds. Other embodiments are contemplated in which t6-t7 may be 20±10 seconds. According to an embodiment, t6-t7 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0188] At the end of the seventh time period t6-t7, the controller may be configured to set a lower target operating temperature. For example, after the end of the seventh time period t6-t7, the controller may be configured to set an eighth target operating temperature T8 for one or more aerosol generators. The eighth target operating temperature T8 may be 382°C. It will be understood that the eighth target operating temperature T8 is lower than the seventh target operating temperature T7. Other embodiments are contemplated in which T7 may be 382±10°C. According to embodiments, T8 may be 372-377°C, 377-382°C, 382-387°C, or 387-402°C. The controller may be configured to set one or more aerosol generators to the eighth target operating temperature T8 during the eighth time period t7-t8. The eighth time period t7-t8 may be 20 seconds. Other embodiments are contemplated in which t7-t8 may be 20±10 seconds. According to an embodiment, t7-t8 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0189] At the end of the eighth time period t7-t8, the controller may be configured to set a lower target operating temperature. For example, after the end of the eighth time period t7-t8, the controller may be configured to set a ninth target operating temperature T9 for one or more aerosol generators. The ninth target operating temperature T9 may be 380°C. It will be understood that the ninth target operating temperature T9 is lower than the eighth target operating temperature T8. Other embodiments are contemplated in which T8 may be 380±10°C. According to embodiments, T9 may be 370-375°C, 375-380°C, 380-385°C, or 385-400°C. The controller may be configured to set one or more aerosol generators to the ninth target operating temperature T9 during the ninth time period t8-t9. The ninth time period t8-t9 may be 20 seconds. Other embodiments are contemplated in which t8-t9 may be 20±10 seconds. According to an embodiment, t8-t9 may be 10-15 seconds, 15-20 seconds, 20-25 seconds, or 25-30 seconds.

[0190] 12, as described above, the total aerosol generation session length may be 180 seconds, i.e., the use session may be configured to end after a total use session length of 195 seconds, and the aerosol delivery device was ready for use after a 15-second ramp-up time or time to first puff (i.e., time t0 to t_start was 15 seconds). Note that, according to an embodiment, the maximum operating temperature set for the heater element may be approximately 380°C.

[0191] It will be understood that many different heating profiles were tested, but only a small number were selected and are disclosed in this application. An initial screening of the different heating profiles was performed by making an initial assessment of sensory attributes such as visible aerosol production, mouth feel, back of throat sensation (i.e., impact), taste quality, and whether any off-notes were detected.

[0192] Those heating profiles that provided either a good or excellent overall sensory experience were then subjected to more detailed testing. The various different heating profiles illustrated and described above with reference to Figures 7-9 and 12 were found, during an initial screening process, to provide an excellent overall sensory experience. The heating profiles were then further tested by a panel of 6-10 users, and the sensory experience was evaluated using a sequential monadic testing method involving taking 10 puffs during the course of a session. The specific heating profiles illustrated and described with reference to Figures 7-9 and 12 were all found to provide an excellent overall sensory experience.

[0193] A common feature of heating profiles such as those disclosed with reference to Figures 7-9 and 12 is that the target operating temperature of one or more aerosol generators or heater elements is progressively reduced over the course of a usage session. The various heating profiles disclosed herein have been found to provide a sensory experience in which taste quality is preserved / extended throughout the aerosol generation session.

[0194] The heating profiles illustrated and described above with reference to Figures 7-9 and 12 were evaluated by a panel of users to assess 16 different sensory attributes. Six sensory attributes related to "immediacy" were assessed after the first two puffs in a session. These sensory attributes were resistance to draw, aerosol warmth, visible aerosol, impact, sting, and flavor intensity. An additional 10 sensory attributes related to "overall experience" were assessed after 10 puffs over the course of a use session. These attributes were resistance to draw, aerosol warmth, visible aerosol, impact, sting, tobacco taste intensity, flavor intensity, overall flavor intensity, off-taste, and flavor consistency. The sensory testing confirmed that the three heating profiles illustrated and described above with reference to Figures 7-9 and 12 provided a superior sensory experience.

[0195] It will be understood that various alternative heating profiles that were evaluated as providing an average or poor sensory experience were rejected, and details of the rejected heating profiles are not included in this application.

[0196] For example, some heating profiles with desired operating temperatures below 300°C were rejected because incomplete or nonexistent aerosol formation was observed. Similarly, some heating profiles with desired operating temperatures above 400°C were rejected because they caused carbonization and / or combustion of the aerosol product. While some of the heating profiles disclosed herein have relatively high maximum operating temperatures, particularly those associated with boost operating modes where the maximum desired operating temperature is, for example, 380°C (FIG. 8) or 390°C (FIG. 9) (or 430°C or 440°C), it should be noted that the heater element is only maintained at the maximum desired operating temperature for a relatively short period before the desired operating temperature is stepped down. Furthermore, the maximum desired operating temperature occurs during the first period t0-t1, which includes the initial ramp-up time. In other words, during the first period t0-t1, in which the desired operating temperature is set relatively high, the aerosol generator or heater element does not achieve the first target operating temperature T1 until several seconds after the initialization of the heating profile.

[0197] According to embodiments, the aerosol generator or heater element may take several seconds to achieve the first target operating temperature T1, and therefore the aerosol generator or heater element may be maintained at the first target operating temperature T1 for x% of the first time period t0-t1, where x% may be <70%, 70-75%, 75-80%, 80-85%, 85-90%, 90-95%, or >95%.

[0198] Additionally, the total length of the aerosol generation session utilizing some of the heating profiles tested was found to result in an unacceptably short total aerosol generation session time. For example, some heating profiles were found to result in the aerosol product being consumed after approximately two minutes. Thus, even if a heating profile was found to provide a good sensory experience, it was rejected if its maximum aerosol generation session time was too short. Similarly, heating profiles that resulted in an unacceptably long time to first puff were also rejected. Note that for the three heating profiles shown and described above with reference to Figures 7-9, there is an inverse relationship between the first target operating temperature T1 and the time to first puff. For example, for the heating profile shown in Figure 7, the time to first puff was 20 seconds and the first target operating temperature T1 was 350°C. In the heating profile shown in Figure 8, the time to the first puff was 15 seconds and the first target operating temperature T1 was 380°C; similarly, in the heating profile shown in Figure 9, the time to the first puff was 10 seconds and the first target operating temperature T1 was 390°C.

[0199] A further criterion for selecting or rejecting a heating profile is that it is desirable to provide an aerosol delivery device capable of operating in at least two different modes that provide two (or more) different sensory experiences to the user. Thus, heating profiles were also selected or rejected based on providing differentiated sensory experiences. Heating profiles that were not found to provide a differentiated sensory experience were rejected.

[0200] Other factors that influenced whether a heating profile was selected or rejected were MNPH (total aerosol) analysis and puff-by-puff emission testing. The various heating profiles shown and described with reference to FIGS. 7-9 and 12 were found not to result in undesirably hot puffs, and the temperature of the aerosol delivery device in the user's hand was found to be within acceptable safety limits. The various heating profiles shown and described with reference to FIGS. 7-9 and 12 were also found not to excessively deplete the aerosol delivery device's battery, such that the aerosol delivery device was capable of performing multiple aerosol generation sessions before needing to be recharged. The various heating profiles shown and described with reference to FIGS. 7-9 and 12 were also found not to cause the production of any undesirable carbonyls or potentially toxic substances. The heating profiles described above with reference to FIGS. 7-9 and 12 were also found not to produce undesirable amounts of condensate.

[0201] According to various embodiments, after the ramp time t_start and / or when the aerosol generator or heating element reaches a first target operating temperature T1, one or more indicator devices may indicate to a user that the aerosol delivery device is ready for use. For example, the indicator device may include one or more light-emitting diodes (LEDs) provided on a user interface of the aerosol delivery device. The number of illuminated LEDs, and / or the color of the one or more illuminated LEDs, and / or the intensity of the one or more illuminated LEDs may indicate to a user when the aerosol delivery device is ready for use. Additionally or alternatively, the indicator device may include a tactile feedback device. Embodiments are also contemplated in which the indicator device may additionally or alternatively include an audible indicator device. The one or more indicator devices, as described above, may also indicate to a user when an aerosol generation session is complete.

[0202] As described in more detail below with reference to FIG. 10 , embodiments are contemplated in which an aerosol product article having flavor capsules can be heated by an aerosol delivery device according to various embodiments as described above, and the aerosol delivery device can be operated in either a first heating mode of operation (e.g., as shown and described with reference to FIG. 7 ) or a second heating mode of operation (e.g., as shown and described with reference to FIGS. 8 and 9 ). Embodiments are contemplated in which the first heating mode of operation provides an optimal sensory experience when the flavor capsules are not fragmented, and the second heating mode of operation provides an optimal sensory experience when the flavor capsules are fragmented. In other embodiments, the first heating mode is contemplated in which the first heating mode provides an optimal sensory experience when the flavor capsules are fragmented, and the second heating mode is contemplated in which the second heating mode provides an optimal sensory experience when the flavor capsules are not fragmented.

[0203] According to embodiments, the aerosol delivery device may include a first aerosol generator including a first heater element and a second aerosol generator including a second heater element, wherein the first heater element may be configured to form a first heating zone capable of heating a first portion of the aerosol product article, and the second heater element may be configured to form a second heating zone capable of heating a second portion of the aerosol product article.

[0204] For completeness, it will be appreciated that the various heating profiles illustrated and described above with reference to Figures 7-9 are particularly suitable when the controller is configured to control the heating profile of a pin-shaped heater element (or blade-shaped heater element) configured to heat an aerosol-production article including multiple distinct sections or portions. The aerosol-production article may, in particular, include a cylindrical article including, for example, a cylindrical portion of aerosol-generating material disposed at a distal portion of the article. The cylindrical portion of aerosol-generating material may have a diameter of approximately 7.0 mm and a length of 12.0 mm. A first tubular element may 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 may 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 may be enclosed in one or more outer wrappings, which may have a combined thickness of approximately 200 μm.

[0205] FIG. 10 illustrates a side cross-sectional view of an aerosol product 1001 that may be utilized with an aerosol delivery device 1003 including a pin-shaped heater element 1002a as described in more detail above, according to various embodiments. The pin-shaped heater element 1002a may be controlled by a controller (not shown), and according to various embodiments, a heating profile such as that shown and described in connection with FIGS. 7-9 may be set for the heater element 1002a. In particular, the heater element 1002a may operate in a first or base mode of operation, such that a heating profile such as that shown in FIG. 7 may be set for the pin-shaped heater element 1002a according to one embodiment. As described above, the heating profile may include a profile that includes a series of four step-downs over the course of a use session. The set temperature for the heater element 1002a may be maintained at ≧320° C. throughout the use session. According to other embodiments, the heater element 1002a may be operated in a second or boost mode of operation, such that a heating profile such as that shown in FIG. 8 or 9 may be set for the pin-shaped heater element 1002a. As described above, the heating profile may have a profile including a series of four step-downs over the course of a use session. The temperature set for the heater element 1002a may be maintained at ≧360° C. throughout the use session. It is noted that while the first or base mode of operation may allow a user to experience an aerosol-generating session lasting approximately 300 seconds after the initial time to the first puff (t_start), the second or base mode of operation may allow a user to experience a different sensory experience in which the aerosol-generating session lasts for a shorter period of time, for example, 180 seconds after the initial time to the first puff (t_start). The different sensory experience is achieved in part by ensuring that the average temperature set for the heater element 1002a during the second or boost mode of operation is higher than the average temperature set for the heater element 1002a during the first or base mode of operation.

[0206] The aerosol product article 1001 may include an aerosol-generation section 1004 that may be inserted into a receiving portion 1002 of an aerosol delivery device 1003 during use. The receiving portion 1002 may include a recess within the aerosol delivery device 1003. The aerosol delivery device 1003 may include one or more aerosol generators, such as a pin-shaped heater 1002a. The pin-shaped heater 1002a may be located within the receiving portion 1002 of the aerosol delivery device 1003, and the pin-shaped heater may be positioned to penetrate the aerosol-generation section 1004 of the aerosol product article 1001 when the aerosol product article 1001 is inserted into the aerosol delivery device 1003 during use. The pin-shaped heater 1002a may be resistively heated and may include a resistive heater element. However, alternative embodiments are envisioned in which the heater element 1002a may include a blade-shaped heater element. Further embodiments are contemplated in which the aerosol generator may include a heater element formed of a heating material that can be inductively heated, and may also include a susceptor element. A magnetic field generator may be provided that is arranged to induce an alternating current in the susceptor element, thereby causing the susceptor element to heat. Still further embodiments are contemplated in which the aerosol-generation section 1004 of the aerosol product article 1001 may include a heating material that can be inductively heated, i.e., the article may include a susceptor element. For example, according to embodiments, the pin-shaped heater element 1002a may be omitted, and a susceptor element comprising a heating material may be located in the aerosol-generation section 1004. According to embodiments, a two-layer susceptor element may be provided, for example, including a stainless steel layer and a nickel-coated layer.

[0207] The article 1001 may include a downstream section 1005 downstream of the aerosol-generating section 1004. The downstream section 1005 may include or have 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 other examples, 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-former material by weight of the aerosol-generating material, calculated on a dry weight basis. The aerosol-former material may include, for example, glycerol or propylene glycol.

[0208] The mouth or downstream portion 1005 may include a first tubular element 1008a disposed immediately downstream of the aerosol-generation section 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 section 1004. The first tubular element 1008a may have a first tubular wall. The mouth 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 body of material 1006 may be provided at the downstream end 1005b of the downstream section 1005. 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 on a common axis. The first and second tubular elements 1008a, 1008b, the aerosol-generation section 1004, and the body of material 1006 may be arranged to have approximately the same outer diameter.

[0209] The first and second tubular elements 1008a, 1008b together can define a chamber into which the aerosol formed in the aerosol-generation section 1004 is drawn, expanded, and cooled. The provision of separate first and second tubular elements 1008a, 1008b allows these components to be designed to achieve different functional effects. For example, the first tubular element 1008a can be effective in reducing migration of aerosol-generating material when the article 1001 is inserted into the recess 1002 and 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 help provide rigidity to the article 1001. The first tubular element 1008a may also be positioned to encourage aerosol flow primarily through an axial region of the second tubular element 1008b to aid in aerosol formation. In contrast, the second tubular element 1008b may be positioned 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 section 1004 can be drawn as the aerosol expands and cools.

[0210] The aerosol product article 1001 may have a circumference of 22.1 mm, corresponding to a diameter of 7.0 mm. The aerosol-generating section 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 1003 may have a length of 17.0 mm. According to various embodiments, the aerosol-generating material provided in the aerosol-generating section 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 dimensions are 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 include first and second overlapping paper layers, each extending around substantially 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 and 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 indicated by arrow "B" in FIG. 10.

[0211] Those skilled in the art will appreciate that band-cast reconstituted tobacco has a relatively high density. Note that the various heating profiles disclosed above with reference to Figures 7-9 and 12 also have relatively high maximum target operating temperatures and relatively high minimum target operating temperatures. Over the course of a use session, the heating profiles described above with reference to Figures 7-9 and 12 can have an average target operating temperature of ≥ 320°C. The relatively high target operating temperature is particularly suited to generating aerosol from articles including band-cast reconstituted tobacco.

[0212] Article 1001 may include one or more vent openings 1012 extending through second tubular element 1008b at locations within second tubular element 1008b that are exterior to housing 1009 when article 1001 is fully inserted into aerosol delivery device 1003. One or more vent openings 1012 may be provided as one or more rows of openings, such as laser or mechanically formed perforations, surrounding article 1001.

[0213] The cylindrical rod of aerosol-generating material may include multiple strands and / or strips of aerosol-generating material surrounded by a wrapper 1015. The wrapper 1015 may be a moisture-impermeable wrapper. The multiple strands or strips of aerosol-generating material may be aligned within the aerosol-generation section 1004 such that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X′ of the article 1001. Alternatively, the strands or strips may be positioned such that their aligned longitudinal dimensions generally transverse the longitudinal axis of the article 1001. If the majority of the strands or strips are positioned within the aerosol-generation section 1004 such that their longitudinal axes are parallel to the longitudinal axis of the aerosol-generation section 1004 of the article 1001, the force required to insert an aerosol generator, such as the heater element 1002a, into the aerosol-generating material may be relatively low. This may result in the article 1001 being easier to use.

[0214] 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 filamentary tow, such as plasticized cellulose acetate tow. The wall of the first tubular element 1008a may be relatively non-porous so that at least 80% of the aerosol generated by the aerosol-generating material passes longitudinally through hollow channels through the tube rather than through the wall material itself. The first and second tubular elements 1008a, 1008b may be configured to provide a temperature difference of at least 40°C between the heated volatile components entering the first, upstream ends of the first and second tubular elements 1008a, 1008b and the heated volatile components exiting the second, downstream ends of the first and second tubular elements 1008a, 1008b. This temperature difference across the length of the first tubular element 1008a and the second tubular element 1008b may protect the temperature sensitive body of material 1006 from the high temperatures of the aerosol-generating material when heated.

[0215] The moisture-impermeable wrapper 1015 surrounding the rod of aerosol-generating material may comprise aluminum foil. The body of material 1006 may be wrapped in a first plug wrap 1007. A second plug wrap 1013 may 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 may be less than about 15 mm, for example, 12 mm. The body of material 1006 may be formed from filamentary tow. For example, the tow may comprise plasticized cellulose acetate tow or polylactic acid (PLA).

[0216] As shown in FIG. 11 , tipping paper 1016 may be wrapped around the entire length of downstream portion 1005 and over a portion of the rod of aerosol-generating material. The tipping paper 1016 may have adhesive on its inner surface to connect downstream portion 1005 and the rod of aerosol-generating material. The rod of aerosol-generating material may be wrapped in a wrapper 1015 forming a first packaging material, and the tipping paper 1016 may form an outer packaging material that extends at least partially over the rod of aerosol-generating material to connect downstream portion 1005 and the rod of aerosol-generating material. The tipping paper 1016 may extend 5 mm over the rod of aerosol-generating material to ensure a secure attachment. The article 1001 may have a ventilation level of approximately 25% of the aerosol drawn through the article 1001. The article 1001 may 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" of about 3.3 mm as shown in FIG.

[0217] The aerosol modifier may be provided within the body of material 1006 in the form of an additive release component. As shown in FIG. 10 , the additive release component may include a capsule 1011. However, it will be understood that the capsule 1011 is optional and may be omitted in various embodiments. If the article 1003 includes the capsule 1011, the first plug wrap 1007 may include an oil-resistant first plug wrap 1007. The capsule 1011 may be a frangible capsule, i.e., include a solid, frangible shell surrounding a liquid payload. The capsule 1011 may include a shell encapsulating a liquid agent, such as a flavoring or other agent. The capsule shell may be ruptured by a user to release the flavoring or other agent into the body of material 1006. The capsule 1011 may be spherical and may have a diameter of approximately 3 mm. The aerosol-generating material may include an aerosol former material. The aerosol former material may include, for example, glycerol or propylene glycol. The aerosol-forming material may also include an aerosol modifier, such as menthol.

[0218] 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 representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or equivalents thereof, and it will be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the 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. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An aerosol delivery device configured to receive at least a portion of an article comprising an aerosol-generating material, the aerosol delivery device comprising: one or more aerosol generators arranged to generate an aerosol from the aerosol-forming material; a controller configured to control the one or more aerosol generators during a session of use, wherein during the session of use, the controller controls the one or more aerosol generators to: (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; (iv) configured to control heating to a fourth target operating temperature T4 during a fourth time period t3-t4; temperatures T1>T2>T3>T4 and times t0<t1<t2<t3<t4, An aerosol delivery device, wherein T4 > 300°C.

2. 2. The aerosol delivery device of claim 1, wherein (i) T1 = 350±10°C, (ii) T2 = 340±10°C, (iii) T3 = 330±10°C, and (iv) T4 = 320±10°C.

3. 2. The aerosol delivery device of claim 1, wherein (i) T1 = 400±10°C, (ii) T2 = 390±10°C, (iii) T3 = 380±10°C, and (iv) T4 = 370±10°C.

4. 4. The aerosol delivery device of claim 1, 2, or 3, wherein (i) t0-t1 = 90±10 seconds, (ii) t1-t2 = 85±10 seconds, (iii) t2-t3 = 85±10 seconds, and (iv) t3-t4 = 60±10 seconds.

5. 2. The aerosol delivery device of claim 1, wherein (i) T1 = 380±10°C, (ii) T2 = 370±10°C, (iii) T3 = 365±10°C, and (iv) T4 = 360±10°C.

6. 2. The aerosol delivery device of claim 1, wherein (i) T1 = 430±10°C, (ii) T2 = 420±10°C, (iii) T3 = 415±10°C, and (iv) T4 = 410±10°C.

7. 7. The aerosol delivery device of claim 1, 5, or 6, wherein (i) t0-t1 = 40±10 seconds, (ii) t1-t2 = 40±10 seconds, (iii) t2-t3 = 40±10 seconds, and (iv) t3-t4 = 75±10 seconds.

8. 2. The aerosol delivery device of claim 1, wherein (i) T1 = 390±10°C, (ii) T2 = 380±10°C, (iii) T3 = 370±10°C, and (iv) T4 = 360±10°C.

9. 2. The aerosol delivery device of claim 1, wherein (i) T1 = 440±10°C, (ii) T2 = 430±10°C, (iii) T3 = 320±10°C, and (iv) T4 = 410±10°C.

10. 10. The aerosol delivery device of claim 1, 8, or 9, wherein (i) t0-t1 = 20±10 seconds, (ii) t1-t2 = 40±10 seconds, (iii) t2-t3 = 40±10 seconds, and (iv) t3-t4 = 90±10 seconds.

11. During the use session, the controller controls the one or more aerosol generators to: (v) heating to a fifth target operating temperature T5 during a fifth time period t4-t5; temperature T4>T5 and time t4<t5; and optionally (vi) heating to a sixth target operating temperature T6 during a sixth time period t5-t6; temperature T6>T5 and time t5<t6, and optionally (vii) heating to a seventh target operating temperature T7 during a seventh time period t6-t7; temperature T7>T6 and time t6<t7; and optionally (viii) heating to an eighth target operating temperature T8 during an eighth time period t7-t8; temperature T8>T7 and time t7<t8, and optionally (ix) heating to a ninth target operating temperature T9 during a ninth time period t8-t9; The aerosol delivery device of any one of claims 1 to 10, further configured to control the temperature T9 > T8 and the time t8 < t9.

12. 12. The aerosol delivery device of claim 11, wherein (i) T1 = 400±10°C, (ii) T2 = 396±10°C, (iii) T3 = 394±10°C, (iv) T4 = 392±10°C, (v) T5 = 390±10°C, (vi) T6 = 386±10°C, (vii) T7 = 384±10°C, (viii) T8 = 382±10°C, and (ix) T9 = 380±10°C.

13. 13. The aerosol delivery device of claim 11 or 12, wherein (i) t0-t1 = 20 ± 10 seconds, (ii) t1-t2 = 20 ± 10 seconds, (iii) t2-t3 = 20 ± 10 seconds, (iv) t3-t4 = 20 ± 10 seconds, (v) t4-t5 = 20 ± 10 seconds, (vi) t5-t6 = 20 ± 10 seconds, (vii) t6-t7 = 20 ± 10 seconds, (viii) t7-t8 = 20 ± 10 seconds, and (ix) t8-t9 = 20 ± 10 seconds.

14. the one or more aerosol generators are operable in at least a first mode and a second mode, and in the first mode, the controller is configured to control the one or more aerosol generators, wherein T1>380°C or 390°C and T4>360°C; 14. The aerosol delivery device of claim 1, wherein in the second mode, the controller is configured to control the one or more aerosol generators such that T1 > 350°C and T4 > 305°C.

15. The aerosol delivery device of any one of claims 1 to 14, wherein the one or more aerosol generators comprise pin-shaped heater elements.

16. 15. The aerosol delivery device of claim 14, wherein the pin-shaped heater element comprises a cylindrical body and a conical tip.

17. 17. The aerosol delivery device of claim 15 or 16, wherein the pin-shaped heater element comprises an elongate body having a cavity and one or more heater coils disposed within the cavity.

18. The aerosol delivery device of any one of claims 1 to 14, wherein the one or more aerosol generators comprise blade-shaped heater elements.

19. 20. The aerosol delivery device of claim 18, wherein the blade-shaped heater element comprises one or more conductive or resistive tracks.

20. The aerosol delivery device of any one of claims 1 to 19, wherein the one or more aerosol generators comprise a resistive heater element.

21. 19. The aerosol delivery device of any one of claims 1 to 16 or 18, wherein the one or more aerosol generators comprise an induction heater element.

22. An aerosol delivery system comprising the aerosol delivery device of any one of claims 1 to 21 and an article comprising an aerosol-generating material.

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

24. 1. A method for generating an aerosol, comprising: Providing an aerosol delivery device according to any one of claims 1 to 21; at least partially inserting an article comprising an aerosol-generating material into a receiving portion of a heating chamber of the aerosol delivery device; and actuating the aerosol delivery device to generate an aerosol from the article.

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