Device for heating aerosolizable material

Abstract

A device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material is described.SOLUTION: The device includes a heating zone for receiving at least a portion of an article including an aerosolizable material. The apparatus also includes a heating assembly having a magnetic field generator and a heating element 220. The magnetic field generator comprises an inductor coil 241 configured to generate a varying magnetic field. The heating element 220 includes a base portion 222 heatable by penetration with a varying magnetic field, and a heating portion 221 projecting from the base portion 222 to heat the heating zone. The heating portion 221 is conductively heatable by the base portion 222, and a thermal conductivity of the heating portion 221 is greater than a thermal conductivity of at least a portion of the base portion 222.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. The present invention also relates to an elongated heating element for use in the apparatus for heating an aerosolizable material, an aerosol delivery device, and an aerosol delivery system comprising an article including the aerosol delivery device and an aerosol-generating material.

[0002] Smoking articles such as cigarettes, cigars, and the like burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds in a non-combustible manner. Examples of such products are heating devices that release compounds by heating a material in a non-combustible manner. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Overview

[0003] According to one aspect, an apparatus is provided for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the apparatus comprising: a heating region for receiving at least a portion of an article including the aerosolizable material; a heating assembly; the heating assembly comprising: a magnetic field generator including an inductor coil configured to generate a varying magnetic field; and a heating element; the heating element comprising: a base portion heatable by penetration of the varying magnetic field; and a heating portion protruding from the base portion to heat the heating region; the heating portion being heatable by thermal conduction through the base portion, and the thermal conductivity of the heating portion being greater than the thermal conductivity of at least a portion of the base portion.

[0004] The inductor coil may be at least one of a planar coil and a spiral coil.

[0005] The spiral coil may be a flat spiral coil.

[0006] The spiral coil may be non-planar.

[0007] The inductor coil may comprise a thin film. The inductor coil may be attached to a substrate. The substrate may comprise a PCB.

[0008] The base portion may extend into the inductor coil. The base portion may extend through the inductor coil.

[0009] The base portion is between the inductor coil and the heating portion.

[0010] The heating portion and the base portion are inseparable. The heating portion and the base portion may be integrally formed.

[0011] As used herein, the term "integrally formed" is intended to mean that the features are not separable. The features may be formed as a single component, i.e., the features are formed together such that no joint is defined between them.

[0012] The heating portion and the base portion may be thermally conductively connected. As used herein, the term "conductively connected" does not necessarily mean that two features are directly connected; such a construction may include one or more additional features between the two features. The heating portion and the base portion may be directly thermally conductively connected. The heating portion and the base portion may be indirectly thermally conductively connected, for example, by an intermediate member. As used herein, the term "conductively connected" is intended to mean the primary means of heat transfer between the heating portion and the base portion.

[0013] The heating portion may include a first material and at least a portion of the base portion may include a second material.

[0014] The thermal conductivity value of the first material may be greater than the thermal conductivity value of the second material.

[0015] The first material may have a lower susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the second material.

[0016] The first material may be a non-ferrous material, and the second material may be one of a ferromagnetic material and a paramagnetic material.

[0017] The base portion may include a collar.

[0018] The collar may be disposed between the inductor coil and the heating portion.

[0019] The base portion may comprise a core. The collar may at least partially surround the core.

[0020] The core and collar may be inseparable. The collar and core may be integrally formed. The core and heating portion may form a single component.

[0021] The collar may comprise an axially extending section. The collar may comprise a radially extending section. The core may be tubular. The axially extending section may be tubular.

[0022] The collar may comprise a plate.

[0023] The support section may upstand from the plate. The heating portion may be supported by the support section. The support section may define an inner diameter. The support section may be a flange.

[0024] The core may extend into the collar. The core may extend through the collar.

[0025] The heating portion may protrude into the heating region. The base portion may be spaced apart from the heating region.

[0026] The heating element may be elongate and may define a longitudinal axis. The radial width of the base portion may be greater than the radial width of the heating portion.

[0027] The heating element may be elongated and may define a longitudinal axis. The radial width of the core may be greater than the radial width of the heating portion.

[0028] The base portion may comprise a radially extending section.

[0029] The radially extending section may include a flange. The flange may extend circumferentially.

[0030] The radially extending section may at least partially overlap the inductor coil.

[0031] The base portion may include an axially extending section that extends through the inductor coil.

[0032] The radially extending section may be between the heating portion and the axially extending section of the base portion.

[0033] The base portion may include a chamber.

[0034] The base portion may be at least partially tubular.

[0035] The base portion may have a closed end. The closed end may be between the tubular section of the base portion and the heating portion. The heating portion may protrude from the closed end.

[0036] The device may include an end wall defining a closed end of the heating cavity. The base portion may be external to the heating region. The base portion may extend through the end wall.

[0037] The heating portion and the inductor coil may be axially offset. The heating region and the base portion may be axially offset. The base portion may be external to the heating region.

[0038] The heating element may be removable from the heating zone. The heating element may be replaceable.

[0039] The device may include a receptacle that defines a heating region.

[0040] The receptacle may have a base defining an end of the heating region, and a peripheral wall upstanding from the base.

[0041] The heating portion may stand upright from the base. The heating portion may protrude into the heating region. The heating portion may have a sharp edge or tip at a free end. The heating portion may be a pin or blade. The heating portion may be configured to extend into an article received by the heating region.

[0042] The heating portion and the base portion may be coaxial. The heating portion and the collar may be coaxial.

[0043] According to one aspect, an apparatus is provided for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the apparatus comprising: a heating region for receiving at least a portion of an article including the aerosolizable material; and a heating assembly, the heating assembly comprising: a magnetic field generator including an inductor coil configured to generate a varying magnetic field; and a heating element comprising a heating portion and a base portion, the base portion being heatable by penetration of the varying magnetic field, the heating portion protruding from the base portion to heat the heating region, the heating portion defining an axis, the base portion having a radial width greater than the heating portion and extending at least partially into the inductor coil.

[0044] The base portion may extend through an upper area defined by the inductor coil. The base portion may extend into and / or through an aperture defined by the inductor coil. The inductor coil may be supported by a substrate. The base portion may extend through an opening defined by the substrate.

[0045] The inductor coil may be at least one of a planar coil and a spiral coil.

[0046] The spiral coil may be a flat spiral coil.

[0047] The spiral coil may be non-planar.

[0048] Apparatus of this aspect may include one or more or all of the features described above, where appropriate.

[0049] According to one aspect, an elongated heating element is provided for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element comprising a base portion, a heating portion, and a radially extending flange between the base portion and the heating portion.

[0050] According to one aspect, there is provided an elongated heating element for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element comprising a base portion and a heating portion, the heating portion being heatable by thermal conduction through the base portion, and the thermal conductivity of the heating portion being greater than the thermal conductivity of at least a portion of the base portion.

[0051] According to one aspect, an elongated heating element is provided for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element comprising an elongated heating portion defining a longitudinal axis and a base portion extending from the elongated heating portion, the base portion being tubular and having a width perpendicular to the longitudinal axis that is greater than the width of the heating portion.

[0052] According to one aspect, there is provided an aerosol delivery device comprising at least one of the apparatuses described above.

[0053] According to one aspect, there is provided an aerosol delivery device comprising at least one elongated heating element as described above.

[0054] According to one aspect, there is provided an aerosol delivery device comprising at least one of the apparatuses described above and at least one of the elongated heating elements described above.

[0055] The item may be a consumable item.

[0056] The aerosol delivery device may be a non-flammable aerosol delivery device.

[0057] The device may be a tobacco heating device, also known as a non-combustion heating device.

[0058] According to one aspect, there is provided an aerosol delivery system comprising the aerosol delivery device described above and an article including an aerosol-forming material.

[0059] The aerosol-forming material may be a non-liquid aerosol-forming material.

[0060] The article may be sized to be at least partially received within the heating region.

[0061] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0062] [Figure 1] FIG. 1 is a front perspective view of an aerosol delivery device. [Figure 2] FIG. 2 is a schematic diagram of the aerosol delivery device of FIG. 1. [Figure 3] 3 is a schematic plan view of a portion of a magnetic field generator of the aerosol delivery device of FIG. 2. [Figure 4] FIG. 1 is a schematic perspective view of a heating assembly of an aerosol delivery device. [Figure 5]FIG. 5 is a schematic side view of the heating assembly of FIG. 4. [Figure 6] FIG. 5 is a schematic cross-sectional side view of the heating assembly of FIG. 4. [Figure 7] 1 is a schematic perspective view of another heating assembly of an aerosol delivery device. [Figure 8] FIG. 8 is a schematic side view of the heating assembly of FIG. 7. [Figure 9] FIG. 8 is a schematic cross-sectional side view of the heating assembly of FIG. 7. Detailed Description

[0063] As used herein, the term "aerosol-forming material" includes materials that, upon heating, deliver volatile components, typically in the form of an aerosol. Aerosol-forming materials include any tobacco-containing material, and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-forming materials may also be, for example, a combination or mixture of materials. Aerosol-forming materials are also sometimes known as "smoking materials."

[0064] Devices are known that heat aerosol-generating materials to volatilize at least one component of the aerosol-generating materials to form an inhalable aerosol, typically without burning or combusting the aerosol-generating materials. Such devices may be described as "aerosol-generating devices," "aerosol-delivery devices," "non-combustion heating devices," "tobacco heating product devices," or "tobacco heating devices," or similar. Similarly, so-called e-cigarette devices also exist, which typically vaporize aerosol-generating materials in liquid form, and such aerosol-generating materials may or may not contain nicotine. The aerosol-generating materials may be in the form of a wand, cartridge, or cassette that can be inserted into the device, or may be provided as part of such a wand, cartridge, or cassette. A heater for heating and volatilizing the aerosol-generating material may be provided as a "permanent" part of the device.

[0065] The aerosol delivery device can receive an article containing an aerosol-forming material for heating. In this context, an "article" refers to a component that contains or houses the aerosol-forming material in use, which is heated to volatilize the aerosol-forming material, and optionally other components in use. A user may insert the article into the aerosol delivery device before heating it to produce an aerosol that the user subsequently inhales. The article may, for example, be of a predetermined or specific size configured to be placed within a heating chamber of a device sized to receive the article.

[0066] 1 shows an example of an aerosol delivery device 100 for generating aerosol from an aerosol-generating medium / material. Device 100 can be used to heat a replaceable item 110 containing an aerosol-generating medium to generate an aerosol or other inhalable medium that can be inhaled by a user of device 100.

[0067] Device 100 includes a housing 102 that surrounds and houses the various components of device 100. Device 100 has an opening 104 at one end through which an item 110 can be inserted for heating by device 100. Item 110 may be fully or partially inserted into device 100 for heating by device 100.

[0068] Device 100 may include a user-operable control element 106, such as a button or switch, that when actuated, e.g., pressed, operates device 100. For example, a user may activate device 100 by pressing switch 106.

[0069] The device 100 defines a longitudinal axis 101 along which the article 110 may extend when inserted into the device 100 .

[0070] 2 is a schematic diagram of the aerosol delivery device 100 of FIG. 1, illustrating various components of the device 100. It will be understood that the device 100 may include other components not shown in FIG.

[0071] As shown in FIG. 2 , device 100 includes an apparatus 200 for heating an aerosolizable material. Apparatus 200 includes a heating assembly 201, a controller (control circuit) 202, and a power supply 204. Apparatus 200 includes a body assembly 210, which may include a chassis and other components that form part of the device. Heating assembly 201 is configured to heat the aerosol-generating medium of an article 110 inserted into device 100, thereby generating an aerosol from the aerosol-generating medium. Power supply 204 provides power to heating assembly 201, which converts the provided electrical energy into thermal energy for heating the aerosol-generating medium.

[0072] The power source 204 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries.

[0073] Battery 204 may be electrically coupled to heating assembly 201 to provide power under the control of controller 202 when needed to heat the aerosol-generating material. Control circuitry 202 may be configured to activate and deactivate heating assembly 201 based on a user operating control element 106. For example, controller 202 may activate heating assembly 201 in response to a user operating switch 106.

[0074] The end of device 100 closest to opening 104 is sometimes known as the proximal end (or mouth end) 107 of device 100, as it is closest to the user's mouth during use. During use, the user inserts item 110 into opening 104, operates user control 106 to begin heating the aerosol-generating material, and inhales the aerosol generated by the device, causing the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0075] The other end of the device furthest from opening 104 is sometimes known as the distal end 108 of device 100, as it is the end furthest from a user's mouth during use. When a user inhales the aerosol generated by the device, the aerosol flows in a direction toward the proximal end of device 100. The terms proximal and distal as applied to features of device 100 are described by reference to the relative positions of such features with respect to one another in the proximal-distal direction along axis 101.

[0076] The heating assembly 201 may include various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is a process of heating an electrically conductive heating element (such as a susceptor) via electromagnetic induction. The induction heating assembly may include an induction element, e.g., one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor (heating element) suitably positioned relative to the induction element, generating eddy currents within the susceptor. The susceptor has an electrical resistance to eddy currents, and the flow of eddy currents across this resistance causes the susceptor to heat via Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat may be generated by magnetic hysteresis losses in the susceptor, i.e., by the magnetic poles of the magnetic material changing orientation as a result of alignment with the varying magnetic field. Induction heating generates heat within the susceptor, allowing for rapid heating, as compared to heating by conduction, for example. Furthermore, no physical contact is required between the inductive element and the susceptor, allowing for greater freedom in construction and application.

[0077] Apparatus 200 includes a heating chamber 211 configured and dimensioned to receive an article 110 to be heated. Heating chamber 211 defines a heating region 215. In this example, article 110 is generally cylindrical, and heating chamber 211 is correspondingly generally cylindrical in shape; however, other shapes could be possible. Heating chamber 211 is formed by a receptacle 212. Receptacle 212 includes end walls 213 and a peripheral wall 214.

[0078] The heating chamber 211 is defined by the inner wall of the receptacle 212. The receptacle 212 acts as a support member. The receptacle constitutes a generally tubular member, extending along and around the longitudinal axis 101 of the device 100 and being substantially coaxial with the longitudinal axis 101. However, other shapes could be possible. The receptacle 212, and thus the heating chamber 211, is open at its proximal end so that an item 110 inserted into the opening 104 of the device 100 can be received by the heating chamber 211 through its proximal end. The receptacle 212 is closed at its distal end by an end wall 213. The receptacle 212 may comprise one or more conduits that form an air passageway. During use, the distal end of the item 110 may be positioned adjacent to or engaged with the end of the heating chamber 211. Air may enter heating chamber 211 through one or more conduits and flow through article 110 towards the proximal end of device 100 .

[0079] The receptacle 212 may be formed from an insulating material. For example, the receptacle 212 may be formed from a plastic such as polyetheretherketone (PEEK). Other suitable materials are possible. The receptacle 212 may be formed from a material that ensures that the heating assembly 201 remains rigid / solid when the assembly is operated. Using a non-metallic material for the receptacle 212 may help limit heating of other components of the device 100. The receptacle 212 may be formed from a rigid material to help support the other components.

[0080] Other configurations for the receptacle 212 may be possible. For example, in one embodiment, the end wall 213 is defined by a portion of the heating assembly 201.

[0081] 2, the heating assembly 201 includes a heating element 220. The heating element 220 is configured to heat a heating region 215. The heating region 215 is defined in a heating chamber 211. In an embodiment, the heating chamber 211 defines a portion of the heating region 215 or an extent of the heating region 215.

[0082] The heating element 220 is heatable to heat the heating region 215. The heating element 220 is an induction heating element. That is, the heating element 220 comprises a susceptor that can be heated by the penetration of a varying magnetic field. The heating element 220 comprises a heating portion 221 and a base portion 222. The base portion 222 acts as a susceptor.

[0083] The susceptor comprises a conductive material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from carbon steel. It will be appreciated that other suitable materials may be used, such as ferromagnetic materials such as iron, nickel, or cobalt.

[0084] The heating assembly 201 includes a magnetic field generator 240. The magnetic field generator 240 is configured to generate one or more varying magnetic fields that penetrate the susceptor and cause heating of the susceptor. The magnetic field generator 240 includes an inductor coil 241 that acts as an inductor element. The inductor coil 241 resides on a printed circuit board (PCB) 250 that acts as a substrate, although other configurations are contemplated.

[0085] The heating element 220 extends into the heating region 215. The heating portion 221 acts as a protruding element and protrudes into the heating region 215. The heating element 220 is spaced from the peripheral wall 214. The heating assembly 201 is configured such that when the item 110 is received by the heating chamber 211, the heating portion 221 of the heating element 220 extends into the distal end of the item 110. The heating portion 221 of the heating element 220 is disposed within the item 110 during use. The heating element 220 is configured to heat the aerosol-generating material of the item 110 from the inside, and for this reason is referred to as an internal heating element. To facilitate this, the internal heating element 220 is configured to pierce the item 110 once it is inserted into the device 100.

[0086] In this embodiment, the heating portion 221 of the heating element 220 comprises a sharp edge or tip at its proximal end 223. The heating portion 221 is a pin. Other shapes are also envisioned, for example, the heating portion 221 in some embodiments is a blade. The heating portion 221 may extend from a distal end of the heating chamber 211 into the heating chamber 211 along the longitudinal axis 101 of the device (axially). In some embodiments, the heating portion 221 extends into the heating chamber 211 spaced apart from the axis 101. The heating portion 211 may be off-axis or non-parallel to the axis 101. While one heating portion 221 of the heating element 220 is shown, it will be understood that in some embodiments, the heating element 220 comprises multiple heating portions 221. In some embodiments, such heating portions are spaced apart from each other but parallel to each other.

[0087] The heating element 220 extends from the heating region 215. The heating element 220 extends outside of the heating region 220. The heating element 220 is received through the receptacle 212. The base portion 222 extends through the end wall 213. The inductor coil 241 is disposed outside of the receptacle 212. The inductor coil 241 is disposed adjacent to the end wall 213. In some embodiments, the inductor coil 241 is attached to the end wall 213. In some embodiments, the inductor coil 241 is spaced from the end wall 213. The end wall 213 may form a substrate that supports the inductor coil 241. In FIG. 2, the base portion 222 is shown outside of the heating chamber 211. In some embodiments, a portion of the base portion 222 extends into the heating chamber 211. In one embodiment, the base portion 222 defines at least a portion of a closed end of the heating chamber 211.

[0088] Base portion 222 of heating element 220 extends into inductor coil 241. That is, inductor coil 241 defines inductor region 241. Inductor region 241 is the space defined by inductor coil 241 that can receive features therein and can become heatable by penetration of the varying magnetic field generated by inductor coil 241. In this embodiment, inductor region 241 is defined in part by an aperture.

[0089] Inductor coil 241 is shown in FIG. 3. Inductor coil 241 is a two-dimensional spiral on the surface of PCB 250. PCB 250 acts as a substrate. The substrate supports coil 241. Inductor coil 241 is defined by a film. In this embodiment, substrate 250 is a non-conductive support; that is, the substrate is an insulator. In other embodiments, the support substrate may be omitted.

[0090] In this embodiment, the inductor coil 241 is deposited on a flat substrate or support. In some embodiments, the inductor coil 241 has a three-dimensional shape, for example, the inductor coil 241 may define a recess.

[0091] Inductor coil 241 is a conductive coil configured to carry a varying electrical current. The coil may be formed by, for example, deposition, printing, etching, chemical or mechanical bonding.

[0092] As shown in FIG. 3 , inductor coil 241 is a generally square or rectangular coil. In other embodiments, inductor coil 241 may have a different shape, such as a generally circular or oval shape. In some embodiments, inductor coil 241 may be a three-dimensional spiral. In some such embodiments, inductor coil 241 may be manufactured using additive manufacturing techniques, such as 3D printing. In this embodiment, adjacent spaced apart portions of inductor coil 241 are regularly spaced apart. In other embodiments, such portions of inductor coil 241 may not be regularly spaced apart.

[0093] An aperture 243 is defined by the inductor coil 241. In this configuration, the aperture 243 is defined at the axial center of the inductor coil 241. The aperture 243 is configured to receive the base portion 222. The aperture 243 extends from a proximal extent 244 of the inductor coil 241. The aperture 241 is defined by the innermost portion of the inductor coil 241. The aperture corresponds to the shape of the inductor coil 241. The aperture 243 is coaxial with the axis 101. In embodiments where the heating element 220 is off-axis, the aperture is also off-axis.

[0094] An opening 251 is formed in substrate 250. Opening 251 is aligned with aperture 243. Opening 251 is configured to receive base portion 222. In embodiments in which base portion 222 extends through inductor coil 241, base portion 222 extends at least into opening 251. Opening 251 and substrate 250 may be omitted.

[0095] When base portion 222 extends through inductor coil 241, base portion 222 is susceptible to changing magnetic flux both proximal and distal to inductor coil 241. Thus, base portion may be susceptible to changing magnetic flux on both sides of inductor coil 241.

[0096] Figures 4, 5, and 6 are more detailed schematic diagrams of one embodiment of heating assembly 201. It will be understood that heating assembly 201 may include other components not shown in Figures 4-6.

[0097] 4-6, the heating assembly 201 includes a heating element 220 and a magnetic field generator 240. An inductor coil 241 of the magnetic field generator 240 is shown in FIGS.

[0098] The heating element 220 includes a base portion 222 with a heating portion 221 protruding from the base portion 222. The heating portion 221 is heatable by the base portion 222 through thermal conduction. The heating portion 221 and the base portion 222 are thermally conductively connected. The base portion 222 has a larger radial extent than the heating portion 221. The base portion 222 is generally cylindrical, although other shapes are contemplated.

[0099] The elongated heating portion 221 extends from a base portion 222 at its distal end. The elongated heating portion 221 and the base portion 222 are coaxial. The base portion 222 has an axial height. The axial height of the base portion 222 is greater than the depth of the inductor coil 241. When assembled, the base portion 222 extends proximally and distally of the inductor coil 241. The base portion 222 extends through the inductor coil 241. Such a configuration helps maximize the magnetic flux intersecting the base portion 222.

[0100] The base portion 222 is generally cylindrical. The base portion 222 defines a chamber 226. That is, the base portion 222 is at least partially hollow. Providing the chamber 226 in the base portion 222 helps minimize the mass of the material to be heated, thus assisting with heat concentration. The chamber 226 is an area where heat can be extracted from the elongated heating portion 221, helping to minimize the heat load on the material. The base portion 222 forms a tubular structure. The chamber 226 may be omitted.

[0101] The base portion 222 has a closed end 227. The heating portion 221 upstands from the closed end 227. The closed end 227 is planar, although other shapes are contemplated. The closed end 227 is disposed between the tubular section of the base portion 222 and the heating portion 221.

[0102] The tubular section of base portion 222 defines an axially extending flange 228. Axially extending flange 228 extends parallel to longitudinal axis 101. Axially extending flange 228 extends coaxially therewith. Accordingly, axially extending flange 228 extends through inductor coil 241. Axially extending flange 228 axially overlaps inductor coil 241.

[0103] Base portion 222 includes a radially extending flange 229. Radially extending flange 229 extends in a circumferential direction. The radially extending flange radially overlaps inductor coil 241. With such a construction, base portion 222, acting as a susceptor, overlaps inductor coil 241 in both the radial and axial directions.

[0104] The base portion 222 comprises a core 224 and a collar 225. The core 224 is an extension of the heating portion 221. The core 224 is integrally formed with the heating portion as a single component. In this embodiment, the core 224 is a radially wider portion than the heating portion 221. In some embodiments, the core 224 has a radial width corresponding to the heating portion 221. The core 224 is an extension of the heating portion 221. Forming the core 224 and the heating portion 221 together can assist in heat conduction along the heating element. The core 224 is conductively connected to the collar 225. Accordingly, when the collar 225 is heated, heat transfer occurs from the collar 225 to the core 224 by conduction. The collar 225 forms an interference fit with the core 224. The collar 225 may be connected to the core 224 by different means.

[0105] The collar 225 surrounds the core 224. In some embodiments, the collar 225 partially surrounds the core 224. In this embodiment, the collar 225 surrounds the upper side of the core 224. The collar 225 defines the outer layer of the core 224. The heating portion 221 protrudes through the collar 225. The collar 225 includes an axial section 230 that surrounds the peripheral surface of the core 224. This provides a larger surface contact area between these features. Accordingly, heat transfer may be maximized. In this embodiment, the collar 225 forms a radially extending flange 229. Accordingly, the collar 225 overlaps the inductor coil 241 both axially and radially. Such a configuration allows the collar 225 to intersect a greater number of magnetic flux lines.

[0106] The heating portion 221 has a thermal conductivity greater than that of the collar 225. The collar 225 is formed from a different material. The base portion 222 and the heating element 220 have different thermal conductivity characteristics. The collar 225 acts as a susceptor and is formed from a material that is susceptible to heating by the penetration of a fluctuating magnetic field. The collar 225 comprises an electrically conductive material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from carbon steel. It will be understood that other suitable materials may be used, for example, ferromagnetic materials such as iron, nickel, or cobalt.

[0107] The core 224 has a thermal conductivity greater than that of the collar 225. The core 224 is formed from a material having a high thermal conductivity, such as one or more of copper, aluminum, and austenitic nickel chromium.

[0108] The material of the heating portion 221 has a lower susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the collar 225. The material from which the collar 225 is made has a higher susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the heating portion 221. The material of the heating portion 221 is a non-ferrous material. The material of the collar 225 is one of a ferromagnetic material and a paramagnetic material.

[0109] The high thermal conductivity of the heating portion 221 aids in heat transfer. Accordingly, when the collar 225 is heated, the heat transfer along the heating portion 221 is maximized. This aids in more uniform heating of the elongated heating element along its axial length.

[0110] As noted above, the base portion comprises a base portion having a core and a collar, although in some embodiments the base portion defines a susceptor and the core portion does not extend to the susceptor, hi other embodiments the core is an extension of the heating portion having a constant cross-sectional profile along its length between the heating portion and the core, as described below.

[0111] Figures 7, 8, and 9 are more detailed schematic diagrams of one embodiment of the heating assembly 201. It will be understood that the heating assembly 201 may include other components not shown in Figures 7-9. The construction of the device 100 is generally as described above and therefore will not be described in detail. The construction of the heating elements differs, as will be described below.

[0112] 7-9, the heating assembly 201 includes a heating element 320 and a magnetic field generator 240. The inductor coil 241 of the magnetic field generator 240 is shown in FIGS.

[0113] Heating element 320 comprises a base portion 322 with a heating portion 321 protruding from base portion 322. Heating portion 321 is heatable by base portion 322 via thermal conductivity. Heating portion 321 and base portion 322 are thermally conductively connected. Base portion 322 has a larger radial extent than heating portion 321. Base portion 322 is generally circular, although other shapes are contemplated.

[0114] Base portion 322 comprises a plate 331 and a support section 332. Support section 332 stands upright from plate 331. Support section 332 stands upright on a proximal side of plate 331. In some embodiments, support section 332 stands upright on a distal side. In some embodiments, support section 332 stands upright on both sides of support section 332. Support section 332 supports heating portion 321. Support section 332 comprises an inner diameter 333. Inner diameter 333 extends through plate 331. In some embodiments, inner diameter 333 is a closed inner diameter.

[0115] The elongated heating portion 321 stands upright from the base portion 322. The core 324 is received in the inner diameter 333. The core 324 is an extension of the heating portion 321. The core 324 is integrally formed with the heating portion as a single component. In this embodiment, the core 324 has a uniform cross-sectional profile with the heating portion 321. That is, the core 324 has a radial width corresponding to the heating portion 321. The core 324 is an extension of the heating portion 321. Forming the core 324 and the heating portion 321 together can assist heat conduction along the heating element. The core 324 is conductively connected to the collar 325. Accordingly, when the collar 325 is heated, heat transfer from the collar 325 to the core 324 occurs by conduction. The collar 325 forms an interference fit with the core 324. The collar 325 may be connected to the core 324 by different means. The collar 325 surrounds the core 324. In some embodiments, the collar 325 partially surrounds the core 324 .

[0116] The heating portion 321 has a thermal conductivity greater than that of the collar 325. The collar 325 is formed from a different material. The base portion 322 and the heating element 320 have different thermal conductivity characteristics. The collar 325 acts as a susceptor and is formed from a material that is susceptible to heating by the penetration of a fluctuating magnetic field. The collar 325 comprises an electrically conductive material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from carbon steel. It will be understood that other suitable materials may be used, for example, ferromagnetic materials such as iron, nickel, or cobalt.

[0117] Core 324 has a thermal conductivity greater than that of collar 325. Core 324 is formed from a material having a high thermal conductivity, such as copper, aluminum, and austenitic nickel chromium.

[0118] The material of the heating portion 321 has a lower susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the collar 325. The material from which the collar 325 is made has a higher susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the heating portion 321. The material of the heating portion 321 is a non-ferrous material. The material of the collar 325 is one of a ferromagnetic material and a paramagnetic material.

[0119] The high thermal conductivity of the heating portion 321 aids in heat transfer. Accordingly, when the collar 325 is heated, the heat transfer along the heating portion 321 is maximized. This aids in more uniform heating of the elongated heating element along its axial length.

[0120] In the embodiment shown, the distal end of the heating portion 321 is surrounded by the base portion of the heating element. In other words, a portion of the base portion axially overlaps some, but not all, of the axial length of the heating portion. Such a configuration provides conductive heating of the heating portion by the base portion and conductive heating of the article by the heating portion.

[0121] The majority of the base portion does not have to surround the heating portion. That is, the majority of the axial height of the base portion does not have to overlap with the heating portion in the axial direction. For example, 5% to 20% or 10% to 15% of the axial length of the base portion may overlap with the heating portion in the axial direction.

[0122] In the above-described embodiments, the inductor coil 241, 341 is a flat spiral coil. Other configurations of the inductor coil are also contemplated. In some embodiments, the inductor coil comprises at least one of a conical configuration, an arcuate configuration, and a helical configuration. For example, in the configurations shown in FIGS. 4-6, as well as other configurations, the inductor coil comprises a helical coil. Such a helical coil extends outside the heating chamber. The helical coil is outside the heating region.

[0123] In each configuration, the inductor coil is configured to generate a varying magnetic field that penetrates the base portion, which acts as a susceptor, causing heating of the base portion and thus indirect conductive heating of the heating portion.

[0124] In the above-described embodiments, the inductor coil is formed as a conductive film. Other configurations are also contemplated. For example, the inductor coil may be formed as a wire. The inductor coil may be a helical or spiral coil comprising a conductive material such as copper. The coil may be formed from a wire, such as Litz wire, wound in a helical or spiral shape around or on a support member. Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in the conductor. Other wire types, such as solid wire, may also be used.

[0125] With a helical inductor coil configuration, the inductor coil may extend around and be supported by a support member (not shown). The inductor coil may be disposed coaxially with the support member and the heating chamber (and the longitudinal axis 101). The helical inductor coil may define an inner diameter, with a base portion extending into the inner diameter. The base portion may extend through the inner diameter.

[0126] In the above-described embodiments, the base portion is disposed at least partially between the inductor coil and the heating region. Accordingly, the base portion acts as a barrier to limit exposure of the varying magnetic field to the heating region and components surrounding the heating region. Such a structure may limit heating induced in any susceptor material introduced into the heating chamber.

[0127] Providing a heating portion with a thermal conductivity greater than that of at least a portion of the base portion can aid in optimized design of the base portion without concern for ensuring that the heating element is exposed to a varying magnetic field.

[0128] In some embodiments, the heating portion of the heating element is separable from the base portion. For example, in the embodiment described with reference to Figures 7-9, the plate forming the base portion may be fixedly attached to the receptacle, and the elongated heating element is separable from the base portion. The base portion may define some or all of the end walls. The base portion may be integrally formed with the receptacle.

[0129] In configurations with separable base portions and heating elements, the collar acts as a support member for supporting the heating element. The collar may also act as a retaining member, for example, by an interference fit.

[0130] In some embodiments, the heating element is removable from the remainder of the device. The heating element is retractable from the heating region. In such configurations, the heating element is removable from the receptacle. When the heating element is retracted from the heating region, it is retracted from the inductor region. The base portion is retracted from the inductor region. An attachment configuration may releasably attach the heating element to the remainder of the device. In some embodiments, a push fit or interference fit may be used. In some embodiments, another attachment configuration, such as a bayonet configuration, may be utilized. By providing a removable heating element, the heating element may be replaceable.

[0131] Providing a base portion with a larger radial width than the heating portion may assist in securely attaching the heating element to the heating zone, and such a construction may benefit the stability of the heating element by providing a wider base.

[0132] In some embodiments, the heating element is fixedly connected to device 100 such that it extends into the heating region at a fixed position relative to the inductor coil. In these embodiments, the heating element extends into article 110 when article 110 is received by the heating region. However, in other embodiments, the heating element may be provided within article 110 that is inserted into device 100. In these embodiments, the heating element may be movable relative to the inductor coil. In these embodiments, the heating element may extend into the heating region when article 110 is received by the heating region.

[0133] In the above-described embodiment, the heating portion is an inner susceptor. That is, the heating portion protrudes into the heating chamber and is positioned to be received by the article. In another embodiment, the heating portion is an outer susceptor. In such a configuration, the heating element may be a generally tubular element extending along the longitudinal axis 101 and being substantially coaxial with the longitudinal axis 101. The heating element may extend at least partially around an axial portion of the heating chamber. The heating element may extend continuously around the entire circumference of the heating chamber, or may extend only partially around the chamber. For example, one or more interruptions, such as holes, gaps, or slots, may be provided in the heating element. The heating element may be configured and dimensioned to extend around an article received by the heating chamber. Thus, the heating element may be positioned around the article during use. The heating element may thus be configured to heat the aerosol-generating material of the article 110 from the outside, and for this reason is referred to as an outer heating element. The heating element may have a circular cross-section, for example, corresponding to the circular cross-section of the article 110. Other cross-sectional shapes may also be possible.

[0134] The heating element may extend any suitable distance along the heating zone. In such embodiments, the heating element may form a receptacle. The base portion is disposed at an end of the tubular member. The outer heating element may form the tubular member at one end. In such embodiments, the base portion may extend axially or radially inward, or both. The base portion may define an end wall. In some embodiments, the base collar is a collar around the tubular member.

[0135] The above-described embodiments should be understood as illustrative of the present invention. Additional embodiments of the present invention are also contemplated. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other features described, or with one or more features of any other embodiment, or with any combination of any other embodiment. Furthermore, equivalents and modifications not described above may be employed without departing from the scope of the present invention, which is defined in the appended claims.

Claims

1. 1. An apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a heating region for receiving at least a portion of an article including an aerosolizable material; a heating assembly; wherein the heating assembly comprises: a magnetic field generator including an inductor coil configured to generate a varying magnetic field; A heating element; The heating element comprises a base portion that can be heated by penetration of the fluctuating magnetic field, and a heating portion that protrudes from the base portion and heats the heating region; the heating portion is heatable by thermal conduction through the base portion; The apparatus, wherein the thermal conductivity of the heating portion is greater than the thermal conductivity of at least a portion of the base portion.

2. The apparatus of claim 1 , wherein the inductor coil is at least one of a planar coil and a spiral coil.

3. The apparatus of claim 1 or 2, wherein the base portion extends through the inductor coil.

4. The device of any one of claims 1 to 3, wherein the base portion is between the inductor coil and the heating portion.

5. The device of any one of claims 1 to 4, wherein the heating portion comprises a first material and the at least part of the base portion comprises a second material.

6. The apparatus of claim 5 , wherein the first material has a thermal conductivity value greater than the second material.

7. 7. An apparatus according to claim 5 or 6, wherein the first material has a lower susceptibility to heating due to penetration of the fluctuating magnetic field than the susceptibility of the second material.

8. The device of any one of claims 1 to 7, wherein the base portion comprises a collar.

9. The device of claim 8 , wherein the base portion comprises a core, and the collar at least partially surrounds the core.

10. The device of claim 9 , wherein the core and the heating portion form a unitary component.

11. An apparatus according to any one of claims 8 to 10, wherein the collar comprises an axially extending section and a radially extending section.

12. An apparatus according to any one of claims 8 to 11, wherein the collar comprises a plate.

13. The device of any preceding claim, wherein the heating element is elongate and defines a longitudinal axis, and the radial width of the base portion is greater than the radial width of the heating portion.

14. The device of any one of claims 1 to 13, wherein the base portion comprises a radially extending section.

15. The apparatus of claim 14 , wherein the radially extending section at least partially overlaps the inductor coil.

16. 16. The apparatus of claim 14 or 15, wherein the base portion comprises an axially extending section that extends through the inductor coil.

17. The apparatus of claim 16 , wherein the radially extending section is between the heating portion and the axially extending section of the base portion.

18. The device of any one of claims 1 to 17, wherein the base portion comprises a chamber.

19. 1. An apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a heating region for receiving at least a portion of an article including an aerosolizable material; a heating assembly; wherein the heating assembly comprises: a magnetic field generator including an inductor coil configured to generate a varying magnetic field; a heating element comprising a heating portion and a base portion; Equipped with the base portion is heatable by penetration of the fluctuating magnetic field, and the heating portion protrudes from the base portion to heat the heating region; the heating portion defines an axis; The apparatus wherein the base portion has a radial width greater than the heating portion and extends at least partially into the inductor coil.

20. 1. An elongated heating element for use in a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element comprising a base portion, a heating portion, and a radially extending flange between the base portion and the heating portion.

21. 1. An elongated heating element for use in a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element comprising a base portion and a heating portion, the heating portion being heatable by thermal conduction through the base portion, and the thermal conductivity of the heating portion being greater than the thermal conductivity of at least a portion of the base portion.

22. 1. An elongated heating element for use in a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element comprising an elongated heating portion defining a longitudinal axis and a base portion extending from the elongated heating portion, the base portion being tubular and having a width perpendicular to the longitudinal axis that is greater than a width of the heating portion.

23. An aerosol delivery device comprising at least one of the apparatuses according to any one of claims 1 to 19 and at least one of the elongated heating elements according to any one of claims 20 to 22.

24. 24. An aerosol delivery system comprising the aerosol delivery device of claim 23 and an article containing an aerosol-forming material.

25. 25. The aerosol delivery system of claim 24, wherein the item is a consumable item.

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