Aerosol Delivery Device

Abstract

To provide an aerosol delivery device that allows a user to easily have different sensory experiences. An aerosol delivery device for generating an aerosol from an aerosol-generating material may include one or more aerosol generators configured to generate an aerosol from the aerosol-generating material and a controller for controlling the one or more aerosol generators. The controller may be operable in a first operating mode to set first heating profiles (601, 602) for the aerosol generators such that an average operating temperature of the aerosol generators is T1 during a use session. The controller may also be operable in a second operating mode to set different second heating profiles (603, 604) for the aerosol generators such that an average operating temperature of the aerosol generators is again T1 during a use session.

Description

[Technical Field]

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

[0002] Articles such as cigarettes, cigars, and the like burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these types of articles that burn tobacco by creating products that release compounds without burning. Devices are known that heat smokable material to volatilize at least one component of the smokable material, typically forming an inhalable aerosol without burning or combusting the smokable material. Such devices are sometimes described as "non-combustion heating" devices or "tobacco heating products" (THPs) or "tobacco heating devices." A variety of different compositions are known for volatilizing at least one component of a smokable material.

[0003] The materials may be, for example, tobacco or other non-tobacco products, or combinations such as blended mixtures that may or may not contain nicotine.

[0004] It is desirable to provide an improved aerosol delivery device.

[0005] According to one aspect, there is provided an aerosol delivery device for generating an aerosol from an aerosol-forming material, the aerosol delivery device comprising: one or more aerosol generators configured to generate an aerosol from the aerosol-generating material; a controller for controlling the one or more aerosol generators; Equipped with the controller is operable in a first operating mode to set a first heating profile for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators during a use session is T1; An aerosol delivery device is provided in which the controller is operable in a second operating mode to set a different second heating profile for one or more aerosol generators so that the average operating temperature of the one or more aerosol generators during a usage session is again T1.

[0006] According to various embodiments, an aerosol delivery device is provided that has the ability to set two or more different heating profiles for one or more aerosol generators, where the two or more different heating profiles are configured to have the same or nearly the same average operating temperature T1 during a use session, thereby enabling the aerosolizable material to be maintained at an optimal or desired average temperature during a use session while also facilitating a user to have different sensory experiences by selecting between the different heating profile selections.

[0007] It should therefore be apparent that the aerosol delivery device according to various embodiments maintains optimal operating conditions for generating aerosol from an aerosol-generating material while allowing the user to vary the sensory experience.

[0008] According to one embodiment, the average operating temperature of heating profile T1 may be in the range of (i) 200-210°C, (ii) 210-220°C, (iii) 220-230°C, (iv) 230-240°C, (v) 240-250°C, (vi) 250-260°C, (vii) 260-270°C, (viii) 270-280°C, (ix) 280-290°C, and (x) 290-300°C.

[0009] According to one embodiment, the first and second heating profiles may be mirror images of each other.

[0010] According to one embodiment, the first heating profile may have a first maximum operating temperature and the second heating profile may have a different second maximum operating temperature.

[0011] According to one embodiment, the first heating profile may be stepped up over time and the second heating profile may be stepped down over time.

[0012] According to an alternative embodiment, the first heating profile may be stepped down as a function of time, and the second heating profile may be stepped up as a function of time.

[0013] According to one embodiment, a use session includes at least a first time period t1 and at least a second subsequent time period t2, and in either the first operating mode and / or the second operating mode, during the first time period t1, the controller controls the one or more aerosol generators to reach a first maximum temperature T 1max and during a second time period t2, the controller is configured to set a second maximum temperature T for the one or more aerosol generators. 2max where (i) T 1max >T 2max , or (ii) T 1max <T 2max Either:

[0014] According to one embodiment, a usage session may include at least a first time period t1, at least a second subsequent time period t2, and at least a further third time period t3, and in either the first operating mode and / or the second operating mode, during the first time period t1, the controller may generate a first maximum temperature T 1max and during a second time period t2, the controller is configured to set a second maximum temperature T 2max and during a third time period t3, the controller is configured to set a third maximum temperature T 3max where (i) T 1max >T 2max >T 3max , (ii) T 1max >T 2max <T 3max , (iii) T 1max <T2max >T 3max or (iv) T 1max <T 2max <T 3max Either:

[0015] According to one embodiment, the first heating profile may have a first duration D1 and the second heating profile may have a different second duration D2.

[0016] According to one embodiment, D1 and D2 may differ by at least 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% or 50%.

[0017] According to one embodiment, D1 may be selected from (i) 200-210 seconds, (ii) 210-220 seconds, (iii) 220-230 seconds, (iv) 230-240 seconds, (v) 240-250 seconds, (vi) 250-260 seconds, (vii) 260-270 seconds, (viii) 270-280 seconds, (ix) 280-290 seconds, or (x) 290-300 seconds.

[0018] According to one embodiment, D2 may be selected from (i) 200-210 seconds, (ii) 210-220 seconds, (iii) 220-230 seconds, (iv) 230-240 seconds, (v) 240-250 seconds, (vi) 250-260 seconds, (vii) 260-270 seconds, (viii) 270-280 seconds, (ix) 280-290 seconds, or (x) 290-300 seconds.

[0019] According to one embodiment, the second heating profile may correspond to the first heating profile but may further include one or more adjustment periods, the purpose of which may be to ensure that the first and second heating profiles have the same average operating temperature T1.

[0020] According to another aspect, there is provided an aerosol delivery device for generating an aerosol from an aerosol-forming material, the aerosol delivery device comprising: one or more aerosol generators configured to generate an aerosol from the aerosol-generating material; A controller; Equipped with the controller is operable in a first operating mode to set a first heating profile for the one or more aerosol generators during a first use session, wherein an operating temperature of the one or more aerosol generators is first increased to a temperature T2 during a first time period, then decreased to a temperature T3 during a second time period, and then increased to a temperature T4 during a third time period; the controller is operable in a second operating mode to set a second heating profile for the one or more aerosol generators during a second use session, wherein the operating temperature of the one or more aerosol generators is first raised to a temperature T5 during a first time period, then further raised to a higher temperature T6 during a second time period, and then further raised to an even higher temperature T7 during a third time period; An aerosol delivery device is provided in which the controller is operable in a third operating mode to set a third heating profile for one or more aerosol generators during a third use session, wherein the operating temperature of the one or more aerosol generators is initially raised to a temperature T8 during a first time period, then lowered to a lower temperature T9 during a second time period, and then further lowered to an even lower temperature T10 during a third time period.

[0021] According to various embodiments, a controller is provided that is operable in at least three different operating modes, in which a different heating profile may be set for one or more aerosol generators, thus providing a more versatile controller that allows a user to experience a greater variety of sensory experiences.

[0022] Optionally, when operated in the second operating mode, the controller is configured to increase the temperature of one or more aerosol generators from T5 to T6 to T7 (i) substantially stepwise or (ii) substantially smoothly.

[0023] Optionally, when operated in the second operating mode, the controller is configured to (i) substantially stepwise or (ii) substantially smoothly reduce the temperature of one or more aerosol generators from T8 to T9 to T10.

[0024] According to one embodiment, a first use session may have a duration D1, a second use session may have a duration D2, and a third use session may have a duration D3, where either (i) D1=D2=D3, (ii) D1=D2≠D3, (iii) D1≠D2=D3, (iv) D1=D3≠D2, or (v) D1≠D2≠D3.

[0025] According to another aspect, there is provided an aerosol delivery device for generating an aerosol from an aerosol-forming material, the aerosol delivery device comprising: one or more aerosol generators configured to generate an aerosol from the aerosol-generating material; a controller for controlling the one or more aerosol generators; Equipped with the controller is operable in a first operating mode to set a first heating profile for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators during a use session is T1; An aerosol delivery device is provided in which the controller is operable in a second operating mode to set a second heating profile for the one or more aerosol generators, the second heating profile corresponding to the first heating profile but further including one or more adjustment periods such that an average operating temperature of the one or more aerosol generators during a usage session is T2, where T1 and T2 are different.

[0026] According to various embodiments, it may be desirable to modify a heating profile that is otherwise configured for one or more aerosol generators to both extend a use session and modify the average operating temperature of one or more aerosol generators throughout a use session.

[0027] According to one embodiment, the one or more aerosol generators comprise one or more induction heating units.

[0028] According to one embodiment, the one or more aerosol generators comprise one or more resistive or non-inductive heating units.

[0029] According to one embodiment, the one or more aerosol generators comprise one or more external heating units.

[0030] According to one embodiment, the one or more aerosol generators comprise one or more internal heating units.

[0031] According to one embodiment, the one or more aerosol generators comprise a first heating unit and a second heating unit.

[0032] According to one embodiment, either (i) the first heating unit comprises an induction heating unit and the second heating unit comprises an induction heating unit, (ii) the first heating unit comprises an induction heating unit and the second heating unit comprises a resistive or non-inductive heating unit, (iii) the first heating unit comprises a resistive or non-inductive heating unit and the second heating unit comprises an induction heating unit, or (iv) the first heating unit comprises a resistive or non-inductive heating unit and the second heating unit comprises a resistive or non-inductive heating unit.

[0033] According to one embodiment, either (i) the first heating unit comprises an external heating unit and the second heating unit comprises an external heating unit, (ii) the first heating unit comprises an external heating unit and the second heating unit comprises an internal heating unit, (iii) the first heating unit comprises an internal heating unit and the second heating unit comprises an internal heating unit, or (iv) the first heating unit comprises an internal heating unit and the second heating unit comprises an external heating unit.

[0034] According to one embodiment, a usage session is determined to begin when power or energy is first supplied to one or more aerosol generators after an aerosol product item is inserted into the aerosol delivery device.

[0035] According to one embodiment, a use session is determined to begin when power or energy is first supplied to one or more aerosol generators to raise their temperature to an operating temperature Tmin so that a user can take a first puff of aerosol generated from the aerosol-generating material. Optionally, Tmin is within the ranges of: (i) 200-210°C, (ii) 210-220°C, (iii) 220-230°C, (iv) 230-240°C, (v) 240-250°C, (vi) 250-260°C, (vii) 260-270°C, (viii) 270-280°C, (ix) 280-290°C, and (x) 290-300°C.

[0036] According to one embodiment, a usage session is determined to end when power or energy is no longer supplied to one or more aerosol generators.

[0037] According to one embodiment, a usage session is determined to end when the aerosol-generating material is substantially consumed or when the user is unable to take further puffs of aerosol generated from the aerosol-generating material.

[0038] According to one embodiment, a usage session is determined to relate to a period of time during which a user can take multiple puffs of aerosol generated from the aerosol-generating material without replacing or refilling the aerosol-generating material.

[0039] According to another aspect of the present disclosure, the aerosol delivery device described above; and an aerosol product article comprising an aerosol-forming material.

[0040] The aerosol product may be inserted into the aerosol delivery device at the time of use.

[0041] According to one aspect, providing an aerosol delivery device comprising one or more aerosol generators configured to generate an aerosol from an aerosol-generating material; inserting an aerosol production article into an aerosol delivery device; selecting between a first mode of operation and a second mode of operation; In a first operating mode, a first heating profile is configured for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators is T1 during a use session; In a second operating mode, a method of generating aerosol is provided in which a different second heating profile is set for one or more aerosol generators so that the average operating temperature of the one or more aerosol generators during a use session is again T1.

[0042] According to one aspect, providing an aerosol delivery device comprising one or more aerosol generators configured to generate an aerosol from an aerosol-generating material; inserting an aerosol production article into an aerosol delivery device; selecting between at least three different modes of operation; In a first operating mode, during a first use session, a first heating profile is set for the one or more aerosol generators, wherein the operating temperature of the one or more aerosol generators is increased to a temperature T2 during a first time period, then decreased to a temperature T3 during a second time period, and then increased to a temperature T4 during a third time period; In a second operating mode, during a second use session, a second heating profile is set for the one or more aerosol generators, wherein the operating temperature of the one or more aerosol generators is increased to a temperature T5 during a first time period, then further increased to a higher temperature T6 during a second time period, and then further increased to an even higher temperature T7 during a third time period; In a third operating mode, a method of generating aerosol is provided in which a third heating profile is set for one or more aerosol generators during a third use session, and the operating temperature of the one or more aerosol generators is increased to a temperature T8 during a first time period, then decreased to a lower temperature T9 during a second time period, and then further decreased to an even lower temperature T10 during a third time period.

[0043] According to one aspect, providing an aerosol delivery device comprising one or more aerosol generators configured to generate an aerosol from an aerosol-generating material; inserting an aerosol production article into an aerosol delivery device; selecting between a first mode of operation and a second mode of operation; In a first operating mode, a first heating profile is configured for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators is T1 during a use session; In a second operating mode, a method of generating aerosol is provided in which a second heating profile is set for one or more aerosol generators, the second heating profile corresponding to the first heating profile but further including one or more adjustment periods such that an average operating temperature of the one or more aerosol generators during a usage session is T2, where T1 and T2 are different.

[0044] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0045] [Figure 1A] FIG. 1 is a schematic diagram of a heating assembly of an aerosol delivery device. [Figure 1B] 1B is a cross-sectional view of the heating assembly shown in FIG. 1A with an aerosol production article disposed therein. [Figure 2A] 1 is a schematic cross-sectional view of an aerosol production article for use with an aerosol delivery device. [Figure 2B] FIG. 1 is a perspective view of an aerosol delivery article. [Figure 3] 1 is a graph showing a typical temperature profile of a first heating unit in an aerosol delivery device during an exemplary smoking session. [Figure 4] 10 is a graph showing a typical temperature profile of a second heating unit in an aerosol delivery device during an exemplary smoking session. [Figure 5] 1 is a graph illustrating a typical programmed heating profile of a heating element in an aerosol delivery device during an exemplary use session. [Figure 6] A diagram showing two different heating profiles that a controller can set for one or more aerosol generators of an aerosol delivery device, according to one embodiment, which are different heating profiles but have the same average operating temperature T1 throughout a usage session. [Figure 7]1 illustrates two different heating profiles that a controller may set for one or more aerosol generators of an aerosol delivery device according to one embodiment, the heating profiles having different maximum and minimum temperatures but the same average operating temperature throughout a usage session. [Figure 8] FIG. 10 illustrates an embodiment in which a first heating profile is stepped upward throughout a use session and a second heating profile is stepped downward throughout a use session, with the two heating profiles having the same average operating temperature throughout the use session. [Figure 9] FIG. 10 illustrates an embodiment in which the controller may apply two different heating profiles having different durations, but the heating profiles have the same average operating temperature. [Figure 10] FIG. 10 illustrates an embodiment in which the controller is configured to set a heating profile for one or more aerosol generators and is operable in at least three different operating modes, allowing a user to select between at least three different heating profiles that may be applied to one or more aerosol generators of the aerosol delivery device. [Figure 11A] FIG. 10 illustrates an embodiment in which in a first mode of operation, the controller sets a heating profile in which the temperature increases and then decreases. [Figure 11B] FIG. 10 illustrates an embodiment in which in a second mode of operation, the controller sets a heating profile that is stepped up. [Figure 11C] FIG. 10 illustrates an embodiment in which in a third mode of operation, the controller sets a heating profile that is stepped down. [Figure 12A] FIG. 10 illustrates an embodiment in which a controller sets a heating profile for one or more aerosol generators, the heating profile having an average operating temperature T1. [Figure 12B]A diagram showing an embodiment in which a dummy buffer period or adjustment period is inserted into a heating profile to extend the duration of the heating profile, thereby having the effect of changing the average operating temperature T2 of one or more aerosol generators throughout a usage session. Detailed Description

[0046] The term "aerosol-forming material" includes materials that provide volatile components upon heating, 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, or wax. Aerosol-forming materials may also be, for example, a combination or blend of materials. Aerosol-forming materials may also be known as "smokable materials." In one embodiment, the aerosol-forming material is a non-liquid aerosol-forming material. In certain embodiments, the non-liquid aerosol-forming material includes tobacco.

[0047] Devices are known that heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, typically forming an inhalable aerosol without burning or combusting the aerosol-generating material. Such devices may be described as "aerosol-generating devices," "aerosol delivery devices," "non-combustion heating devices," "tobacco heating products," "tobacco heating product devices," "tobacco heating devices," or the like. In one embodiment, the aerosol delivery device is a tobacco heating product. Non-liquid aerosol-generating materials for use with tobacco heating products include tobacco.

[0048] Electronic cigarette devices are also known that include an aerosol delivery device that vaporizes a liquid aerosol-forming material, which may or may not contain nicotine. The aerosol-forming material may be in the form of, or provided as part of, a rod, cartridge, or cassette that can be inserted into the device. A heater for heating and vaporizing the aerosol-forming material may be provided as a "permanent" part of the device.

[0049] Aerosol delivery devices are also known that generate an aerosol from a hybrid aerosol product, the hybrid aerosol product comprising a section that includes a cartomizer containing a liquid or gel aerosol-forming material and another section that contains a solid aerosol-forming material, such as tobacco granules.

[0050] The aerosol delivery device can accept an article containing an aerosol-generating material for heating, also referred to as a "smoking article." In this context, an "article," "aerosol-producing item," or "smoking article" is a component that, upon use, includes or contains an aerosol-generating material that is heated to volatilize the aerosol-generating material, and optionally other components upon use. A user can insert the article into the aerosol delivery device before the article is heated to generate an aerosol, which the user then inhales. The article may be, for example, of a predetermined or specific size configured to be placed within a heating chamber of a device sized to accept the article.

[0051] An aerosol delivery device according to various embodiments comprises a plurality of aerosol generators for generating an aerosol from an aerosol-generating material during use.

[0052] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material to 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, pressure increase, or electrostatic energy.

[0053] A heating unit typically refers to a component configured to receive electrical energy from an electrical energy source and provide thermal energy to an aerosol-generating material. A heating unit may include a heating element. A heating element is typically a material configured to provide heat to an aerosol-generating material during use. A heating unit that includes a heating element may include any other necessary components, such as components for converting the electrical energy received by the heating unit. In other examples, the heating element itself may be configured to convert electrical energy into thermal energy.

[0054] The heating unit may include an induction coil. In some examples, the coil is configured to cause heating of at least one electrically conductive heating element such that thermal energy is conducted from the at least one electrically conductive heating element to the aerosol-forming material, thereby causing heating of the aerosol-forming material.

[0055] In some examples, the coil may be configured to, in use, generate a varying magnetic field that penetrates at least one heating element, thereby causing inductive heating and / or magnetic hysteresis heating of the at least one heating element. In such configurations, the heating element or each heating element may be referred to as a "susceptor." A coil configured to, in use, generate a varying magnetic field that penetrates at least one conductive heating element, thereby causing inductive heating of the at least one conductive heating element may be referred to as an "induction coil" or "inductor coil."

[0056] In some examples, the coil may be helical. In some examples, the coil may surround at least a portion of a heating zone of an aerosol delivery device configured to receive the aerosol-generating material. In some examples, the coil is a helical coil that surrounds at least a portion of the heating zone.

[0057] It has been found that inductive heating units in an aerosol delivery device reach their maximum operating temperature much more quickly than corresponding resistive heating elements. According to various embodiments, the aerosol delivery device may be configured such that one or both heating units reach their maximum operating temperature at a rate of at least 100° C. per second. In certain embodiments, the aerosol delivery device may be configured such that one or both heating units reach their maximum operating temperature at a rate of at least 150° C. per second.

[0058] Induction heating systems may also be of interest because the magnitude of the varying magnetic field can be easily controlled by controlling the power supplied to the heating unit. Furthermore, induction heating does not require a physical connection between the source of the varying magnetic field and the heat source, which may allow for greater design freedom and control over the heating profile and lower costs.

[0059] The aerosol delivery device may include a heating assembly. The heating assembly may include a first heating unit and a second heating unit.

[0060] The first and second heating units may comprise induction heating units, and the units may be independently controllable. Heating the aerosol-generating material with independent heating units may provide more precise control of the heating of the aerosol-generating material. Independently controllable heating units may also provide different thermal energy to each portion of the aerosol-generating material, resulting in different temperature profiles between the portions of the aerosol-generating material.

[0061] According to various embodiments, the first and second heating units may be configured to have different temperature profiles during use, which may provide asymmetric heating of the aerosol-generating material along a longitudinal plane between the mouth end and distal end of the aerosol delivery device during use of the aerosol delivery device.

[0062] Alternatively, the first and second heating units may be configured to have substantially the same temperature profile during use, which may provide symmetric heating of the aerosol-generating material along a longitudinal plane between the mouth end and distal end of the aerosol delivery device during use of the aerosol delivery device.

[0063] An object that can be inductively heated is known as a susceptor. If the susceptor contains a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses within the susceptor, i.e., by the fluctuating orientation of magnetic dipoles within the magnetic material as a result of their alignment with a fluctuating magnetic field. In induction heating, heat is generated within the susceptor, allowing for rapid heating compared to, for example, heating by conduction. Furthermore, no physical contact between the induction heater and the susceptor is required, allowing for greater flexibility in construction and application.

[0064] Throughout this specification, reference may be made to the temperature of one or more heating units or heating elements. The temperature of a heating unit or heating element may also be referred to as the temperature of the heating unit comprising the heating element for convenience. This does not necessarily mean that the entire heating unit is at a given temperature. For example, when reference is made to the temperature of an induction heating unit, it does not necessarily mean that both the induction element and the susceptor have such a temperature. Rather, in this example, the temperature of the induction heating unit corresponds to the temperature of the heating element configured within the induction heating unit. For the avoidance of doubt, the temperature of the heating element and the temperature of the heating unit may be used interchangeably.

[0065] As used herein, a "temperature profile" or "heating profile" refers to the change in temperature of a material over time. For example, the changing temperature of a heating element or heating unit measured at the heating element or heating unit over the duration of a smoking session may be referred to as the temperature profile or heating profile of the heating element or heating unit. During use, the heating element or heating unit provides heat to the aerosol-generating material to generate aerosol. Thus, the temperature profile or heating profile of the heating element or heating unit induces a temperature profile in the aerosol-generating material located near the heating element or heating unit.

[0066] As used herein, "operating temperature" with respect to a heating element or heating unit refers to any heating element temperature at which the element can heat the aerosol-generating material to generate enough aerosol for a satisfactory puff without burning the aerosol-generating material. The maximum operating temperature of a heating element or heating unit is the highest temperature the heating element or heating unit reaches during a smoking session. The minimum operating temperature of a heating element or heating unit refers to the lowest heating element temperature at which the heating element or heating unit can generate enough aerosol from the aerosol-generating material for a satisfactory puff. When multiple heating elements or heating units are present in the aerosol delivery device, each heating element or heating unit has an associated maximum operating temperature. The maximum operating temperature of each heating element or heating unit may be the same or may vary from one heating element or heating unit to another.

[0067] In one embodiment of the aerosol delivery device, each heating element or heating unit may be configured to non-combustibly generate an aerosol from the aerosol-generating material. While the temperature profile or heating profile of each heating element or heating unit may induce a temperature profile in the associated portion of the aerosol-generating material, the temperature profiles or heating profiles of the heating element or heating unit and the associated portion of the aerosol-generating material may not correspond exactly. For example, there may be "bleed" in the form of conduction, convection, and / or radiation of thermal energy from one portion of the aerosol-generating material to another, there may be fluctuations in the conduction, convection, and / or radiation of thermal energy from the heating element or heating unit to the aerosol-generating material, and there may be a delay between a change in the temperature profile of the heating element or heating unit and a change in the temperature profile of the aerosol-generating material depending on the heat capacity of the aerosol-generating material.

[0068] The aerosol delivery device may include a controller for controlling each heating unit present within the aerosol delivery device. The controller may include a printed circuit board ("PCB"). The controller may be configured to control the power supplied to each heating unit and thus the "programmed heating profile" of each heating unit present within the aerosol delivery device. For example, the controller may be configured to control the current supplied to multiple inductors to control the resulting temperature or heating profile of the corresponding induction heating element or induction heating unit. As with the temperature profiles of the heating element / unit and the aerosol-generating material described above, the programmed heating profile of a heating element or heating unit may not exactly correspond to the observed temperature profile of the heating element or heating unit for the same reasons described above.

[0069] The term "operating temperature" can also be used with respect to an aerosol-generating material. In this case, the term refers to any temperature of the aerosol-generating material itself at which sufficient aerosol is generated from the aerosol-generating material for a satisfactory puff. The maximum operating temperature of an aerosol-generating material is the highest temperature reached by any portion of the aerosol-generating material during a smoking session. In some embodiments, the maximum operating temperature of an aerosol-generating material is greater than 200°C, 210°C, 220°C, 230°C, 240°C, 250°C, 260°C, or 270°C. In some embodiments, the maximum operating temperature of an aerosol-generating material is less than 300°C, 290°C, 280°C, 270°C, 260°C, or 250°C. The minimum operating temperature is the lowest temperature of an aerosol-generating material at which sufficient aerosol is generated from the material to generate sufficient aerosol for a satisfactory "puff." In some embodiments, the minimum operating temperature of an aerosol-generating material is greater than 90°C, 100°C, 110°C, 120°C, 130°C, 140°C, or 150°C. In some embodiments, the minimum operating temperature of the aerosol-forming material is less than 150°C, 140°C, 130°C, or 120°C.

[0070] Various embodiments are disclosed that reduce the time it takes to prepare an aerosol delivery device for use and, more generally, improve the user's inhalation experience. Surprisingly, it has been found that reducing the time it takes for a heating element or heating unit to reach operating temperature can at least partially mitigate "hot puffs," a phenomenon that occurs when the generated aerosol contains a high water content. Accordingly, aerosol delivery devices according to various embodiments may provide consumers with inhalable aerosols that have superior organoleptic properties than aerosols provided by conventional aerosol delivery devices that do not include heating units that rapidly reach their maximum operating temperature.

[0071] In some embodiments, the aerosol delivery device is configured such that at least one heating element or heating unit therein reaches its maximum operating temperature within 20 seconds, and the maximum operating temperature is a first temperature at which the at least one heating unit is held for at least 1, 2, 3, 4, 5, 10, or 20 seconds, i.e., in these embodiments, the heating unit is not held at a temperature other than the maximum operating temperature before reaching the maximum operating temperature.

[0072] In some embodiments, the at least one heating unit reaches its maximum operating temperature from ambient temperature within a given period of time.

[0073] The aerosol delivery device may be configured to operate as described herein. The aerosol delivery device may be configured to do so at least in part by a controller that can be programmed to operate the device in one or more different modes. Thus, references herein to an aerosol delivery device or components thereof may refer to a controller that is programmed to operate the aerosol delivery device disclosed herein, among other features (such as the spatial arrangement of the heating unit).

[0074] Aerosol-producing products for aerosol delivery devices (such as tobacco heating products) typically contain more water and / or aerosol-forming agents than combustible smoking articles to facilitate the formation of aerosol during use. This higher water and / or aerosol-forming agent content can increase the risk of condensation collecting within the aerosol delivery device during use, particularly at locations away from the heating unit. This problem may be greater in aerosol delivery devices with sealed heating chambers, particularly those with external heaters, than in aerosol delivery devices with internal heaters (such as "blade" heaters). Without wishing to be bound by theory, it is believed that a larger proportion / surface area of ​​the aerosol-generating material is heated by the external heating assembly, resulting in more aerosol being emitted than in aerosol delivery devices that internally heat the aerosol-generating material, resulting in more condensation of the aerosol within the aerosol delivery device.

[0075] Various programmed heating profiles may be used in an aerosol delivery device configured to externally and / or internally heat an aerosol-generating material to provide a user with a desired amount of aerosol while keeping the amount of aerosol condensing inside the aerosol delivery device relatively low. For example, the maximum operating temperature of a heating unit may affect the amount of condensation formed. A lower maximum operating temperature may result in less undesirable condensation. The difference between the maximum operating temperatures of heating units within a heating assembly may also affect the amount of condensation formed. Furthermore, the point in a use session at which each heating unit reaches its maximum operating temperature may affect the amount of condensation formed.

[0076] In use, the aerosol delivery device may heat the aerosol-generating material to provide an inhalable aerosol. The aerosol delivery device may be referred to as "ready for use" when at least a portion of the aerosol-generating material reaches a minimum operating temperature and a user can take a puff containing a satisfactory amount of aerosol. In some embodiments, the aerosol delivery device may be ready for use within about 20 seconds, 15 seconds, 10 seconds, or 5 seconds after power is supplied to one or both heating units. The aerosol delivery device may be ready for use within about 20 seconds, 15 seconds, 10 seconds, or 5 seconds after activation of the device. The aerosol delivery device may begin supplying power to a heating unit, such as the first heating unit or the second heating unit, when the device is activated, or may begin supplying power to the heating unit after the aerosol delivery device is activated. The aerosol delivery device may be configured to begin supplying power to one or more heating units some time after activation of the aerosol delivery device, for example, at least 1 second, 2 seconds, or 3 seconds after activation of the aerosol delivery device. The aerosol delivery device may be configured such that power is not supplied to one of the heating units, or to any heating units present in the heating assembly, until at least 2.5 seconds after activation of the aerosol delivery device, which may extend battery life by avoiding unintentional activation of the heating units.

[0077] The aerosol delivery device may be ready for use more quickly than corresponding aerosol delivery devices known in the art, providing an improved user experience. Because it typically takes some time to transfer sufficient thermal energy from the heating units to the aerosol-generating material to generate an aerosol, the aerosol delivery device becomes usable some time after one of the heating units reaches its maximum operating temperature. The aerosol delivery device may be ready for use within 20 seconds, 15 seconds, 10 seconds, or 5 seconds after one of the heating units reaches its maximum operating temperature.

[0078] In some embodiments, the user's sensory experience resulting from the aerosol produced by the device is similar to the sensory experience of smoking a combustible cigarette, such as a factory-made cigarette.

[0079] The aerosol delivery device may indicate readiness for use via an indicator. In one embodiment, the aerosol delivery device may be configured such that the indicator indicates that the aerosol delivery device is ready for use within about 20 seconds, 15 seconds, 10 seconds, or 5 seconds after power is applied to one of the heating units. In certain embodiments, the aerosol delivery device may be configured such that the indicator indicates that the aerosol delivery device is ready for use within about 20 seconds, 15 seconds, 10 seconds, or 5 seconds after activation of the device. In another embodiment, the device is configured such that the indicator indicates that the device is ready for use within about 20 seconds, 15 seconds, or 10 seconds after the first heating unit reaches its maximum operating temperature.

[0080] As used herein, a "puff" refers to a single inhalation by a user of the aerosol produced by the aerosol delivery device.

[0081] As used herein, a "use session" refers to a single period of use of an aerosol delivery device by a user. A use session begins when power is first applied to at least one heating unit or aerosol generator present in the heating assembly. The device is ready for use after a period of time has elapsed since the start of the use session.

[0082] A use session may end when no power is supplied to any of the heating units or aerosol generators in the aerosol delivery device. The end of a use session may coincide with the point at which the aerosol product is depleted (the point at which the total particulate matter yield (mg) in each puff is deemed unacceptably low by the user). A session may include multiple puffs. A session may have a duration of less than 7 minutes, or less than 6 minutes, or less than 5 minutes, or less than 4 minutes 30 seconds, or less than 4 minutes, or less than 3 minutes 30 seconds. In some embodiments, a use session may have a duration of 2 to 5 minutes, or 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or about 4 minutes. A session may be initiated by a user activating a button or switch on the device, which initiates a temperature increase of at least one heating unit or aerosol generator upon activation or some time thereafter.

[0083] A use session may be determined to begin when power or energy is first supplied to one or more heating units or aerosol generators after an aerosol product item is inserted into the aerosol delivery device. A use session may be determined to begin when power or energy is first supplied to one or more heating units or aerosol generators to raise their temperature to an operating temperature, T, so that a user can take the first puff of aerosol generated from the aerosol-generating material. According to various embodiments, T may be within the following ranges: (i) 200-210°C, (ii) 210-220°C, (iii) 220-230°C, (iv) 230-240°C, (v) 240-250°C, (vi) 250-260°C, (vii) 260-270°C, (viii) 270-280°C, (ix) 280-290°C, and (x) 290-300°C.

[0084] A use session may be determined to end when power or energy is no longer supplied to one or more heating units or aerosol generators. A use session may be determined to end when the aerosol-generating material is substantially consumed or when a user is unable to take additional puffs of aerosol generated from the aerosol-generating material.

[0085] A usage session may be determined to relate to a period of time during which a user can take multiple puffs of aerosol generated from the aerosol-generating material without replacing or refilling the aerosol-generating material.

[0086] In some embodiments, the aerosol delivery device may be operable in at least a first (eg, base) mode of operation and a second (eg, boost) mode of operation.

[0087] The heating assembly may be operable in up to two modes of operation, or may be operable in more than two modes, such as three modes, four modes, or five modes.

[0088] Each operating mode may be associated with a predetermined heating profile, such as a programmed heating profile, for each heating unit in the heating assembly. One or more of the programmed heating profiles may be programmed or selected by a user. Additionally or alternatively, one or more of the programmed heating profiles may be programmed by a manufacturer. In these examples, the programmed heating profile(s) may be fixed such that an end user cannot change the programmed heating profile(s).

[0089] The operating mode may be user-selectable. For example, a user may select a desired operating mode by interacting with a user interface. Power may begin to be supplied to the first heating unit substantially simultaneously with the desired operating mode being selected.

[0090] Each mode may be associated with a temperature profile that is different from the temperature profiles of the other modes. Furthermore, one or more modes may be associated with a different time point at which the device is ready for use. For example, the heating assembly may be configured such that in a first mode, the device is ready for use a first period of time after the start of a use session, and in a second mode, the device is ready for use a second period of time after the start of the session. The first period of time may be different from the second period of time.

[0091] In some examples, the heating assembly may be configured to be ready for use within 30, 25, 20, or 15 seconds of applying power to the heating unit when the aerosol delivery device is operating in a first mode. The heating assembly may also be configured to be ready for use within a shorter period of time when the aerosol delivery device is operating in a second mode, i.e., within 25, 20, 15, or 10 seconds of applying power to the heating unit when operating in the second mode.

[0092] In certain embodiments, the aerosol delivery device may be configured such that an indicator indicates that the aerosol delivery device is ready for use within 20 seconds of selecting the first (e.g., base) mode and within 10 seconds of selecting the second (e.g., boost) mode.

[0093] Providing an aerosol delivery device, such as a tobacco heating product, with a heating assembly operable in multiple modes (e.g., base mode and boost mode) offers consumers more options, especially when each mode is associated with a different maximum heater temperature. Furthermore, such aerosol delivery devices can provide different aerosols with different characteristics because volatile components in the aerosol-generating material volatilize at different rates and concentrations at different heater temperatures. This allows users to select a particular mode based on the desired characteristics of the inhalable aerosol, such as the degree of tobacco flavoring, nicotine concentration, and aerosol temperature. For example, a mode in which the aerosol delivery device is ready for use more quickly (e.g., second or "boost" mode) may provide a quicker first puff, or more nicotine content per puff, or a more concentrated flavor per puff. Conversely, a mode in which the aerosol delivery device is ready for use later in a use session (e.g., first or base mode) may provide a longer overall use session, a lower nicotine content per puff, and a more sustained delivery of flavor.

[0094] In embodiments in which the aerosol delivery device is ready for use more quickly in the second (e.g., boost) mode and / or the first and / or second heating units or aerosol generators have a higher maximum operating temperature in the second mode, the second mode may be referred to as a "boost" mode. Various embodiments provide an aerosol delivery device that is operable in a first "regular" or "base" mode and a second "boost" mode. The "boost" mode may provide a faster first puff, or more nicotine content per puff, or a more concentrated flavor per puff.

[0095] The aerosol delivery device may include up to two aerosol generators. In other examples, the aerosol delivery device may include more than two independently controllable aerosol generators, such as three, four, or five independently controllable aerosol generators.

[0096] As described above, in some embodiments, at least one of the heating unit or the aerosol generator provided in the heating assembly may include an induction heating unit. In these embodiments, the heating unit may include an inductor (e.g., one or more inductor coils), and the aerosol delivery device may be configured to pass a varying current, such as an alternating current, through the inductor. The varying current in the inductor generates a varying magnetic field. When the inductor and the heating element are appropriately positioned relative to one another so that the varying magnetic field generated by the inductor penetrates the heating element, one or more eddy currents are generated within the heating element. Because the heating element has a resistance to the flow of current, when such eddy currents are generated within the object, their flow against the object's electrical resistance heats the object by Joule heating. Supplying a varying magnetic field to the susceptor may conveniently be referred to as supplying energy to the susceptor.

[0097] An aerosol generating system is disclosed that includes the aerosol delivery device described herein in combination with an aerosol product article.

[0098] The aerosol delivery device may comprise a non-combustible device or tobacco heating product ("THP") for heating smokable material without burning or combusting the smokable material.

[0099] The aerosol delivery device or aerosol generating device will now be described in more detail.

[0100] FIG. 1A shows an inductive heating assembly 100 of an aerosol delivery device, provided for illustrative purposes to illustrate various aspects of a non-thermal aerosol delivery device. FIG. 1B shows a cross-sectional view of the inductive heating assembly 100 of the device. In an alternative embodiment, the heating assembly may comprise a resistive heating assembly in which the aerosol generator comprises one or more electrical resistance heaters. According to one embodiment, the one or more electrical resistance heaters may comprise windings of an electrically resistive wire or thin film. The windings of the electrically resistive wire or thin film may be provided in a tubular configuration that surrounds the aerosol product article.

[0101] The heating assembly 100 has a first or proximal or mouth end 102 and a second or distal end 104. In use, a user inhales the formed aerosol from the mouth end of the aerosol generating device, which may be open-ended.

[0102] The heating assembly 100 includes a first induction heating unit 110 and a second induction heating unit 120. The first induction heating unit 110 includes a first inductor coil 112 and a first heating element 114. The second induction heating unit 120 includes a second inductor coil 122 and a second heating element 124.

[0103] 1A and 1B show the aerosol product article 130 received within a susceptor 140 (see FIG. 1B). The susceptor 140 forms the first induction heating element 114 and the second induction heating element 124. The susceptor 140 may be formed from any material suitable for heating by induction. For example, the susceptor 140 may include a metal. In some embodiments, the susceptor 140 may include a non-ferrous metal such as copper, nickel, titanium, aluminum, tin, or zinc, and / or an iron-based material such as iron, nickel, or cobalt. Additionally or alternatively, the susceptor 140 may include a semiconductor such as silicon carbide, carbon, or graphite.

[0104] Each induction heating element present in the aerosol delivery device may have any suitable shape. In the embodiment shown in Figure 1B, the induction heating elements 114, 124 surround the aerosol product article and define a receptacle for externally heating the aerosol product article. In other embodiments (not shown), the one or more induction heating elements may be generally elongated and configured to penetrate the aerosol product article and heat the aerosol product article internally.

[0105] 1B, the first induction heating element 114 and the second induction heating element 124 may be provided together as an integrated element 140. That is, in some embodiments, there is no physical distinction between the first heating element 114 and the second heating element 124. Rather, the different characteristics between the first aerosol generator 110 and the second aerosol generator 120 are defined by separate inductor coils 112, 122 surrounding each induction heating element 114, 124 so that they may be controlled independently of one another. In other embodiments (not shown), physically separate induction heating elements may be used.

[0106] The first and second inductor coils 112, 122 may be made from a conductive material. In this example, the first and second inductor coils 112, 122 are made from litz wire / cable that is helically wound to provide the helical inductor coils 112, 122. 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 within the conductor. In the exemplary induction heating assembly 100, the first and second inductor coils 124, 126 are made from copper litz wire with a circular cross-section. In other examples, the litz wire can have a cross-section of other shapes, such as circular.

[0107] The first inductor coil 112 is configured to generate a first varying magnetic field for heating the first induction heating element 114, and the second inductor coil 122 is configured to generate a second varying magnetic field for heating a second section of the susceptor 124. The first inductor coil 112 and the first induction heating element 114 together comprise the first induction heating unit 110. Similarly, the second inductor coil 122 and the second induction heating element 124 together form the second induction heating unit 120.

[0108] In this example, the first inductor coil 112 is adjacent to the second inductor coil 122 in a direction along the longitudinal axis of the device heating assembly 100 (i.e., the first and second inductor coils 112, 122 do not overlap). The susceptor structure 140 may comprise a single susceptor. Ends 150 of the first and second inductor coils 112, 122 may be connected to a controller, such as a PCB (not shown). In an embodiment, the controller comprises a PID controller (proportional-integral-derivative controller).

[0109] The varying magnetic field generates eddy currents in the first induction heating element 114, thereby rapidly heating the first induction heating element 114 to its maximum operating temperature within a short period of time, e.g., 20, 15, 12, 10, 5, or 2 seconds, after supplying the alternating current to the coil 112. Locating the first induction heating unit 110, which is configured to reach its maximum operating temperature more quickly, closer to the mouth end 102 of the heating assembly 100 than the second induction heating unit 120 can mean that an acceptable aerosol is provided to the user as soon as possible after the start of a use session.

[0110] It will be appreciated that the first and second inductor coils 112, 122 may have at least one characteristic that differs from one another in some examples. For example, the first inductor coil 112 may have at least one characteristic that differs from the second inductor coil 122. More specifically, in one example, the first inductor coil 112 may have a different inductance value than the second inductor coil 122. In FIGS. 1A and 1B, the first and second inductor coils 112, 122 are different lengths such that the first inductor coil 112 is wound across a smaller section of the susceptor 140 than the second inductor coil 122. Thus, the first inductor coil 112 may include a different number of turns than the second inductor coil 122 (assuming the spacing between individual turns is approximately the same). In yet another example, the first inductor coil 112 may be made of a different material than the second inductor coil 122. In some examples, the first and second inductor coils 112, 122 may be substantially identical.

[0111] In this example, the first inductor coil 112 and the second inductor coil 122 are wound in the same direction. However, in another embodiment, the inductor coils 112, 122 may be wound in opposite directions. This may be useful when the inductor coils are active at different times. For example, the first inductor coil 112 may operate to heat the first induction heating element 114 first, and then the second inductor coil 122 may operate to heat the second induction heating element 124. Winding the coils in opposite directions helps reduce the current induced in inactive coils when used with certain types of control circuits. In one example, the first inductor coil 112 may be a right-handed spiral, and the second inductor coil 122 may be a left-handed spiral. In another example, the first inductor coil 112 may be a left-handed spiral, and the second inductor coil 122 may be a right-handed spiral.

[0112] The coils 112, 122 may have any suitable shape. Without wishing to be bound by theory, configuring the induction heating element smaller (e.g., smaller helix pitch, fewer helix turns, shorter overall helix length) may increase the rate at which the induction heating element can reach its maximum operating temperature. In some embodiments, the first coil 112 may have a length in the longitudinal direction of the heating assembly 100 of less than about 20 mm, less than 18 mm, less than 16 mm, or about 14 mm. The first coil 112 may have a shorter length in the longitudinal direction of the heating assembly 100 than the second coil 124. Such a configuration may provide asymmetric heating of the aerosol product article along the length of the aerosol product article.

[0113] The susceptor 140 in this example is hollow and thus defines a receptacle within which the aerosol-generating material is received. For example, the item 130 can be inserted into the susceptor 140. In this example, the susceptor 140 is tubular with a circular cross section.

[0114] The induction heating elements 114 and 124 surround the aerosol product article 130 and are configured to heat the aerosol product article 130 externally. The aerosol delivery device is configured such that when the aerosol product article 130 is received within the susceptor 140, the outer surface of the article 130 abuts the inner surface of the susceptor 140. This ensures that heating occurs most efficiently. The article 130 in this example includes an aerosol-generating material. The aerosol-generating material is disposed within the susceptor 140. The article 130 may also include other components, such as a filter, packaging material, and / or a cooling structure.

[0115] The heating assembly 100 is not limited to two heating units. In some examples, the heating assembly 100 may include three, four, five, six, or more than six heating units. Each of these heating units may be controllable independently of the other heating units present in the heating assembly 100.

[0116] 2A and 2B, there are shown a partial cross-sectional view and a perspective view of an example aerosol product 200. The aerosol product 200 shown in Figures 2A and 2B corresponds to the aerosol product 130 shown in Figure 1.

[0117] The aerosol product article 200 may be in any shape suitable for use with an aerosol delivery device. The aerosol product article 130 may be in the form of, or provided as part of, a cartridge, cassette, or rod that can be inserted into the device. In the embodiment shown in FIGS. 1A, 1B, and 2, the aerosol product article 130 is in the form of a generally cylindrical rod including a body of smokable material 202 and a filter assembly 204 in the form of a rod. The filter assembly 204 includes three segments: a cooling segment 206, a filter segment 208, and a mouth end segment 210. The article 200 has a first end 212, also known as the mouth end or proximal end, and a second end 214, also known as the distal end. The body of aerosol-generating material 202 is disposed toward the distal end 214 of the article 200. In one example, the cooling segment 206 is positioned adjacent to the body of the aerosol-generating material 202, between the body of the aerosol-generating material 202 and the filter segment 208, such that the cooling segment 206 is in abutting relationship with the aerosol-generating material 202 and the filter segment 208. In other examples, there may be a separation between the body of the aerosol-generating material 202 and the cooling segment 206, and between the body of the aerosol-generating material 202 and the filter segment 208. The filter segment 208 is positioned between the cooling segment 206 and the mouth end segment 210. The mouth end segment 210 is positioned adjacent to the filter segment 208 toward the proximal end 212 of the article 200. In one example, the filter segment 208 is in abutting relationship with the mouth end segment 210. In one embodiment, the overall length of the filter assembly 204 is between 37 mm and 45 mm, and optionally, the overall length of the filter assembly 204 is 41 mm.

[0118] In use, portions 202a and 202b of the body of aerosol-forming material 202 may correspond to first induction heating element 114 and second induction heating element 124, respectively, of portion 100 shown in FIG. 1B.

[0119] The body of smokable material may have multiple portions 202a, 202b corresponding to multiple induction heating elements present in the aerosol delivery device. For example, the aerosol product article 200 may have a first portion 202a corresponding to the first induction heating element 114 and a second portion 202b corresponding to the second induction heating element 124. These portions 202a, 202b may exhibit different temperature profiles from one another during a use session. The temperature profiles of portions 202a, 202b may be derived from the temperature profiles of the first induction heating element 114 and the second induction heating element 124, respectively.

[0120] When there are multiple portions 202 a, 202 b of the body of aerosol-generating material 202, any number of the substrate portions 202 a, 202 b may have substantially the same composition. In certain examples, all of the substrate portions 202 a, 202 b have substantially the same composition. In one embodiment, the body of aerosol-generating material 202 is a single, continuous body, with no physical separation between the first portion 202 a and the second portion 202 b, and the first and second portions have substantially the same composition.

[0121] In one embodiment, the body of aerosol-forming material 202 includes tobacco. However, in each other embodiment, the body of smokable material 202 may consist of tobacco, consist substantially entirely of tobacco, include tobacco and aerosol-forming materials other than tobacco, include aerosol-forming materials other than tobacco, or be tobacco-free. The aerosol-forming material may include an aerosol-forming agent, such as glycerol.

[0122] In certain embodiments, the aerosol-forming material may include one or more tobacco components, filler components, binders, and aerosol-forming agents.

[0123] The filler component may be any suitable inorganic filler material. Suitable inorganic filler materials include, but are not limited to, calcium carbonate (i.e., chalk), perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. Calcium carbonate is particularly suitable. In some cases, the filler includes organic materials such as wood pulp, cellulose, and cellulose derivatives.

[0124] The binder may be any suitable binder, hi some embodiments, the binder comprises one or more of alginate, cellulose or modified cellulose, polysaccharide, starch or modified starch, and natural gum.

[0125] Suitable binders include, but are not limited to, alginates containing any suitable cation, such as sodium alginate, calcium alginate, and potassium alginate; cellulose or modified cellulose, such as hydroxypropyl cellulose and carboxymethyl cellulose; starch or modified starch; polysaccharides, such as pectins containing any suitable cation, such as sodium pectinate, potassium pectinate, calcium pectinate, or magnesium pectinate; xanthan gum; guar gum; and any other suitable natural gum.

[0126] The binder may be included in the aerosol-forming material in any suitable amount and concentration.

[0127] An "aerosol-generating agent" is an agent that facilitates the generation of an aerosol. An aerosol-generating agent may facilitate the generation of an aerosol by facilitating the initial vaporization and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, an aerosol-generating agent may improve the delivery of flavor from an aerosol product.

[0128] Generally, any suitable aerosol-generating agent may be included in the aerosol-generating material, including, but not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols and high-boiling hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristic acid, including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate.

[0129] In certain embodiments, the aerosol-forming material comprises a tobacco component in an amount of 60-90% by weight of the tobacco composition, a filler component in an amount of 0-20% by weight of the tobacco composition, and an aerosol-generating agent in an amount of 10-20% by weight of the tobacco composition. The tobacco component may comprise paper-reconstituted tobacco in an amount of 70-100% by weight of the tobacco component.

[0130] In one example, the body of aerosol-generating material 202 is between 34 mm and 50 mm in length, optionally, the body of aerosol-generating material 202 is between 38 mm and 46 mm in length, and further optionally, the body of aerosol-generating material 202 is 42 mm in length.

[0131] In one example, the total length of article 200 is between 71 mm and 95 mm, optionally, the total length of article 200 is between 79 mm and 87 mm, and further optionally, the total length of article 200 is 83 mm.

[0132] The axial end of the body of aerosol-generating material 202 is visible at the distal end 214 of the article 200. However, in other embodiments, the distal end 214 of the article 200 may include an end member (not shown) that covers the axial end of the body of aerosol-generating material 202.

[0133] The body of aerosol-generating material 202 is disposed substantially circumferentially around the filter assembly 204 to surround it and is joined to the filter assembly 204 by an annular beveled paper (not shown) that extends partially along the length of the body of aerosol-generating material 202. In one example, the tipping paper is made from 58 GSM tipping paper. In one example, it has a length between 42 mm and 50 mm; optionally, the tipping paper has a length of 46 mm.

[0134] In one example, cooling segment 206 is an annular tube disposed about the cooling segment, defining a void therein. The void provides a chamber for the flow of heated volatile components generated from the body of aerosol-generating material 202. Cooling segment 206 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 200 during insertion into device 100. In one example, the wall thickness of cooling segment 206 is approximately 0.29 mm.

[0135] The cooling segment 206 provides a physical displacement between the aerosol-generating material 202 and the filter segment 208. The physical displacement provided by the cooling segment 206 provides a thermal gradient along the length of the cooling segment 206. In one example, the cooling segment 206 is configured to provide a temperature difference of at least 40° C. between the heated volatile component entering the first end of the cooling segment 206 and the heated volatile component exiting the second end of the cooling segment 206. In one example, the cooling segment 206 is configured to provide a temperature difference of at least 60° C. between the heated volatile component entering the first end of the cooling segment 206 and the heated volatile component exiting the second end of the cooling segment 206. This temperature difference along the length of the cooling segment 206 protects the temperature-sensitive filter segment 208 from the high temperature of the aerosol-generating material 202 when heated by the heating assembly 100 of the aerosol delivery device. If no physical displacement is provided between the filter segment 208 and the body of the aerosol-generating material 202 and the heating elements 114, 124 of the heating assembly 100, the temperature-sensitive filter segment 208 may be damaged during use and therefore will not effectively perform its required function.

[0136] In one example, the length of the cooling segment 206 is at least 15 mm. In one example, the length of the cooling segment 206 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, more specifically between 25 mm and 27 mm, and more specifically 25 mm.

[0137] Cooling segment 206 is made of paper, meaning that it is constructed of a material that does not produce compounds of concern, such as toxic compounds, when used adjacent to heater assembly 100 of an aerosol delivery device. In one example, cooling segment 206 is fabricated from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

[0138] In another example, cooling segment 206 is a recess carved out of rigid plug wrap or tipping paper that is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 200 during insertion into device 100.

[0139] For each example of cooling segment 206, the dimensional accuracy of the cooling segment is sufficient to meet the dimensional accuracy requirements of high speed manufacturing processes.

[0140] The filter segment 208 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the smokable material. In one example, the filter segment 208 is made of a monoacetate material, such as cellulose acetate. The filter segment 208 provides cooling and reduced irritation from the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

[0141] The density of the cellulose acetate tow material of filter segment 208 controls the pressure drop across filter segment 208, which in turn controls the retraction resistance of article 200. Therefore, the selection of material for filter segment 208 is important in controlling the retraction resistance of article 200. Additionally, filter segment 208 performs a filtration function within article 200.

[0142] In one example, the filter segment 208 is made from 8Y15 grade filter tow material, which provides filtration for the heated volatile material while also reducing the size of condensed aerosol droplets resulting from the heated volatile material, thereby satisfactorily reducing the irritation and throat hit of the heated volatile material.

[0143] The presence of filter segment 208 provides an insulating effect by providing additional cooling to the heated volatile components exiting cooling segment 206. This additional cooling effect reduces the contact temperature of the user's lips on the surface of filter segment 208.

[0144] One or more flavors may be added to the filter segment 208 in the form of direct injection of a flavored liquid into the filter segment 208 or by embedding or disposing one or more flavored breakable capsules or other flavor carriers within the cellulose acetate tow of the filter segment 208.

[0145] In one example, the filter segment 208 is between 6 mm and 10 mm in length, optionally 8 mm.

[0146] The mouth end segment 210 is an annular tube that is disposed about the mouth end segment 210 and defines a void therein. The void provides a chamber for the heated volatile components that flow from the filter segment 208. The mouth end segment 210 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use when the article is inserted into the device 100. In one example, the wall thickness of the mouth end segment 210 is approximately 0.29 mm.

[0147] In one example, the length of the mouth end segment 210 is between 6 mm and 10 mm, optionally 8 mm. In one example, the thickness of the mouth end segment is 0.29 mm.

[0148] The mouth end segment 210 may be manufactured from a spirally wound paper tube that provides a hollow interior chamber yet maintains critical mechanical stiffness. A spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

[0149] The mouth end segment 210 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 208 from coming into direct contact with the user.

[0150] It should be appreciated that in one example, the mouth end segment 210 and the cooling segment 206 may be formed from a single tube, with the filter segment 208 positioned within the tube separating the mouth end segment 210 and the cooling segment 206.

[0151] Article 200 is provided with a ventilation region 216 that allows air to flow from the exterior of article 200 to the interior of article 200. In one example, ventilation region 216 takes the form of one or more vent holes 216 formed through an outer layer of article 200. The vent holes may be disposed within cooling segment 206 to aid in cooling article 200. In one example, ventilation region 216 includes one or more rows of holes, optionally each row of holes disposed circumferentially around article 200 in a cross section generally perpendicular to the longitudinal axis of article 200.

[0152] In one example, there are 1 to 4 rows of vent holes to provide ventilation to article 200. Each row of vent holes may have between 12 and 36 vent holes 216. Ventilation holes 216 may, for example, be between 100 and 500 μm in diameter. In one example, the axial separation between rows of vent holes 216 is between 0.25 mm and 0.75 mm, and optionally, the axial separation between rows of vent holes 216 is 0.5 mm.

[0153] In one example, the vent holes 216 are uniformly sized. In another example, the sizes of the vent holes 216 vary. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical perforation of the cooling segment 206, or pre-perforation of the cooling segment 206 before it is formed into the article 200. The vent holes 216 are positioned to provide effective cooling to the article 200.

[0154] In one example, the row of vent holes 216 is positioned at least 11 mm from the proximal end 212 of the article, and optionally, the vent holes are positioned between 17 mm and 20 mm from the proximal end 212 of the article 200. The positions of the vent holes 216 are positioned such that a user does not block the vent holes 216 when the article 200 is in use.

[0155] Providing the row of vent holes between 17 mm and 20 mm from the proximal end 212 of the article 200 allows the vent holes 216 to be located on the exterior of the device 100 when the article 200 is fully inserted into the device 100, as can be seen in Figure 1. By locating the vent holes on the exterior of the device, unheated air can enter the article 200 from outside the device 100 through the vent holes to help cool the article 200.

[0156] The length of the cooling segment 206 is such that when the article 200 is fully inserted into the device 100, the cooling segment 206 is partially inserted into the device 100. The length of the cooling segment 206 serves two functions: first, to provide a physical gap between the heater arrangement and the temperature-sensitive filter arrangement 208 of the device 100 when the article 200 is fully inserted into the device 100; and second, to allow the vent 216 to be disposed within the cooling segment while also being disposed outside the device 100. As can be seen in FIG. 1 , the majority of the cooling element 206 is disposed within the device 100. However, there is a portion of the cooling element 206 that extends from the device 100. It is this portion of the cooling element 206 where the vent 216 is disposed that extends from the device 100.

[0157] FIG. 3 illustrates a temperature profile 300 of a first heating element in an aerosol delivery device, such as the first induction heating element 114 shown in FIG. 1B, during an exemplary use session 302. The temperature profile 300 suitably refers to the temperature profile of the first induction heating element 114 in any operating mode of the heating assembly. The temperature profile 300 of the first heating element 114 is measured by a suitable temperature sensor disposed in the first heating element 114. Suitable temperature sensors include thermocouples, thermopiles, or resistance temperature detectors (RTDs, also referred to as resistance thermometers). In certain embodiments, the device includes at least one RTD. In one embodiment, the device includes a thermocouple disposed in each heating element 114, 124 present in the aerosol delivery device. Temperature data measured by the or each temperature sensor may be communicated to a controller. Furthermore, this data may be communicated to the controller when the heating elements 114, 124 reach a predetermined temperature, so that the controller may accordingly modify the supply of power to elements in the aerosol delivery device. Optionally, the controller comprises a PID (proportional integral derivative) controller that uses a control loop feedback mechanism to control the temperature of the heating elements based on data provided from one or more temperature sensors located within the device. In one embodiment, the controller comprises a PID controller configured to control the temperature of each heating element based on temperature data provided from a thermocouple located in each of the heating elements.

[0158] A use session 302 begins when the device is activated 304 and the controller controls the device to supply energy to at least the first induction heating unit 110. The device may be activated by a user, for example, by actuating a push button or by inhaling through the device. Activation means for use with aerosol delivery devices are known to those skilled in the art. In the context of a heater assembly comprising induction heating means, a use session begins when the controller commands a varying current to be supplied to the inductors (e.g., first and second coils 112, 122), and thus a varying magnetic field to the induction heating element, to generate a temperature increase in the induction heating element. As noted above, this may conveniently be referred to as "supplying energy to the induction heating unit."

[0159] The end 306 of a use session 302 occurs when the controller commands elements within the device to stop supplying energy to all aerosol generators present in the aerosol delivery device. In the context of a heater assembly including an induction aerosol generator, the use session ends when no fluctuating current is supplied to any of the induction heating elements provided within the heating assembly, thereby preventing any fluctuating magnetic field from being supplied to the induction heating elements.

[0160] At the beginning of a smoking session 302, the temperature of the first heating element rises rapidly until it reaches a maximum operating temperature 308. The time 310 it takes to reach the maximum operating temperature 308 may be referred to as the "ramp-up" period, and according to various embodiments, has a duration of less than 20 seconds.

[0161] The temperature of the first heating element may optionally drop from the maximum operating temperature 308 to a lower temperature 314 later in the use session 302. When the temperature drops from the maximum operating temperature 308 later in the use session 302, the temperature 314 to which the first heating element drops is preferably the operating temperature. The operating temperature 314 to which the first heating element drops may appropriately be referred to as a “second operating temperature” 314. Optionally, the temperature of the first heating element does not drop below the minimum operating temperature of the first heating element until the end 306 of the use session 302. The first heating element optionally remains at or above the second operating temperature 314 until the end 306 of the use session 302.

[0162] In embodiments in which the heating assembly is operable in multiple modes (e.g., base mode and boost mode), the temperature of the first heating element may drop from the maximum operating temperature 308 to the second operating temperature 314 in at least one of the modes. Optionally, the temperature of the first heating element drops from the maximum operating temperature 308 to the second operating temperature 314 in all operable modes. For the avoidance of doubt, the maximum operating temperature 308 and second operating temperature 314 of the first heating element may differ for each mode.

[0163] In some examples, the second operating temperature 314 is between 180 and 240°C. If the heating assembly is operable in multiple modes, the second operating temperature 314 in at least one operating mode may be between 180 and 240°C. Optionally, the second operating temperature 314 in all operating modes may be between 180 and 240°C. Further optionally, the second operating temperature 314 is at least 220°C. In some examples, the first heating element or aerosol generator remains at or above the second operating temperature 314 in all operating modes until the end of the use session. Without wishing to be bound by theory, configuring the heating assembly so that the first heating element does not drop below 220°C until the end of the use session 220 may at least partially prevent condensation from forming on the first portion of the aerosol product article during the use session and / or may also reduce the resistance to suction offered by the first portion of the aerosol product article.

[0164] In these embodiments, the first heating element may remain at or near its maximum operating temperature for at least 25%, 50%, or 75% of the session. For example, the first heating element may remain at its maximum operating temperature for a first duration of the use session, then drop to and remain at a second operating temperature for a second duration of the use session, the first duration being at least 25%, 50%, or 75% of the session. The first duration may be longer or shorter than the second duration. Optionally, in at least one operating mode, the first duration is longer than the second duration. In this example, the ratio of the first duration to the second duration may be 1.1:1 to 7:1, 1.5:1 to 5:1, 2:1 to 3:1, or approximately 2.5:1.

[0165] In certain embodiments, the device is operable in multiple modes, and the above ratio applies to the first operating mode. In the second operating mode, the first duration may be longer or shorter than the second duration. Optionally, the second duration is longer than the first duration. Thus, one embodiment is a device configured such that in the first operating mode, the first duration is longer than the second duration, but in the second operating mode, the second duration is longer than the first duration. In one embodiment, in the second operating mode, the ratio of the second duration to the first duration may be 1.1:1 to 5:1, 1.2 to 2:1, or 1.3:1 to 1.4:1. In other embodiments, in the second operating mode, the ratio of the second duration to the first duration may be 2:1 to 12:1, 2.5:1 to 11:1. In particular, the ratio may be 3:1 to 4:1. Alternatively, the ratio may be 8:1 to 10:1. This embodiment may be particularly suitable for reducing the amount of condensation that forms within the device during a usage session.

[0166] It has been found that operating the first heating element at its maximum operating temperature for a greater proportion of a use session can help reduce the amount of condensation that collects within the device during use. This effect can be particularly noticeable in so-called "boost" operating modes, in which the heating unit operates at a higher maximum operating temperature during shorter use sessions.

[0167] The maximum operating temperature 308 may be between about 200°C and 300°C, or between 210°C and 290°C, or between 220°C and 280°C, or between 230°C and 270°C, or between 240°C and 260°C.

[0168] 4 illustrates a temperature profile 400 of a second heating element, such as the second induction heating element 124 shown in FIG. 1B, when present in an aerosol delivery device during an exemplary smoking session 402. The smoking session 402 corresponds to the smoking session 302 shown in FIG. 3. The temperature profile 400 suitably refers to the temperature profile of the second induction heating element 124 in any operating mode of the heating assembly.

[0169] A use session 402 begins when the device is activated 404 and energy is supplied to at least a first induction heating unit. In this example, the controller is configured not to supply energy to a second induction heating unit at the start of the use session 402. Nevertheless, the temperature of the second induction heating element will likely increase somewhat due to thermal "bleed"—conduction, convection, and / or radiation—of thermal energy from the first heating element 114 to the second heating element 124.

[0170] At a first programmed time point 406 after the start of a use session, the controller commands energy to be supplied to the second heating unit 120, and the temperature of the second heating element 124 rapidly increases until time point 408 when it reaches a predetermined first operating temperature 410. The controller then controls the second heating unit 120 so that the second heating element 124 remains at substantially this temperature for a further period of time. The predetermined first operating temperature 410 may be lower than the maximum operating temperature 412 of the second heating element 124. In other embodiments (not shown), the first predetermined operating temperature is the maximum operating temperature. That is, the second heating element 124 is directly heated to the maximum operating temperature upon activation of the second heating unit 120.

[0171] In some embodiments, the predetermined first operating temperature 410 is between 150°C and 200°C. The predetermined first operating temperature 410 may be greater than 150°C, 160°C, 170°C, 180°C, or 190°C. The predetermined first operating temperature 410 may be less than 200°C, 190°C, 180°C, 170°C, or 160°C. Optionally, the predetermined first operating temperature 410 is between 150°C and 170°C. A lower first operating temperature 410 may help reduce the amount of undesirable condensation that collects within the device.

[0172] In embodiments in which the heating assembly is operable in multiple modes, the heating assembly may be configured in at least one mode for the second heating element 124 to rise to the first operating temperature 410, maintain the first operating temperature 410, and then subsequently rise to the maximum operating temperature 412. Optionally, the heating assembly is configured in all operable modes for the second heating element 124 to rise to the first operating temperature 410, maintain the first operating temperature 410, and then subsequently rise to the maximum operating temperature 412.

[0173] The first programmed time point 406 at which power is first supplied to the second heating unit 120 may be at least about 10, 20, 30, 40, 50, or 60 seconds after activation of the device 404. For embodiments in which the heating assembly is operable in multiple modes, the first programmed time point 406 is at least about 10, 20, 30, 40, 50, 60, 70, or 80 seconds after activation of the device 404 in at least one mode. Optionally, the first programmed time point 406 is at least about 10, 20, 30, 40, 50, 60, 70, or 80 seconds after activation of the device 404 in all operable modes. The first programmed time point 406 may be the same in each mode or may differ between modes. Optionally, the first programmed time point 406 differs between modes. In particular, the first programmed point 406 may be later in the usage session in the first mode than in the second mode.

[0174] In some embodiments, the heating assembly 100 may be configured to raise the second induction unit 120 to the predetermined operating temperature 410 within 10 seconds, or within 5, 4, 3, or 2 seconds of a programmed time point 406 for raising the temperature of the second induction heating element 124 to the first predetermined operating temperature 410. In other words, the period 414 between the two times 406, 408 may have a duration of 10 seconds or less, 5 seconds or less, 4 seconds or less, 3 seconds or less, or 2 seconds or less. Optionally, the period 414 has a duration of 2 seconds or less.

[0175] The second heating element 124 may be maintained at the predetermined first operating temperature 410 for a predetermined period of time until a second programmed point 416 at which the controller controls the second heating unit such that the second heating element 124 increases to its maximum operating temperature 412. At this second programmed point 416, the temperature of the second heating element 124 increases rapidly until it reaches the maximum operating temperature 412 at point 418. The controller then controls the second heating unit such that the second heating element 124 remains at substantially this temperature for a further period of time.

[0176] The second program time point 416 may be at least approximately 10, 20, 30, 40, 50, or 60 seconds after activation of the device 404 .

[0177] In some embodiments, the heating assembly 100 may be configured to increase the second induction element 124 from the first predetermined operating temperature 410 to the maximum operating temperature 412 within 10 seconds, or within 5, 4, 3, or 2 seconds of a programmed time point 416 for increasing the temperature of the second induction heating element 124 to the maximum operating temperature 412. In other words, the period 420 between the two times 416, 418 may have a duration of 10 seconds or less, 5 seconds or less, 4 seconds or less, 3 seconds or less, or 2 seconds or less. Optionally, the period 420 has a duration of 2 seconds or less.

[0178] The temperature of the second heating element during the period from time 416 to time 418 may increase at a rate of at least 50° C. per second, or 100° C. per second, or 150° C. per second.

[0179] In some embodiments, the heating assembly 100 may be configured such that the second induction heating element 124 reaches the maximum operating temperature 412 at least about 30, 40, 50, 60, 80, 100, or 120 seconds after activation of the device 404. Optionally, the heating assembly 100 is configured such that the second induction heating element 124 reaches the maximum operating temperature 412 at least about 120 seconds after activation of the device 404.

[0180] In some embodiments, the heating assembly 100 may be configured such that the second induction heating element 124 reaches its maximum operating temperature 412 at least about 10, 20, 30, 40, 50, 60, 80, 100, or 120 seconds after the first induction heating element 122 reaches its maximum operating temperature 308. Optionally, the heating assembly 100 is configured such that the second induction heating element 124 reaches its maximum operating temperature 412 at least about 120 seconds after the first induction heating element 122 reaches its maximum operating temperature 308. In other words, with reference to FIGS. 3 and 4 , the time point 418 may be at least 120 seconds later than the time point 310 during the smoking session 302, 402.

[0181] The second heating element 124 may be maintained at its maximum operating temperature 412 for a predetermined period of time until the end of the smoking session 422, at which point the controller controls the heating assembly to stop supplying energy to all heating elements present in the aerosol delivery device. Optionally, after the temperature of the second heating element 124 reaches the operating temperature (approximately around the first predetermined time point 406), the temperature of the second heating element 124 does not fall below the minimum operating temperature 424 of the second heating element 124 until the end of the smoking session 402.

[0182] In embodiments in which the first heating element 122 drops from its maximum operating temperature 308 to a lower temperature later in the smoking session, the second heating element 124 may reach its maximum operating temperature 412 before, after, or simultaneously with the temperature drop of the first heating element 122. In one embodiment, the second heating element 124 reaches its maximum operating temperature 412 before the first heating element 122 drops from its maximum operating temperature 308 to a lower temperature.

[0183] In some embodiments, the maximum operating temperature 308 of the first heating element 122 is approximately the same as the maximum operating temperature of the second heating element 124. In other embodiments, the maximum operating temperatures 308, 412 of the first and second heating elements 122, 124 may be different. For example, the maximum operating temperature 308 of the first heating element 122 may be higher than the maximum operating temperature of the second heating element 124, or the maximum operating temperature 412 of the second heating element 124 may be higher than the maximum operating temperature of the first heating element 122. In one embodiment, the maximum operating temperature 308 of the first heating element 122 is higher than the maximum operating temperature 412 of the second heating element 124. In another embodiment, the maximum operating temperature 308 of the first heating element 122 is approximately the same as the maximum operating temperature of the second heating element 124.

[0184] During periods when the heating elements remain at a substantially constant temperature, there may be slight variations in temperature around the target temperature defined by the controller. In some embodiments, the variations are less than about ±10°C, or ±5°C, or ±4°C, or ±3°C, or ±2°C, or ±1°C. Optionally, the variations are less than about ±3°C for at least the first heating element, at least the second heating element, or both the first and second heating elements.

[0185] 3 and 4 discussed above reflect measured or observed temperature profiles of heating units present in device 100. FIG. 5 reflects a programmed heating profile of any heating unit present in device 100. Any programmed heating profile of any heating unit present in the heating assembly of the present device may be represented by a generic programmed heating profile such as that shown in FIG.

[0186] The programmed heating profile 500 includes a first temperature, temperature A502, that the heating unit is programmed to reach during a given use session at time A504, which may be conveniently defined in terms of the number of seconds elapsed from the start of the use session, i.e., from the time power is first supplied to at least one heating unit present in the heating assembly.

[0187] Optionally, the programmed heating profile 500 may include a second temperature, temperature B506. Temperature B506 is a different temperature than temperature A502. In some embodiments, the device is programmed to reach temperature B506 during a given use session at time B508, which occurs in time after time A504.

[0188] From time A504 to time B508, the device is programmed to have temperature A502 that is approximately the same temperature. However, in some embodiments, there may be variation about temperature A502 during this period. For example, the heating unit may have a temperature that is within 10°C of temperature A502 during this period, optionally within 5°C of temperature A502 during this period. Such a profile would still be considered to correspond to the profile generally shown in Figure 5. In other embodiments, there is substantially no variation from temperature A502 during this period.

[0189] Although FIG. 5 shows temperature B506 being greater than temperature A502, the programmed heating profiles of the present disclosure are not so limited, and temperature B506 may be greater or less than temperature A502 for any given heating profile.

[0190] Optionally, the programmed heating profile 500 includes a second temperature, temperature B 506.

[0191] Optionally, the programmed heating profile 500 may include a third temperature, temperature C510, which is different from temperature B. In some embodiments, the device is programmed to reach temperature C510 during a given use session at time C512, which occurs in time after time B508 and thus time A502.

[0192] Temperature C510 may or may not be the same temperature as temperature A502.

[0193] 5 shows temperature C 510 being higher than temperature B 506 and temperature A 502, the programmed temperature profiles of the present disclosure are not so limited, and temperature C 510 may be higher or lower than temperature A 502 for any given heating profile. Temperature C 510 may be higher or lower than temperature B 506 for any given heating profile.

[0194] The programmed heating profile 500 includes an end point 514 at which energy ceases to be supplied to the heating unit for the remainder of the use session. The end point 514 may coincide with the end of the use session.

[0195] Surprisingly, it has been found that the temperatures 502, 506, 510 and time points 504, 508, 512, 514 of the heating unit's programmed heating profile can be modulated to reduce the buildup of condensation within the device 100. In particular, by configuring the device so that time point B 508 occurs after 50% of a use session has elapsed, and optionally after 75% of a use session has elapsed, the amount of condensation that collects within the device during use can be reduced.

[0196] In embodiments where the heating assembly includes at least two aerosol generators, the heating assembly may be configured so that the first and second aerosol generators have approximately the same maximum operating temperature. The inventors have determined that this configuration may also reduce condensation buildup within the device.

[0197] 6 illustrates an embodiment in which a controller may set two different heating profiles for one or more aerosol generators of an aerosol delivery device. The controller may be operable in a first operating mode to set first heating profiles 601, 602 for one or more aerosol generators of the aerosol delivery device. As shown in FIG. 6, the first heating profiles 601, 602 may be stepped down over time. When operated in the first operating mode, the controller is configured to set the first heating profiles 601, 602 such that the average operating temperature of the one or more aerosol generators during a use session (i.e., between times 610 and 612) is configured to be temperature T1.

[0198] 6, in a first mode of operation, the controller is initially configured at the start of a session to set a temperature 601 for one or more aerosol generators at an initial time point 610. The initial temperature 601 may be maintained for a time period t1, after which the temperature may be reduced to a lower temperature 602 at time point 611 for the remainder of the use session. The session is considered to end at time point 612 when the controller stops supplying energy to the one or more aerosol generators.

[0199] The controller may also be operated in a second operating mode as shown in FIG. 6, in which the controller is configured to set different second heating profiles 603, 604 for one or more aerosol generators so that the average operating temperature of the one or more aerosol generators during a usage session (i.e., between times 610 and 612) is again configured to be temperature T1.

[0200] Thus, the controller may be configured to operate in at least a first mode and a second mode, in which different heating profiles may be utilized, but the different heating profiles set the same average operating temperature T1 for one or more aerosol generators.

[0201] It will be appreciated that it may be desirable to maintain the aerosolizable material at a particular optimum average temperature throughout a use session, and therefore it is desirable for the heating profile applied to one or more aerosol generators to have an average operating temperature T1 that substantially matches or corresponds to the desired optimum average temperature.

[0202] According to an embodiment, the average operating temperature T1 of the heating profiles 601, 602; 603, 604 may be in the range of (i) 200-210°C, (ii) 210-220°C, (iii) 220-230°C, (iv) 230-240°C, (v) 240-250°C, (vi) 250-260°C, (vii) 260-270°C, (viii) 270-280°C, (ix) 280-290°C, and (x) 290-300°C.

[0203] The first and second heating profiles 601, 602; 603, 604 may be mirror images of each other, such as the example shown and described with reference to Figure 6. In the example shown in Figure 6, the first heating profiles 601, 602 are configured to set a first temperature 601 during a first time period t1 from time 610 to 611, then at time 611 the first heating profile sets a lower temperature 602 for the remaining time period t2 from time 611 to 612. Conversely, the second heating profiles 603, 604 are configured to set a temperature 603 during time period t1 from time 610 to 611, then at time 611 the second heating profile sets a higher temperature 604 for the remaining time period 611 to 612.

[0204] It has been found that a desired or optimal sensory experience for a user may be achieved by maintaining the average operating temperature of one or more aerosol generators at a particular average operating temperature T1 during a use session (i.e., during time points 610-612). However, as shown in FIG. 6, different heating profiles having the same average operating temperature T1 may be utilized.

[0205] The ability to set different heating profiles that have the same average operating temperature T1 during a use session allows the aerosolizable material to be maintained at an optimal average temperature during a use session, while also facilitating the user to have different sensory experiences by selecting between two or more different heating profiles.

[0206] According to one embodiment, a usage session may include at least a first time period t1 and at least a second subsequent time period t2, as shown in FIG.

[0207] 6, in a first operating mode during a first time period t1, the controller may be configured to set a first maximum temperature 601 of the one or more aerosol generators. During a second time period t2, the controller may be configured to set a second maximum temperature 602 of the one or more aerosol generators. The first maximum temperature 601 may be higher than the second maximum temperature 602.

[0208] According to an alternative embodiment, the first maximum temperature may be lower than the second maximum temperature.

[0209] In the second operating mode during a first time period t1, the controller may be configured to set a first maximum temperature 603 for the one or more aerosol generators. During a second time period t2, the controller may then be configured to set a second maximum temperature 604 for the one or more aerosol generators. The first maximum temperature 603 may be lower than the second maximum temperature 604.

[0210] According to an alternative embodiment, the first maximum temperature may be higher than the second maximum temperature.

[0211] FIG. 7 shows an embodiment in which the controller may be configured to set a first heating profile 701, 702, 703, 704 having a first maximum operating temperature 701, 703 and a second heating profile 705, 706, 707, 708 having a different second maximum operating temperature 705, 707, but both heating profiles have the same average operating temperature T1.

[0212] Similarly, the first heating profiles 701, 702, 703, 704 may have a first minimum operating temperature 702, 704, and the second heating profiles 705, 706, 707, 708 may have a different second minimum operating temperature 706, 708.

[0213] 8 illustrates an embodiment in which a controller may set first heating profiles 801, 802, 803, 804 for one or more aerosol generators, where the first heating profiles 801, 802, 803, 804 may be stepped up over time, with an average operating temperature of T1 throughout a use session. The controller may also be configured to set second heating profiles 810, 811, 812, 813 for one or more aerosol generators, where the second heating profiles 810, 811, 812, 813 may be stepped down over time. The second heating profiles 810, 811, 812, 813 may be configured to have the same average operating temperature as the first heating profile, i.e., T1, throughout a use session.

[0214] In the particular example shown in Figure 8, the two heating profiles are mirror images of each other, however, it will be appreciated that it is not necessary for the two heating profiles to be mirror images.

[0215] According to other embodiments, a first heating profile may be stepped down over time and a second heating profile may be stepped up over time, where both heating profiles may have the same average operating temperature T1 throughout a usage session.

[0216] As another example, a use session may include at least a first time period t1, at least a second subsequent time period t2, and at least a third further time period t3. The controller may be operable in a first mode of operation and a second mode of operation. During the first time period t1, the controller may generate a first maximum temperature T 1maxand during the second time period t2, the controller may be configured to set a second maximum temperature T 2max and during a third time period t3, the controller is configured to set a third maximum temperature T 3max According to one embodiment, T 1max >T 2max >T 3max According to another embodiment, T 1max >T 2max <T 3max According to another embodiment, T 1max <T 2max >T 3max According to another embodiment, T 1max <T 2max <T 3max is.

[0217] FIG. 9 illustrates another embodiment in which a controller can be configured to set two different heating profiles for one or more aerosol generators. A first heating profile 900 has an average operating temperature T1 and a duration D1. A second heating profile 901 has the same average operating temperature T1 but a different duration D2. D1 and D2 may differ by at least 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50%. D1 may be 200-210 seconds, 210-220 seconds, 220-230 seconds, 230-240 seconds, 240-250 seconds, 250-260 seconds, 260-270 seconds, 270-280 seconds, 280-290 seconds, or 290-300 seconds. Similarly, D2 may be 200 to 210 seconds, 210 to 220 seconds, 220 to 230 seconds, 230 to 240 seconds, 240 to 250 seconds, 250 to 260 seconds, 260 to 270 seconds, 270 to 280 seconds, 280 to 290 seconds, or 290 to 300 seconds.

[0218] FIG. 10 illustrates an embodiment in which a controller for setting a heating profile to one or more aerosol generators is operable in at least three different modes of operation 1001, 1002, 1003.

[0219] Thus, a controller is provided that allows the user to choose from a greater variety of sensory experiences.

[0220] 11A, a user may select the controller to operate in a first operating mode 1001, and the controller may be configured to set a first heating profile for one or more aerosol generators during a first use session (between times t0 and t3), where the operating temperature of the one or more aerosol generators is first raised to a temperature T2 during a first time period t0-t1, then lowered to a lower temperature T3 during a second time period t1-t2, and then raised to a higher temperature T4 during a third time period t2-t3. The use session shall end at time t3.

[0221] 11B, a user may select the controller to operate in a second operating mode 1002, and the controller may be configured to set a second heating profile for the one or more aerosol generators during a second use session (between times t0 and t3), in which the operating temperature of the one or more aerosol generators is first raised to a temperature T5 during a first time period t0-t1, then further raised to a higher temperature T6 during a second time period t1-t2, and then further raised to an even higher temperature T7 during a third time period t2-t3. The use session shall end at time t3.

[0222] 11C, a user may select the controller to operate in a third operating mode 1003, and the controller may be configured to set a third heating profile for the one or more aerosol generators during a third use session (between times t0 and t3), where the operating temperature of the one or more aerosol generators is initially set to temperature T8 during time period t0-t1, and then reduced to a lower temperature T9 at time t1. The controller is further configured to reduce the temperature to a further lower temperature T10 at time t2. In one embodiment, the temperature is maintained at temperature T10 for time period t2-t3. The use session shall end at time t3.

[0223] According to one embodiment, a first use session may have a duration D1, a second use session may have a duration D2, and a third use session may have a duration D3.

[0224] In the example shown in FIGS. 11A-11C, all three use sessions have the same duration, so D1 = D2 = D3. However, other embodiments are contemplated, for example, where D1 = D2 ≠ D3. According to another embodiment, D1 ≠ D2 = D3. According to a further embodiment, D1 = D3 ≠ D2. According to yet a further embodiment, D1 ≠ D2 ≠ D3. The various heating profiles shown in FIGS. 11A-11C include stepped profiles in which the operating temperature set for one or more aerosol generators changes in a stepped manner over time. However, other embodiments are contemplated in which the operating temperature set for one or more aerosol generators may change smoothly or continuously over time.

[0225] 12A illustrates a heating profile according to another embodiment. In a first mode of operation as illustrated in FIG. 12A, the controller sets a first heating profile 1200, 1201 for one or more aerosol generators. The first heating profile includes setting a first temperature 1200 during a time period t0-t1, then setting a second temperature 1201 during a time period t1-t2, then setting a third temperature 1200 during a time period t2-t3, and then setting a fourth temperature 1201 during a time period t3-t4. The use session is assumed to end at time t4.

[0226] During such a use session, the average operating temperature of the one or more aerosol generators is T1.

[0227] As shown in FIG. 12B, according to one embodiment, the controller may be operated in an operational mode in which a dummy buffer period or adjustment period may be inserted into the heating profile to form a new second heating profile.

[0228] In the particular example shown in FIG. 12B, a dummy buffer period or adjustment period is inserted into the heating profile at the end of the first heating profile at time t4 to extend the usage session so that it ends at a later time t5.

[0229] Accordingly, various embodiments are disclosed in which the controller is operable in a second operating mode to set a second heating profile for one or more aerosol generators, the second heating profile corresponding to the first heating profile but further including one or more dummy buffer periods, which may also be referred to as one or more adjustment periods.

[0230] However, it should be understood that it is not necessary for the dummy buffer period (or adjustment period) to be at the end of the first heating profile, as shown in Figure 12B. Embodiments are contemplated in which one or more dummy buffer periods or adjustment periods may be inserted into the first heating profile at any point within the first heating profile.

[0231] 12B, in a second mode of operation, the controller sets a heating profile having a first temperature 1200 during time period t0-t1, then sets a second temperature 1201 during time period t1-t2, then sets a third temperature 1200 during time period t2-t3, then sets a fourth temperature 1201 during time period t3-t4. The controller further includes a dummy buffer or adjustment period between times t4 and t5, during which the temperature is maintained at temperature 1200.

[0232] In the second mode of operation, the average operating temperature of the one or more aerosol generators is T2, which will be understood to be different from the average operating temperature T1 in the first mode of operation.

[0233] One or more dummy or adjustment periods may be inserted into the first heating profile for various reasons. For example, it may be desirable to operate the aerosol delivery device in a second operating mode having a different average operating temperature than the first operating mode. Other embodiments are contemplated in which it may be desirable to modify another characteristic of the temperature profile set for the aerosol generator, such as the mark-space ratio or the time period before setting a higher or lower temperature.

[0234] It is also contemplated that when one or more dummy or adjustment periods are inserted into the first heating profile, the use session may end before the end of the temperature profile set for the aerosol generator.

[0235] With reference to the above-described embodiments, the one or more aerosol generators may comprise one or more inductive heating units or one or more resistive or non-inductive heating units. The one or more aerosol generators may comprise one or more external or internal heating units.

[0236] An external heating unit is understood to comprise a heating unit that surrounds the aerosol product article and directs heat to an outer portion of the aerosol product article, which then heats the remainder of the aerosol product article. The external heating unit may comprise an induction heating unit and / or a resistance heating unit.

[0237] In contrast, an internal heating unit includes a heating unit that enters or is provided within the body of the aerosol product article. For example, the internal heating unit may include a blade provided within the base of the heating chamber of the aerosol delivery device. When the aerosol product article is inserted into the aerosol delivery device, it is pressed down onto the blade, causing the blade to extend into the distal end of the aerosol product article. According to various embodiments, the internal heating unit may include a resistive heating unit, through which an electric current is passed to heat the heating unit. However, other embodiments are contemplated in which the internal heating unit may include an inductive heating unit. The inductive heating unit may include an induction coil for generating a time-varying magnetic field and a susceptor. The induction coil and susceptor are appropriately positioned relative to one another so that the varying magnetic field generated by the inductor penetrates the susceptor and generates one or more eddy currents within the susceptor. Because the susceptor has a resistance to the flow of electrical current, when such eddy currents are generated within the susceptor, their flow against the electrical resistance of the susceptor heats the susceptor by Joule heating. For example, a susceptor may be provided within the base of a heating chamber of an aerosol delivery device such that the aerosol product article is forced onto the susceptor when inserted into the aerosol delivery device. The susceptor may then be heated by an induction coil, which may be spaced a distance from the internal susceptor.

[0238] The one or more aerosol generators may comprise a first heating unit and a second heating unit. According to one embodiment, (i) the first heating unit comprises an inductive heating unit and the second heating unit comprises an inductive heating unit, (ii) the first heating unit comprises an inductive heating unit and the second heating unit comprises a resistive or non-inductive heating unit, (iii) the first heating unit comprises a resistive or non-inductive heating unit and the second heating unit comprises an inductive heating unit, or (iv) the first heating unit comprises a resistive or non-inductive heating unit and the second heating unit comprises a resistive or non-inductive heating unit.

[0239] According to one embodiment, either (i) the first heating unit comprises an external heating unit and the second heating unit comprises an external heating unit, (ii) the first heating unit comprises an external heating unit and the second heating unit comprises an internal heating unit, (iii) the first heating unit comprises an internal heating unit and the second heating unit comprises an internal heating unit, or (iv) the first heating unit comprises an internal heating unit and the second heating unit comprises an external heating unit.

[0240] A use session may be determined to begin when power or energy is first supplied to one or more aerosol generators after an aerosol product is inserted into the aerosol delivery device. A use session may also be determined to begin when power or energy is first supplied to one or more aerosol generators to raise their temperature to an operating temperature Tmin so that a user can take the first puff of aerosol generated from the aerosol-generating material. Tmin may be within the following ranges: (i) 200-210°C, (ii) 210-220°C, (iii) 220-230°C, (iv) 230-240°C, (v) 240-250°C, (vi) 250-260°C, (vii) 260-270°C, (viii) 270-280°C, (ix) 280-290°C, and (x) 290-300°C. A use session may also be determined to end when power or energy is no longer supplied to one or more aerosol generators. According to one embodiment, a usage session is determined to end when the aerosol-generating material is substantially consumed or when the user is unable to take further puffs of aerosol generated from the aerosol-generating material.

[0241] According to one embodiment, a usage session is determined to relate to a period of time during which a user can take multiple puffs of aerosol generated from the aerosol-generating material without replacing or refilling the aerosol-generating material.

[0242] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. 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 limitations on the equivalents of the claims, and it should 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 present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

[0243] The present disclosure includes the following embodiments. (Embodiment 1) 1. An aerosol delivery device for generating an aerosol from an aerosol-forming material, the aerosol delivery device comprising: one or more aerosol generators configured to generate an aerosol from the aerosol-generating material; a controller for controlling the one or more aerosol generators; Equipped with the controller is operable in a first operating mode to set a first heating profile for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators is T1 during a use session; The aerosol delivery device, wherein the controller is operable in a second operating mode to set a different second heating profile for the one or more aerosol generators so that the average operating temperature of the one or more aerosol generators during a usage session is again T1. (Embodiment 2) 2. The aerosol delivery device of embodiment 1, wherein T1 is within the range of: (i) 200-210°C, (ii) 210-220°C, (iii) 220-230°C, (iv) 230-240°C, (v) 240-250°C, (vi) 250-260°C, (vii) 260-270°C, (viii) 270-280°C, (ix) 280-290°C, and (x) 290-300°C. (Embodiment 3) 3. The aerosol delivery device of embodiment 1 or 2, wherein the first and second heating profiles are mirror images of each other. (Embodiment 4) 3. The aerosol delivery device of embodiment 1 or 2, wherein the first heating profile has a first maximum operating temperature and the second heating profile has a different second maximum operating temperature. (Embodiment 5) 5. The aerosol delivery device of any one of embodiments 1 to 4, wherein the first heating profile is stepped up over time and the second heating profile is stepped down over time. (Embodiment 6) 5. The aerosol delivery device of any one of embodiments 1 to 4, wherein the first heating profile is stepped down over time and the second heating profile is stepped up over time. (Embodiment 7) The use session includes at least a first time period t1 and at least a second subsequent time period t2, and in either the first operating mode and / or the second operating mode, during the first time period t1, the controller controls the one or more aerosol generators to reach a first maximum temperature T 1max and during the second time period t2, the controller sets a second maximum temperature T 2max where (i) T 1max >T 2max , or (ii) T 1max <T 2max7. The aerosol delivery device according to any one of embodiments 1 to 6, wherein: (Embodiment 8) The use session includes at least a first time period t1, at least a second subsequent time period t2, and at least a third further time period t3, and in either the first operating mode and / or the second operating mode, during the first time period t1, the controller 1max and during the second time period t2, the controller sets a second maximum temperature T 2max and during the third time period t3, the controller sets a third maximum temperature T 3max where (i) T 1max >T 2max >T 3max , (ii) T 1max >T 2max <T 3max , (iii) T 1max <T 2max >T 3max or (iv) T 1max <T 2max <T 3max 8. The aerosol delivery device according to any one of embodiments 1 to 7, wherein: (Embodiment 9) 9. The aerosol delivery device of any one of embodiments 1 to 8, wherein the first heating profile has a first duration D1 and the second heating profile has a different second duration D2. (Embodiment 10) 10. The aerosol delivery device of embodiment 9, wherein D1 and D2 differ by at least 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50%. (Embodiment 11) 11. The aerosol delivery device of embodiment 9 or 10, wherein D1 is selected from (i) 200 to 210 seconds, (ii) 210 to 220 seconds, (iii) 220 to 230 seconds, (iv) 230 to 240 seconds, (v) 240 to 250 seconds, (vi) 250 to 260 seconds, (vii) 260 to 270 seconds, (viii) 270 to 280 seconds, (ix) 280 to 290 seconds, or (x) 290 to 300 seconds. (Embodiment 12) 12. The aerosol delivery device of embodiment 9, 10, or 11, wherein D2 is selected from: (i) 200 to 210 seconds, (ii) 210 to 220 seconds, (iii) 220 to 230 seconds, (iv) 230 to 240 seconds, (v) 240 to 250 seconds, (vi) 250 to 260 seconds, (vii) 260 to 270 seconds, (viii) 270 to 280 seconds, (ix) 280 to 290 seconds, or (x) 290 to 300 seconds. (Embodiment 13) 1. An aerosol delivery device for generating an aerosol from an aerosol-forming material, the aerosol delivery device comprising: one or more aerosol generators configured to generate an aerosol from the aerosol-generating material; A controller; Equipped with the controller is operable in a first operating mode to set a first heating profile for the one or more aerosol generators during a first use session, wherein an operating temperature of the one or more aerosol generators is increased to a temperature T2 during a first time period, then decreased to a temperature T3 during a second time period, and then increased to a temperature T4 during a third time period; the controller is operable in a second operating mode to set a second heating profile for the one or more aerosol generators during a second use session, wherein the operating temperature of the one or more aerosol generators is increased to a temperature T5 during a first time period, then further increased to a higher temperature T6 during a second time period, and then further increased to an even higher temperature T7 during a third time period; The controller is operable in a third operating mode to set a third heating profile for the one or more aerosol generators during a third use session, wherein the operating temperature of the one or more aerosol generators is increased to a temperature T8 during a first time period, then decreased to a lower temperature T9 during a second time period, and then further decreased to an even lower temperature T10 during a third time period. (Embodiment 14) An aerosol delivery device as described in embodiment 13, wherein the controller, when operated in the second operating mode, is configured to increase the temperature of the one or more aerosol generators from T5 to T6 to T7 either (i) substantially stepwise or (ii) substantially smoothly. (Embodiment 15) An aerosol delivery device as described in embodiment 13 or 14, wherein the controller, when operated in the second operating mode, is configured to reduce the temperature of the one or more aerosol generators from T8 to T9 to T10 either (i) substantially stepwise or (ii) substantially smoothly. (Embodiment 16) 16. The aerosol delivery device of embodiment 13, 14 or 15, wherein the first use session has a duration D1, the second use session has a duration D2, and the third use session has a duration D3, where (i) D1=D2=D3, (ii) D1=D2≠D3, (iii) D1≠D2=D3, (iv) D1=D3≠D2, or (v) D1≠D2≠D3. (Embodiment 17) 1. An aerosol delivery device for generating an aerosol from an aerosol-forming material, the aerosol delivery device comprising: one or more aerosol generators configured to generate an aerosol from the aerosol-generating material; a controller for controlling the one or more aerosol generators; Equipped with the controller is operable in a first operating mode to set a first heating profile for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators is T1 during a use session; The controller is operable in a second operating mode to set a second heating profile for the one or more aerosol generators, the second heating profile corresponding to the first heating profile but further including one or more adjustment periods such that an average operating temperature of the one or more aerosol generators is T2 during a usage session, where T1 and T2 are different, an aerosol delivery device. (Embodiment 18) 18. The aerosol delivery device of any one of embodiments 1-17, wherein the one or more aerosol generators comprise one or more induction heating units. (Embodiment 19) 19. The aerosol delivery device of any one of embodiments 1-18, wherein the one or more aerosol generators comprise one or more resistive or non-inductive heating units. (Embodiment 20) 20. The aerosol delivery device of any one of embodiments 1-19, wherein the one or more aerosol generators comprise one or more external heating units. (Embodiment 21) 21. The aerosol delivery device of any one of embodiments 1 to 20, wherein the one or more aerosol generators comprise one or more internal heating units. (Embodiment 22) 22. The aerosol delivery device of any one of embodiments 1-21, wherein the one or more aerosol generators comprise a first heating unit and a second heating unit. (Embodiment 23) 23. The aerosol delivery device of embodiment 22, wherein: (i) the first heating unit comprises an induction heating unit and the second heating unit comprises an induction heating unit; (ii) the first heating unit comprises an induction heating unit and the second heating unit comprises a resistance or non-inductive heating unit; (iii) the first heating unit comprises a resistance or non-inductive heating unit and the second heating unit comprises an induction heating unit; or (iv) the first heating unit comprises a resistance or non-inductive heating unit and the second heating unit comprises a resistance or non-inductive heating unit. (Embodiment 24) 24. The aerosol delivery device of embodiment 22 or 23, wherein: (i) the first heating unit comprises an external heating unit and the second heating unit comprises an external heating unit; (ii) the first heating unit comprises an external heating unit and the second heating unit comprises an internal heating unit; (iii) the first heating unit comprises an internal heating unit and the second heating unit comprises an internal heating unit; or (iv) the first heating unit comprises an internal heating unit and the second heating unit comprises an external heating unit. (Embodiment 25) An aerosol delivery device as described in any one of embodiments 1 to 24, wherein a usage session is determined to begin when power or energy is first supplied to the one or more aerosol generators after an aerosol product is inserted into the aerosol delivery device. (Embodiment 26) An aerosol delivery device as described in any one of embodiments 1 to 25, wherein a usage session is determined to start when power or energy is first supplied to the one or more aerosol generators to raise the temperature of the one or more aerosol generators to an operating temperature Tmin so that a user can take the first puff of aerosol generated from the aerosol-generating material. (Embodiment 27) 27. The aerosol delivery device of embodiment 26, wherein Tmin is within the range of: (i) 200-210°C, (ii) 210-220°C, (iii) 220-230°C, (iv) 230-240°C, (v) 240-250°C, (vi) 250-260°C, (vii) 260-270°C, (viii) 270-280°C, (ix) 280-290°C, and (x) 290-300°C. (Embodiment 28) An aerosol delivery device as described in any one of embodiments 1 to 27, wherein a usage session is determined to end when power or energy is no longer supplied to the one or more aerosol generators. (Embodiment 29) An aerosol delivery device as described in any one of embodiments 1 to 28, wherein a usage session is determined to end when the aerosol-generating material is substantially consumed or when the user is unable to take further puffs of aerosol generated from the aerosol-generating material. (Embodiment 30) An aerosol delivery device as described in any one of embodiments 1 to 29, wherein a usage session is determined to relate to a period of time during which a user can take multiple puffs of aerosol generated from the aerosol-generating material without replacing or refilling the aerosol-generating material. (Embodiment 31) An aerosol delivery device according to any one of embodiments 1 to 30; an aerosol-producing article comprising an aerosol-forming material; An aerosol generating system comprising: (Embodiment 32) 32. An aerosol generation system according to embodiment 31, wherein the aerosol product article is inserted into the aerosol delivery device at the time of use. (Embodiment 33) providing an aerosol delivery device comprising one or more aerosol generators configured to generate an aerosol from an aerosol-generating material; inserting an aerosol production item into the aerosol delivery device; selecting between a first mode of operation and a second mode of operation; Including, In the first operating mode, a first heating profile is configured for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators is T1 during a use session; In the second operating mode, a different second heating profile is configured for the one or more aerosol generators such that the average operating temperature of the one or more aerosol generators during a use session is again T1. A method for generating an aerosol. (Embodiment 34) providing an aerosol delivery device comprising one or more aerosol generators configured to generate an aerosol from an aerosol-generating material; inserting an aerosol production item into the aerosol delivery device; selecting between at least three different modes of operation; Including, In a first operating mode, a first heating profile is set for the one or more aerosol generators during a first use session, wherein an operating temperature of the one or more aerosol generators is increased to a temperature T2 during a first time period, then decreased to a temperature T3 during a second time period, and then increased to a temperature T4 during a third time period; in a second operating mode, a second heating profile is set for the one or more aerosol generators during a second use session, wherein the operating temperature of the one or more aerosol generators is increased to a temperature T5 during a first time period, then further increased to a higher temperature T6 during a second time period, and then further increased to an even higher temperature T7 during a third time period; In a third operating mode, a third heating profile is set for the one or more aerosol generators during a third use session, wherein the operating temperature of the one or more aerosol generators is increased to a temperature T8 during a first time period, then decreased to a lower temperature T9 during a second time period, and then further decreased to an even lower temperature T10 during a third time period. A method for generating an aerosol. (Embodiment 35) providing an aerosol delivery device comprising one or more aerosol generators configured to generate an aerosol from an aerosol-generating material; inserting an aerosol production item into the aerosol delivery device; selecting between a first mode of operation and a second mode of operation; Including, In the first operating mode, a first heating profile is configured for the one or more aerosol generators such that an average operating temperature of the one or more aerosol generators is T1 during a use session; In the second operating mode, a second heating profile is configured for the one or more aerosol generators, the second heating profile corresponding to the first heating profile but further including one or more adjustment periods such that an average operating temperature of the one or more aerosol generators during a use session is T2, where T1 and T2 are different; A method for generating an aerosol.

Claims

1. 1. An aerosol delivery device for generating an aerosol from an aerosol-forming material, the aerosol delivery device comprising: one or more aerosol generators configured to generate an aerosol from the aerosol-forming material; a controller for controlling the one or more aerosol generators; Equipped with the controller is operable in a first operating mode to set a first heating profile for the one or more aerosol generators, wherein in the first heating profile, a use session ends at a time t4 after the use session begins; The aerosol delivery device, wherein the controller is operable in a second operating mode to insert an adjustment period into the first heating profile to extend the use session so that the use session ends at time t5 after the use session starts, time t5 being later than time t4.

2. The aerosol delivery device of claim 1 , wherein the temperature is maintained at a first temperature during the conditioning period.

3. The aerosol delivery device of claim 2 , wherein the first heating profile includes a maximum temperature corresponding to a second temperature.

4. The aerosol delivery device of claim 3 , wherein the first temperature is lower than the second temperature.

5. 3. The aerosol delivery device of claim 1, wherein the controller is operable in the second operating mode to insert the adjustment period into the first heating profile before the end of the first heating profile.

6. The aerosol delivery device of claim 1 or 2, wherein the first heating profile with the adjustment period inserted corresponds to a second heating profile.

7. 7. The aerosol delivery device of claim 6, wherein the first heating profile has an average operating temperature T1 and the second heating profile has an average operating temperature T2, where T2 is different from T1.

8. The aerosol delivery device of claim 7 , wherein T2 is lower than T1.

9. 3. The aerosol delivery device of claim 1, wherein the one or more aerosol generators comprise one or more induction heating units.

10. The aerosol delivery device of claim 1 or 2; an aerosol-producing article comprising an aerosol-forming material; An aerosol generating system comprising:

11. providing an aerosol delivery device comprising one or more aerosol generators configured to generate an aerosol from an aerosol-generating material; inserting an aerosol production item into the aerosol delivery device; setting a first heating profile for the one or more aerosol generators in a first mode of operation, wherein a use session in the first heating profile ends at a time t4 after the use session begins; inserting an adjustment period into the first heating profile to extend the use session in a second mode of operation so that the use session ends at a time t5 after the use session begins, the time t5 being later than time t4; A method for generating an aerosol, comprising:

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