Aerosol Delivery Device

Abstract

An aerosol delivery device (100) is provided that comprises a heating chamber (210) configured to receive an article comprising an aerosol-generating material (150) and an airflow chamber (310a) in fluid communication with the heating chamber (210), the airflow chamber (310a) comprising one or more side apertures (350, 360) configured to allow vapor to escape from the airflow chamber (310a).

Description

[Technical Field]

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

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

[0003] Aerosol delivery systems are known that cover the above-mentioned devices and products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. In many cases, the medium used must be replaced or changed to deliver a different aerosol for inhalation. It is known to use an induction heating system as a heater for generating an aerosol from a suitable medium. An induction heating system generally consists of a magnetic field generating device for generating a fluctuating magnetic field and a susceptor or heating material that can be heated by penetration by the fluctuating magnetic field to heat the suitable medium.

[0004] A conventional aerosol delivery device comprises a cylindrical heating chamber into which a rod-shaped consumable is inserted. Summary of the Invention

[0005] According to one aspect, a heating chamber configured to receive an article comprising an aerosol-forming material; an airflow chamber in fluid communication with the heating chamber, the airflow chamber comprising one or more side apertures configured to allow vapor to escape from the airflow chamber; An aerosol delivery device is provided.

[0006] The airflow chamber may include an inlet conduit.

[0007] Optionally, the airflow chamber comprises a first end having a first opening and a second end having a second opening, and is configured such that, during use, air passes through the first opening into the airflow chamber and then through the second opening into the heating chamber.

[0008] Optionally, the airflow chamber comprises a sidewall, and the one or more lateral apertures extend through the sidewall of the airflow chamber.

[0009] Optionally, the airflow chamber extends in a first longitudinal direction, and the one or more lateral apertures are inclined at an angle α with respect to the first longitudinal direction, where α<30°, 30-45°, 45-60°, 60-75°, 75-90°, 90-115°, 115-130°, 130-145°, 145-160°, or >160°.

[0010] Optionally, the airflow chamber fluidly connects the heating chamber to an exterior opening on the exterior of the aerosol delivery device.

[0011] Optionally, the heating chamber is configured to receive an article comprising an aerosol-generating material at a proximal end of the aerosol delivery device, and the outer opening is located at a distal end of the aerosol delivery device, the distal end of the aerosol delivery device being opposite the proximal end of the aerosol delivery device.

[0012] Optionally, the airflow chamber extends in a direction from the heating chamber towards the distal end of the aerosol delivery device.

[0013] Optionally, the aerosol delivery device further comprises one or more exhaust channels arranged to allow vapor that escapes from the airflow chamber through the one or more side apertures to escape outside the aerosol delivery device.

[0014] Optionally, the one or more side apertures include a first set of side apertures and a second set of side apertures, the first and second sets of side apertures being located at different circumferential and / or radial and / or axial positions.

[0015] Optionally, vapor is allowed or encouraged to escape the airflow chamber through one or more side apertures by an air pressure differential created across at least a portion of the airflow chamber.

[0016] Optionally, the one or more side apertures include a first set of one or more side apertures and a second set of one or more side apertures.

[0017] Optionally, the air flow chamber is arranged so that, during use, air flows along a flow path from a region outside the aerosol delivery device, through a first set of one or more side apertures, through at least a portion of the air flow chamber, and then exits the aerosol delivery device via a second set of one or more side apertures.

[0018] Optionally, the aerosol supply device further comprises one or more exhaust channels for allowing vapor that escapes from the airflow chamber through the one or more side apertures to escape from the aerosol supply device, the one or more exhaust channels being in fluid communication with the one or more side apertures and an exterior of the aerosol supply device.

[0019] Optionally, the one or more exhaust channels include a first exhaust channel and a second exhaust channel, the first exhaust channel being arranged to allow vapor escaping from the airflow chamber to escape to the exterior from a first side of the aerosol delivery device, and the second exhaust channel being arranged to allow vapor escaping from the airflow chamber to escape to the exterior from a second, different side of the aerosol delivery device, which may be opposite the first side.

[0020] Optionally, one or more of the side apertures in the first set have a first cross-sectional area A1 and one or more of the side apertures in the second set have a second cross-sectional area A2, where either (i) A1>A2 or (ii) A2>A1.

[0021] According to various embodiments, A1 is <1 mm 2 , 1~2mm 2 , 2~3mm 2 , 3~4mm 2 , 4~5mm 2 , 5~6mm 2 , 6~7mm 2 , 7~8mm 2 , 8~9mm 2 , 9~10mm 2 , or >10 mm 2 According to various embodiments, A2 can be <1 mm 2 , 1~2mm 2 , 2~3mm 2 , 3~4mm 2 , 4~5mm 2 , 5~6mm 2 , 6~7mm 2 , 7~8mm 2 , 8~9mm 2 , 9~10mm 2 , or >10 mm 2 It could be.

[0022] Optionally, the aerosol delivery device further comprises an airflow delivery device configured to force vapor out of the airflow chamber through one or more side apertures.

[0023] Optionally, the airflow supply device is configured to force air through the airflow chamber so as to cause vapour to escape from the airflow chamber through one or more side apertures.

[0024] Optionally, the air flow supply device comprises one or more fans and / or one or more pumps.

[0025] Optionally, the airflow supply device is configured to create a pressure differential within the airflow chamber such that vapor within the airflow chamber is forced out or expelled from the airflow chamber through the one or more side apertures.

[0026] According to one aspect, the aerosol delivery device described above; an article comprising an aerosol-forming material; An aerosol delivery system is provided, comprising: According to one aspect, providing an aerosol delivery device as described above; at least partially inserting an article comprising an aerosol-forming material into an aerosol delivery device; activating an aerosol delivery device; A method for generating an aerosol is provided, comprising:

[0027] According to various embodiments, an aerosol delivery device is provided that includes an airflow chamber, the airflow chamber including one or more side apertures for allowing vapor to escape from the airflow chamber.

[0028] According to various embodiments, an aerosol delivery device is provided that includes an air flow chamber having an air inlet conduit and one or more side apertures for allowing vapor to escape from the air flow chamber.

[0029] According to various embodiments, an aerosol delivery device is provided that includes an airflow chamber and a fan for moving air into the airflow chamber and / or vapor out of the airflow chamber.

[0030] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0031] [Figure 1] 1 illustrates an example of an article that includes an aerosol delivery device and an aerosol-generating material partially inserted within the aerosol delivery device. [Figure 2] 1 illustrates an enlarged cross-sectional view of an example aerosol delivery device showing an article comprising an aerosol-generating material partially inserted within the aerosol delivery device, the article abutting a condensation chamber. [Figure 3A] An enlarged cross-sectional view of the condensation chamber of an aerosol delivery device is shown with an article comprising an aerosol-generating material abutted against the condensation chamber, showing the flow of air through the condensation chamber and the distal end of the article as a user inhales on the article, and also showing the flow of heat into the article. [Figure 3B] The condensation chamber and the overall length of the article are shown, the flow of air through the condensation chamber and the article is shown, and the flow of air and heat into the article through vents in the article when a user inhales on the article is also shown. [Figure 4A] An enlarged cross-sectional view of the condensation chamber of an aerosol delivery device is shown with an article comprising an aerosol-generating material abutted against the condensation chamber, illustrating the flow of air into the condensation chamber and the diffusion of hot vapor from the distal end of the article into the condensation chamber when the user is between puffs. [Figure 4B] The condensation chamber and the entire length of the article are shown, showing the flow of air into the condensation chamber and the diffusion of hot vapor from both the distal end of the article into the condensation chamber and further into the central portion, and also showing the flow of heat into the article when the user is between puffs. [Figure 5]1 shows a cross-sectional view of an article comprising an aerosol delivery device and an aerosol-generating material. [Figure 6] FIG. 1 shows an enlarged cross-sectional view of an airflow chamber of an aerosol delivery device according to various embodiments, in which one or more lateral apertures are provided in the side walls of the airflow chamber, allowing vapor to escape from the airflow chamber through one or more exhaust channels (not shown). [Figure 7] 1 shows a cross-sectional view of an article comprising an aerosol delivery device and an aerosol-generating material, showing one or more exit channels. [Figure 8A] FIG. 1 shows an example of an aerosol delivery device according to various embodiments, in which vapor may escape from the airflow chamber to the exterior of the aerosol delivery device through two exhaust channels on either side of the aerosol delivery device, and air is not forced through the aerosol delivery device. [Figure 8B] 10 shows an example of an aerosol delivery device according to various embodiments, where vapor may escape from the airflow chamber through an exhaust channel to the exterior of the aerosol delivery device, and air is forced through the aerosol delivery device. [Figure 9] 10A-10C show cross-sectional views of aerosol delivery devices according to various embodiments, in which an exhaust channel is provided to allow vapor within the airflow chamber of the aerosol delivery device to escape to the exterior of the aerosol delivery device. [Figure 10] 1 shows an example of an aerosol delivery device according to various embodiments, where three exhaust channels are provided to allow vapor to escape from within the airflow chamber of the aerosol delivery device to the exterior of the aerosol delivery device. DETAILED DESCRIPTION OF THE INVENTION

[0032] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0033] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0034] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0035] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0036] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, where one or more aerosol-generating materials can be heated. Each of the aerosol-generating materials can be, for example, in solid, liquid, or gel form and can contain nicotine or not. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material can include, for example, tobacco or a non-tobacco product.

[0037] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0038] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that comprise aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices.

[0039] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0040] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0041] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage areas, aerosol-generating material transfer components, aerosol generators, aerosol-generating areas, housings, packaging, filters, mouthpieces, and / or aerosol modifiers.

[0042] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-forming material can be, for example, in solid, liquid, or semi-solid (such as a gel) form, which may or may not contain active substances and / or flavorings.

[0043] The aerosol-generating material may include a binder and an aerosol-forming agent. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0044] The aerosol-generating material may comprise an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as an active agent, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such as a construction of individual portions of film on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0045] The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form shredded sheets.

[0046] The aerosol-generating materials may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0047] 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 provide thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to provide one or more of vibration, pressure increase, or electrostatic energy to the aerosol-generating material.

[0048] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which is intended to be consumed upon use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that generates heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0049] The susceptor is a heating material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. An aerosol delivery device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0050] The non-combustion aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable article. In some implementations, the non-combustion aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may comprise a power source, such as, for example, a battery or a rechargeable battery. In some implementations, the non-combustion aerosol delivery device may also comprise an aerosol generating component. However, in other implementations, an article may comprise, in part or entirely, the aerosol generating component.

[0051] Induction heating is a process in which a conductive object, called a susceptor, is heated by passing a varying magnetic field through the object. This process is explained by Faraday's law and Ohm's law. An induction heater may include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. The electromagnet and the object to be heated are suitably positioned relative to one another so that one or more eddy currents are generated within the object when the resulting varying magnetic field generated by the electromagnet penetrates the object. The object has a resistance to the flow of current, and when such eddy currents are generated within the object, the flow of the eddy currents against the object's electrical resistance causes the object to heat. This process is called Joule heating, Ohmic heating, or resistance heating.

[0052] Magnetic hysteresis heating is a process by which an object made of a magnetic material is heated by passing a changing magnetic field through the object. The magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field passes through such a material, the magnetic dipoles align with the field. Thus, when a changing magnetic field, such as an alternating magnetic field generated by an electromagnet, passes through a magnetic material, the orientation of the magnetic dipoles changes with the applied changing magnetic field. Such magnetic dipole reorientation causes the generation of heat within the magnetic material.

[0053] When an object is both conductive and magnetic, a varying magnetic field penetrating the object can induce both Joule heating and magnetic hysteresis heating within the object. Furthermore, the magnetic field can be strengthened by the use of magnetic materials, which can enhance Joule heating.

[0054] The aerosol delivery system will now be described in more detail.

[0055] 1 shows an aerosol delivery device 100 configured to generate an aerosol from an article 150 comprising an aerosol-generating material. The article 150 can be inserted into the aerosol delivery device 100 during use.

[0056] Aerosol delivery device 100 is an elongated structure extending along a longitudinal axis. Aerosol delivery device 100 has a proximal end 110 that is closest to a user (e.g., a user's mouth) when used by the user to inhale the aerosol generated by aerosol delivery device 100. Aerosol delivery device 100 also includes a distal end 120 that is farthest from the user when in use. Proximal end 110 may also be referred to as the "mouth end." Accordingly, aerosol delivery device 100 also defines a proximal direction that is oriented toward the user when in use, i.e., from distal end 120 to proximal end 110. Furthermore, aerosol delivery device 100 similarly defines a distal direction that is oriented away from the user when in use, i.e., from proximal end 110 to distal end 120. The proximal and distal directions may be parallel to the longitudinal axis of aerosol delivery device 100.

[0057] 2 shows a cross-sectional view of a portion of aerosol delivery device 100. Aerosol delivery device 100 includes a heating chamber 210 for receiving an article 150 comprising an aerosol-generating material. Heating chamber 210 has a base 215 at a distal end of heating chamber 210. Heating chamber 210 may be elongated to extend along a longitudinal axis, which may be substantially parallel to the longitudinal axis of aerosol delivery device 100. Rod-shaped article 150 comprising an aerosol-generating material may be inserted into heating chamber 210 in an insertion direction that is parallel to the longitudinal axis of heating chamber 210 and may be parallel to the longitudinal axis of aerosol delivery device 100.

[0058] Article 150 may be held within heating chamber 210 of aerosol delivery device 100. Article 150 may be heated by heating assembly 230. Heating assembly 230 may include one or more heating elements 235 configured to heat the article such that an aerosol or other inhalable medium may be generated from the aerosol-generating material of article 150 and then inhaled by a user of aerosol delivery device 100.

[0059] The heating element 235 may at least partially surround the heating chamber 210. For example, the heating element 235 may enclose the heating chamber 210. The heating element 235 may be generally tubular. According to various embodiments, the heating element 235 may comprise a susceptor that is indirectly heated by one of more induction coils.

[0060] In other embodiments, the heating element 235 may extend or protrude into the heating chamber 210. For example, according to various embodiments, the heating element 235 may comprise a pin (not shown) that protrudes into the base of the heating chamber 210 and is configured to be inserted into the distal end of the article 150 when the article 150 is received within the heating chamber 210 during use. In this embodiment, the pin heater (not shown) is configured to heat the article 150 from the inside.

[0061] Other embodiments are contemplated in which the heating element 235 may comprise a blade (not shown). The blade may comprise a flat portion and a pointed portion. The pointed portion of the blade may be configured to be inserted into the distal end of the article 150 to heat the article 150 from within during use. The pin heating element and the blade heating element may comprise a resistive heating element. The heating element 235 may comprise a resistive heating element. Alternatively, the heating element 235 may comprise an inductive heating element. Other embodiments are also contemplated (not shown) in which at least a portion of the heating element (e.g., a susceptor) may be provided as part of the article 150 rather than forming part of the aerosol delivery device 100.

[0062] During use, once the article 150 is inserted into the heating chamber 210 of the aerosol delivery device 100, the user may then conduct a session in which the heating assembly 230 is configured to heat the article 150. During the session, the article 150 may be heated by the heating element 235. It will be appreciated that a use session may last several minutes. For example, according to various embodiments, a use session may last 2-3 minutes, 3-4 minutes, 4-5 minutes, or 5-6 minutes.

[0063] Aerosol delivery device 100 includes condensation chamber 310. Condensation chamber 310 functions as an airflow chamber. Condensation chamber 310, which acts as an airflow chamber, is fluidly connected to and extends in a first direction from heating chamber 210, in which item 150 is received. Condensation chamber 310 may include an inlet conduit 320 formed, for example, from iron or steel. Inlet conduit 320 and / or condensation chamber 310 may extend in the first direction from heating chamber 210.

[0064] Condensation chamber 310 can be configured to fluidly connect heating chamber 210 with an outer opening 330 on the exterior of aerosol delivery device 100. Inlet conduit 320 and condensation chamber 310 provide a flow path configured to support airflow. The flow path extends from heating chamber 210 to outer opening 330 on the exterior of aerosol delivery device 100. Inlet conduit 320 and condensation chamber 310 have inner surfaces exposed to air flowing, for example, from the exterior of aerosol delivery device 100 along inlet conduit 320 through condensation chamber 310 to heating chamber 210. Acting as an airflow chamber, condensation chamber 310 allows air to flow from outer opening 330 through condensation chamber 310 to heating chamber 210 during use of aerosol delivery device 100.

[0065] 3A shows in more detail the condensation chamber 310 and the air flow within the article 150 when a user inhales on the article 150. The condensation chamber 310 is fluidly connected to a heating chamber (not shown).

[0066] During use, a heating assembly (not shown) is used to heat an article 150 received within the heating chamber (not shown). When a user inhales on the article 150, air may be drawn into the aerosol delivery device through the exterior opening 330. The air is then drawn along the inlet conduit 320 and through the condensation chamber 310 before flowing toward the heating chamber 210, and particularly toward the distal end of the article 150. The air entering the aerosol delivery device may be relatively cool. As the cool air passes through the inlet conduit 320 and the condensation chamber 310 toward the heating chamber 210 and the distal end of the article 150, the inlet conduit 320 and the condensation chamber 310 may be cooled by the incoming air.

[0067] As the air travels toward the heating chamber 210 and enters the distal end of the article 150, the air passing through the article 150 becomes heated. The warmed air may then collect or entrain aerosols generated by heating of the aerosol-generating material of the article 150 by a heating assembly (not shown). The air and aerosols may then be drawn from the article 150 to be inhaled by a user.

[0068] 3B shows the condensation chamber 310 and the entire length of article 150. The flow of air through condensation chamber 310 and article 150 is shown. Air is also shown entering the article through one or more vents located within article 150 relatively close to the proximal end of article 150. The flow of heat into article 150 when a user inhales on article 150 is also shown.

[0069] 4A shows that between uses (i.e., when the user is not inhaling on the article 150), air that may contain vapor may exit the article 150 and / or exit the heating chamber 210. This warm air, laden with vapor, may then enter the condensation chamber 310 and proceed toward the inlet conduit 320. However, the inlet conduit 320 and the condensation chamber 310 may be at a lower temperature than the temperature of the air exiting the article 150 and / or the heating chamber 210. As a result, the vapor tends to condense within the condensation chamber 310, for example, on the walls of the condensation chamber 310 and / or the inlet conduit 320. Note also that the warm air laden with vapor entering the condensation chamber 310 may encounter an opposing flow of relatively cooler air entering the inlet conduit 320 via the outer opening 330.

[0070] 4B shows the entire length of condensation chamber 310 and article 150, illustrating how relatively cool air flows into condensation chamber 310 and meets hot vapor diffusing into condensation chamber 310 from the distal end of article 150. Air within article 150 also moves to the central portion of article 150. The flow of heat into article 150 when the user is in a state between puffs is also shown.

[0071] 5 shows a cross-sectional view of aerosol delivery device 100 provided with condensation chamber 310 fluidly connected to heating chamber 210, and in which outer opening 330 on the exterior of aerosol delivery device 100 does not include an aperture. In such a configuration, the path for vapor to escape from condensation chamber 310 may be limited.

[0072] 6 shows an enlarged cross-sectional view of selected internal components of the aerosol delivery device 100, according to various embodiments. In particular, various embodiments address the potential problem of vapor condensation within the condensation chamber. It will be appreciated that condensation or condensation forming within the condensation chamber is generally undesirable and may collect within the distal end of the aerosol delivery device. The condensation may then drip from the distal end of the aerosol delivery device, which is undesirable from a user's perspective.

[0073] It will be appreciated that the condensation chamber 310, described in detail above with reference to Figures 2-6, generally corresponds to the airflow chamber 310a. Air can enter the heating chamber 210 through the condensation chamber 310 from the outer opening 330.

[0074] According to various embodiments, an aerosol delivery device 100 is provided that includes a heating chamber 210 for receiving an article (not shown). The heating chamber 210 is shown abutting an airflow chamber 310a having an inlet conduit portion 320.

[0075] Inlet conduit 320 and / or air flow chamber 310a may be elongated so as to extend in a first direction along a longitudinal axis. The first direction may extend distally from heating chamber 210, for example, from base 215 of heating chamber 210 toward distal end 120 of aerosol delivery device 100. The longitudinal axes of inlet conduit 320 and air flow chamber 310a may be substantially parallel to the longitudinal axis of aerosol delivery device 100.

[0076] The longitudinal axes of inlet conduit 320 and airflow chamber 310a may also be substantially parallel to the longitudinal axis of heating chamber 210. An exterior opening 330 on the exterior of aerosol delivery device 100 may be located at distal end 210 of aerosol delivery device 100.

[0077] The inlet conduit 320 and the air flow chamber 310a may have a first end (e.g., a distal end) having a first opening 321 and a second end (e.g., a proximal end) having a second opening 322.

[0078] During use, air may be configured to pass through first opening 321 into inlet conduit 320 and airflow chamber 310a, and then through second opening 322 into heating chamber 210. It will be apparent that first opening 321 is fluidly connected to heating chamber 210. Similarly, second opening 322 is fluidly connected to outer opening 330 on the exterior of aerosol delivery device 100.

[0079] The width of the volume within inlet conduit 320 and airflow chamber 310a may be different from the width of heating chamber 210, e.g., smaller than the width of heating chamber 210. For example, the average width value may be smaller than the average width value of heating chamber 210. This may, for example, provide a user with a desired amount of suction or resistance to flow.

[0080] The aerosol delivery device 100 further includes one or more side apertures 350, 360 positioned to allow vapor to escape from the airflow chamber 310a. Each of the side apertures 350, 360 may be positioned to allow vapor to escape from the airflow chamber 310a. The one or more side apertures 350, 360 may extend at an angle of at least 10°, at least 20°, at least 30°, or at least 40° relative to the longitudinal direction of the inlet conduit 320 and the airflow chamber 310a.

[0081] One or more side apertures 350, 360 may extend through the sidewall of airflow chamber 310a. The sidewall of airflow chamber 310a and inlet conduit 320 may extend from first opening 321 to second opening 322. Vapor escaping airflow chamber 310a through one or more side apertures 350, 360 may then pass through one or more exhaust channels (not shown) before exiting aerosol delivery device 100.

[0082] 7, the one or more side apertures may be arranged such that vapor passing through the one or more side apertures, and thus escaping from airflow chamber 310a, can reach one or more exhaust channels 370 that are in fluid communication with both the one or more side apertures and the exterior of aerosol supply device 100. The one or more exhaust channels 370 allow vapor that escapes from airflow chamber 310a through the one or more apertures to escape to the exterior of aerosol supply device 100. As a result, vapor that escapes from airflow chamber 310a through the one or more side apertures can then be exhausted to the exterior of aerosol supply device 100 via one or more exhaust channels 370.

[0083] Referring to FIG. 6, according to various embodiments, one or more of the side apertures 350, 360 may be <1 mm 2 , 1~2mm 2 , 2~3mm 2 , 3~4mm 2 , 4~5mm 2 , 5~6mm 2 , 6~7mm 2 , 7~8mm 2 , 8~9mm 2 , 9~10mm 2 , or >10 mm 2 may have a cross-sectional area of

[0084] The one or more side apertures 350, 360 may include a first set of one or more side apertures 350 and a second set of one or more side apertures 360. The side apertures of the first set of one or more side apertures 350 may have a different size, e.g., average cross-sectional area or length, compared to the side apertures of the second set of one or more side apertures 360. This may create different pressures in each set of side apertures, resulting in airflow from one of the sets of side apertures to the other set of side apertures.

[0085] Each set of one or more lateral apertures 350, 360 may be grouped together such that each set of one or more lateral apertures 350, 360 is positioned within a respective contiguous region, with each region being non-overlapping and spaced apart from one another.

[0086] A first set of one or more side apertures 350 may be disposed on a first side of the airflow chamber 310a, and a second set of side apertures 360 may be disposed on a second, different side of the airflow chamber 310a. The second side of the airflow chamber 310a may be opposite the first side of the airflow chamber 310a. For example, the average location of the first set of one or more side apertures 350 may be separated from the average location of the second set of one or more side apertures 360 by an angle of at least 150° about the center of the airflow chamber 310a. Such an arrangement may help ensure that air flow between the first set of one or more side apertures 350 and the second set of one or more side apertures 360 passes through the center of the airflow chamber 310a.

[0087] 8A , the one or more exhaust channels 370, 380 can include a first exhaust channel 370 and a second exhaust channel 380. According to various embodiments, the first exhaust channel 370 can be positioned to allow vapor escaping from the airflow chamber to escape to the exterior at a first side of the aerosol delivery device 100. The second exhaust channel 380 can be positioned to allow vapor escaping from the airflow chamber to escape to the exterior at a second side of the aerosol delivery device 100. The second side can be opposite the first side.

[0088] According to various embodiments in which a first set of one or more side apertures and a second set of one or more side apertures are provided, the first exhaust channel 370 may be fluidly connected to one or more side apertures of the first set, while the second exhaust channel 380 may be fluidly connected to one or more side apertures of the second set.

[0089] The aerosol delivery device 100 may further include an airflow delivery device configured to force air out of the airflow chamber through one or more side apertures. A controller may also be provided that may be configured to control the airflow delivery device. The airflow delivery device may include, for example, a fan for actively delivering air and / or a pump for actively delivering air.

[0090] The controller may be configured to activate the air flow supply device, for example, when plugged in or after a use session. According to other embodiments, the air flow supply device may be activated between puffs during a use session.

[0091] 8B, according to various embodiments, an air flow supply device may be provided that is configured to force air flow from outside aerosol delivery device 100 through a first set of one or more side apertures into the airflow chamber via a first exhaust channel 370. The air is then forced out of the airflow chamber through a second set of one or more side apertures and out of aerosol delivery device 100 via a second exhaust channel 380.

[0092] According to various embodiments, the one or more side apertures may include one or more side apertures of a third set. One or more of the side apertures of the first set, second set, and third set may be grouped together, respectively. The one or more side apertures of each of the first, second, and third sets may be disposed within or on different first, second, and third sides of the condensation chamber. For example, the average position of the one or more side apertures of each of the first, second, and third sets may be separated from the average position of the one or more side apertures of each of the other sets by an angle of at least 60°, at least 70°, at least 80°, or at least 90°.

[0093] 9 and 10, the one or more exhaust channels may include a third exhaust channel 390 in addition to the first exhaust channel 370 and the second exhaust channel 380 as described above. The third exhaust channel 390 may be positioned on a third side of the aerosol delivery device 100, different from the first and second sides, to allow vapor that escapes from the airflow chamber to escape to the outside.

[0094] According to various embodiments, the first exhaust channel 370 may be fluidly connected to one or more of the side apertures in the first set, the second exhaust channel 380 may be fluidly connected to one or more of the side apertures in the second set, and the third exhaust channel 390 may be fluidly connected to one or more of the side apertures in the third set.

[0095] It will be appreciated that various embodiments provide an aerosol delivery device including an airflow chamber in fluid communication with a heating chamber, the airflow chamber forming a condensation chamber. The condensation chamber includes one or more side apertures configured to allow vapor to escape from the condensation chamber. As a result, undesirable accumulation of condensate in the condensation chamber can be avoided.

[0096] 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. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. a heating chamber configured to receive an article comprising an aerosol-forming material; an airflow chamber in fluid communication with the heating chamber, the airflow chamber comprising one or more side apertures configured to allow vapor to escape from the airflow chamber; Aerosol delivery device.

2. 2. The aerosol delivery device of claim 1, wherein the airflow chamber has a first end having a first opening and a second end having a second opening, and wherein air is configured to pass through the first opening into the airflow chamber and then through the second opening into the heating chamber during use.

3. 3. The aerosol delivery device of claim 2, wherein the airflow chamber comprises a sidewall, and the one or more lateral apertures extend through the sidewall of the airflow chamber.

4. 4. The aerosol delivery device of claim 1, wherein the airflow chamber extends in a first longitudinal direction and the one or more lateral apertures are inclined at an angle α to the first longitudinal direction, where α is < 30°, 30-45°, 45-60°, 60-75°, 75-90°, 90-115°, 115-130°, 130-145°, 145-160°, or > 160°.

5. The aerosol delivery device of any one of claims 1 to 4, wherein the airflow chamber fluidly connects the heating chamber to an exterior opening on the exterior of the aerosol delivery device.

6. 6. The aerosol delivery device of claim 5, wherein the heating chamber is configured to receive an article comprising an aerosol-generating material at a proximal end of the aerosol delivery device, the outer opening is located at a distal end of the aerosol delivery device, and the distal end of the aerosol delivery device is opposite the proximal end of the aerosol delivery device.

7. The aerosol delivery device of claim 6 , wherein the airflow chamber extends in a direction from the heating chamber toward the distal end of the aerosol delivery device.

8. 8. The aerosol delivery device of claim 1, further comprising one or more exhaust channels arranged to allow vapor that escapes from the airflow chamber through the one or more side apertures to escape outside the aerosol delivery device.

9. 9. The aerosol delivery device of claim 1, wherein the one or more side apertures include a first set of side apertures and a second set of side apertures, and the first and second sets of side apertures are arranged at different circumferential and / or radial and / or axial positions.

10. 10. The aerosol delivery device of claim 1, wherein vapor is allowed or encouraged to escape from the airflow chamber through the one or more side apertures by an air pressure differential created across at least a portion of the airflow chamber.

11. 11. The aerosol delivery device of claim 1, wherein the one or more side apertures include a first set of one or more side apertures and a second set of one or more side apertures.

12. 12. The aerosol delivery device of claim 11, wherein the air flow chamber is arranged such that, during use, air flows along a flow path from an area outside the aerosol delivery device, through one or more side apertures of the first set, through at least a portion of the air flow chamber, and then exits the aerosol delivery device via one or more side apertures of the second set.

13. 13. The aerosol delivery device of claim 11 or 12, further comprising one or more exhaust channels for allowing vapor that has escaped from the airflow chamber through the one or more side apertures to escape from the aerosol delivery device, the one or more exhaust channels being in fluid communication with the one or more side apertures and the outside of the aerosol delivery device.

14. 14. The aerosol delivery device of claim 13, wherein the one or more exhaust channels include a first exhaust channel and a second exhaust channel, the first exhaust channel being arranged to allow vapor that has escaped from the air flow chamber to escape from a first side of the aerosol delivery device to the exterior, and the second exhaust channel being arranged to allow vapor that has escaped from the air flow chamber to escape from a second, different side of the aerosol delivery device to the exterior, the second side being opposite the first side.

15. 15. The aerosol delivery device of claim 12, wherein the one or more side apertures of the first set have a first cross-sectional area A1 and the one or more side apertures of the second set have a second cross-sectional area A2, where either (i) A1 > A2 or (ii) A2 > A1.

16. 16. The aerosol delivery device of any one of claims 1 to 15, further comprising an airflow delivery device configured to force vapor out of the airflow chamber through the one or more side apertures.

17. 17. The aerosol delivery device of claim 16, wherein the air flow delivery device is configured to force air through the air flow chamber so as to allow vapor to escape from the air flow chamber through the one or more side apertures.

18. 18. The aerosol delivery device of claim 16 or 17, wherein the air flow delivery device comprises one or more fans and / or one or more pumps.

19. 19. The aerosol delivery device of any one of claims 16 to 18, wherein the air flow supply device is configured to create a pressure differential within the air flow chamber such that vapor within the air flow chamber is forced out or expelled from the air flow chamber through the one or more side apertures.

20. An aerosol delivery device according to any one of claims 1 to 19; an aerosol-producing article comprising an aerosol-forming material; An aerosol delivery system comprising:

21. Providing an aerosol delivery device according to any one of claims 1 to 19; inserting an article comprising an aerosol-forming material at least partially into the aerosol delivery device; activating the aerosol delivery device; A method for generating an aerosol, comprising:

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