Aerosol Delivery Device

Abstract

An aerosol delivery device (110) is disclosed that includes a heating chamber configured to receive an aerosol product article (150), an airflow chamber (310a) in fluid communication with the heating chamber, the airflow chamber (310a) including an air inlet (330) configured to admit air into the airflow chamber (310a), and a valve (440) disposed between the heating chamber and the airflow chamber (310a).

Description

[Technical Field]

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

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products 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, which may or may not contain nicotine.

[0003] Aerosol delivery systems are known that cover the above-mentioned devices or products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. In many cases, it is necessary to replace or change the medium used 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 with 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 aerosol product; an airflow chamber in fluid communication with the heating chamber, the airflow chamber including an air inlet configured to admit air into the airflow chamber; a valve disposed between the heating chamber and the air flow chamber; An aerosol delivery device is provided, comprising:

[0006] According to various embodiments, an aerosol delivery device is provided that includes a valve configured to substantially open when a user is attempting to inhale aerosol from an aerosol product article at least partially inserted into the aerosol delivery device to allow air to enter the distal end of the article, and to substantially close when the user is not attempting to inhale aerosol (i.e., between puffs) to prevent hot vapor from entering the airflow chamber.

[0007] According to various embodiments, an aerosol delivery device is provided that includes a valve disposed between a first region having a pressure P1 and a second region having a pressure P2, the valve being configured to be substantially open when P1 > P2. Optionally, the valve may be configured to be substantially closed when P2 ≥ P1. According to various embodiments, the first region may include an airflow chamber and the second region may include a heating chamber.

[0008] Optionally, the valve comprises a fixed valve seat and a movable valve member, wherein in the closed position the movable valve member engages the fixed valve seat and in the open position the movable valve member is disengaged from the fixed valve seat.

[0009] Optionally, the fixed valve seat comprises either a portion of the airflow chamber or a base of the heating chamber.

[0010] Optionally, the fixed valve seat is located within the air flow chamber.

[0011] Optionally, at least a portion of the fixed valve seat and / or at least a portion of the movable valve member has a static coefficient of friction μ static<0.30, <0.25, <0.20, <0.15, <0.10 or <0.05.

[0012] Optionally, at least a portion of the fixed valve seat and / or at least a portion of the movable valve member are formed from polyetheretherketone ("PEEK") or acrylonitrile butadiene styrene ("ABS").

[0013] Optionally, the aerosol delivery device further comprises a biasing member configured to open and / or close the valve.

[0014] Optionally, the biasing member comprises one or more springs.

[0015] Optionally, the biasing member includes one or more magnetic mechanisms.

[0016] Optionally, the biasing member comprises one or more resilient elements.

[0017] Optionally, the valve comprises a membrane valve.

[0018] Optionally, the membrane valve comprises a flexible membrane comprising, for example, natural rubber, silicone rubber, ethylene propylene diene monomer rubber, fluororubber, or nitrile rubber.

[0019] Optionally, the valve comprises a butterfly valve.

[0020] Optionally, the butterfly valve comprises a disk attached to a rod, wherein in a closed position the disk is rotated to a position that restricts the flow of air and / or steam between the heating chamber and the airflow chamber, and in an open position the disk is rotated to a position that allows air to flow from the airflow chamber to the heating chamber.

[0021] Optionally, the valve comprises a ball valve, a gate valve, a needle valve, a pinch valve or a plug valve.

[0022] Optionally, the valve comprises a freely hinged flap or a check valve.

[0023] Optionally, a pressure differential may be used to open and / or close the valve.

[0024] Optionally, in use, a user may create a pressure differential when the user inhales or inhales the aerosol product article located within the heating chamber.

[0025] Optionally, the air inlet and / or valve are configured to be substantially closed when the aerosol product article is at least partially inserted into the heating chamber and a user is not attempting to inhale aerosol from the aerosol product article.

[0026] The aerosol delivery device may include one or more magnetic mechanisms configured to open and / or close the valve. The aerosol delivery device may include one or more elastic elements configured to open and / or close the valve. The aerosol delivery device may include one or more springs configured to open and / or close the valve. According to one aspect, an aerosol delivery device as described above; an article containing an aerosol-forming material; An aerosol delivery system is provided, comprising: According to one aspect, there is provided a method of generating an aerosol, comprising the steps of: Providing an aerosol delivery device as described above; at least partially inserting an article including an aerosol-forming material into an aerosol delivery device; activating an aerosol delivery device; A method is provided, comprising:

[0027] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0028] [Figure 1] 1 illustrates an example of an article that includes an aerosol delivery device and an aerosol-generating material partially inserted into the aerosol delivery device. [Figure 2] 1 shows an enlarged cross-sectional view of an example aerosol delivery device, showing an article including an aerosol-generating material partially inserted into the aerosol delivery device, the article abutting the base of the heating chamber or the upper portion of the condensation chamber. [Figure 3A] An enlarged cross-sectional view of the condensation chamber of an aerosol delivery device is shown, with an article containing an aerosol-generating material abutted against the upper portion of the condensation chamber, showing the flow of air through the condensation chamber and into the distal end of the article when 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 down the length of the article is shown, and the flow of air and heat into the article via vents in the article when a user sucks on the proximal end of the article is shown. [Figure 4A] FIG. 1 shows an enlarged cross-sectional view of the condensation chamber of an aerosol delivery device, 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 an article containing an aerosol-generating material is abutted against the upper portion of the condensation chamber and the user is between puffs. [Figure 4B] The condensation chamber and the entire length of the article are shown, 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 and then into the central portion of the article, and the flow of heat into the article when the user is between puffs. [Figure 5] 1 shows a cross-sectional view of an aerosol delivery device and an article including an aerosol-generating material. [Figure 6] 1 shows a cross-sectional view of a portion of an aerosol delivery device including a condensation chamber. [Figure 7A]An example of an aerosol delivery device according to various embodiments is shown, with a valve positioned between the airflow chamber and the heating chamber, the valve in an open position, thereby allowing air to flow from the airflow chamber to the distal end of the article when a user inhales on the article, and heat flow to the article is also shown. [Figure 7B] The valve is shown in a closed position when the user is between puffs, preventing air and hot steam from passing from the distal end of the article and from the heating chamber to the air flow chamber, and also showing heat flow to the article. [Figure 8A] An example of an aerosol delivery device according to various embodiments is shown, with a valve positioned between the airflow chamber and the heating chamber, the valve in an open position, thereby allowing air to flow from the airflow chamber to the distal end of the article when a user inhales on the article, and heat flow to the article is also shown. [Figure 8B] The valve is shown in a closed position when the user is between puffs, preventing air and hot steam from passing from the distal end of the article and from the heating chamber to the air flow chamber, and also showing heat flow to the article. DETAILED DESCRIPTION OF THE INVENTION

[0029] 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.

[0030] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0031] 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.

[0032] 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.

[0033] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0034] 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.

[0035] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0036] In some embodiments, a non-combustion aerosol delivery system, e.g., the 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.

[0037] 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.

[0038] 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.

[0039] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-forming material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain an active agent and / or flavoring.

[0040] 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.

[0041] The aerosol-generating material may include or be 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%, 70%, 80%, 85%, or 90% by weight 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.

[0042] The aerosol-generating film may include or be a sheet that can optionally be shredded to form shredded sheets.

[0043] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0044] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, elevated pressure, or electrostatic energy.

[0045] A consumable is an article containing or consisting of an aerosol-generating material, some or all of which is intended to be consumed during 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.

[0046] 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 can 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 can 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 can be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. An aerosol delivery device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0047] 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 (i.e., 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.

[0048] Induction heating is a process in which a conductive object, called a susceptor, is heated by penetrating a varying magnetic field into the object. This process is explained by Faraday's law of induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a variable current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are properly positioned relative to each other so that the resulting varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current, and when such eddy currents are generated within the object, their flow against the object's electrical resistance heats the object. This process is called Joule heating, ohmic heating, or resistive heating.

[0049] Magnetic hysteresis heating is a process by which an object made of a magnetic material is heated by the penetration of a fluctuating magnetic field into the object. The magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles become aligned with the magnetic field. Thus, when a fluctuating magnetic field, such as an alternating magnetic field produced by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the applied fluctuating magnetic field. Such magnetic dipole reorientation generates heat within the magnetic material.

[0050] When an object is both conductive and magnetic, penetrating a varying magnetic field into 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, thereby enhancing Joule heating.

[0051] The aerosol delivery system will now be described in more detail.

[0052] 1 shows an aerosol delivery device 100 configured to generate an aerosol from an article 150 that includes an aerosol-forming material. The article 150 may be inserted into the aerosol delivery device 100 during use.

[0053] The aerosol delivery device 100 is an elongated structure extending along a longitudinal axis. The aerosol delivery device has a proximal end 110 that is closest to a user (e.g., a user's mouth) during use by the user to inhale the aerosol generated by the aerosol delivery device 100. The aerosol delivery device 100 also has a distal end 120 that is farthest from the user during use. The proximal end 110 is sometimes referred to as the "mouth end." The aerosol delivery device 100 also defines a proximal direction that faces toward the user during use, i.e., from the distal end 120 to the proximal end 110. Furthermore, the aerosol delivery device 100 also defines a distal direction that faces away from the user during use, i.e., from the proximal end 110 to the distal end 120. The proximal and distal directions may be parallel to the longitudinal axis of the aerosol delivery device 100.

[0054] 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 including 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 and extend along a longitudinal axis that may be substantially parallel to the longitudinal axis of aerosol delivery device 100. Rod-shaped article 150 including 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 that may be parallel to the longitudinal axis of aerosol delivery device 100.

[0055] 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, which may then be inhaled by a user of aerosol delivery device 100.

[0056] The heating element 235 may at least partially surround the heating chamber 210. For example, the heating element 235 may surround the heating chamber 210. The heating element 235 may be generally tubular.

[0057] According to various embodiments, the heating element 235 may comprise a susceptor that is indirectly heated by one or more induction coils.

[0058] 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 include a pin (not shown) that protrudes into the base of the heating chamber 210 and that, in use, is configured to be inserted into the distal end of the article 150 when the article 150 is received within the heating chamber 210. In this embodiment, the pin heater (not shown) is configured to heat the article 150 internally.

[0059] 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 internally during use. The pin and blade heating elements may comprise resistive heating elements. 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.

[0060] During use, once the article 150 is inserted into the heating chamber 210 of the aerosol delivery device 100, the user may perform a session during 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.

[0061] Aerosol delivery device 100 includes condensation chamber 310. Condensation chamber 310 functions as an airflow chamber. Condensation chamber 310, which functions as an airflow chamber, is fluidly connected to and extends in a first direction from heating chamber 210, within 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.

[0062] Condensation chamber 310 can be configured to fluidly connect heating chamber 210 with an external 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 external opening 330 on the exterior of aerosol delivery device 100. Inlet conduit 320 and condensation chamber 310 have inner surfaces exposed to air flowing along inlet conduit 320, for example, from the exterior of aerosol delivery device 100, through condensation chamber 310, and to heating chamber 210. Functioning as an airflow chamber, condensation chamber 310 allows air to flow from external opening 330, through condensation chamber 310, and into heating chamber 210 during use of aerosol delivery device 100.

[0063] 3A shows in more detail the condensation chamber 310 and the flow of air within article 150 when a user sucks on the proximal end of article 150. The condensation chamber 310 is fluidly connected to a heating chamber (not shown).

[0064] During use, a heating assembly (not shown) is used to heat an article 150 received within a heating chamber (not shown). When a user inhales on an article 150, air may be drawn into the aerosol delivery device through an exterior opening 330. The air is then drawn along and through an inlet conduit 320 and through a condensation chamber 310 and flows toward the heating chamber, particularly 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 and the distal end of the article 150, the inlet conduit 320 and the condensation chamber 310 may be cooled by the incoming air.

[0065] As the air moves toward the heating chamber and enters the distal end of article 150, the air passing through article 150 is heated. The warmed air can then collect or entrain aerosols generated by heating of the aerosol-generating material of article 150 by a heating assembly (not shown). The air and aerosols can then be drawn from article 150 to be inhaled by a user.

[0066] 3B shows the condensation chamber 310 and the overall length of the article 150. The flow of air through the condensation chamber 310 and the article 150 is shown. Air is also shown entering the article 150 through one or more vents provided in the article 150 that are relatively close to the proximal end of the article 150. The flow of heat into the article 150 as a user inhales on the article 150 is also shown.

[0067] 4A illustrates that between uses (i.e., when the user is not inhaling the article 150), air, which may contain vapor, may exit the article 150 and / or exit the heating chamber. This warm air, containing vapor, may then enter the condensation chamber 310 and continue toward the inlet conduit 320. However, the inlet conduit 320 and the condensation chamber 310 may be cooler than the temperature of the air exiting the article 150 and / or the heating chamber. 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 containing vapor entering the condensation chamber 310 may be joined by an opposing flow of relatively cooler air entering the inlet conduit 320 via the exterior opening 330.

[0068] 4B shows the condensation chamber 310 and the entire length of the article 150, illustrating the incoming flow of relatively cool air into the condensation chamber 310, which merges with the diffusion of hot vapor from the distal end of the article 150 into the condensation chamber 310. Air within the article 150 also moves to the central portion of the article 150. The flow of heat into the article 150 when the user is between puffs is also shown.

[0069] 5 shows a cross-sectional view of aerosol delivery device 100 provided with heating chamber 210 and condensation chamber 310 fluidly connected to external opening 330 on the exterior of aerosol delivery device 100. In such a configuration, the path for vapor to escape from condensation chamber 310 may be restricted.

[0070] 6 shows an enlarged cross-sectional view of selected internal components of aerosol delivery device 100. Aerosol delivery device 100 includes a heating chamber 210 for receiving an article, a condensation chamber 310, and an inlet conduit 320.

[0071] Inlet conduit 320 and condensation chamber 310 may be elongate and 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 condensation chamber 310 may be substantially parallel to the longitudinal axis of aerosol delivery device 100. The longitudinal axes of inlet conduit 320 and condensation chamber 310 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 disposed at distal end 120 of aerosol delivery device 100.

[0072] Inlet conduit 320 and condensation chamber 310 may have a first (distal) end having a first opening and a second (proximal) end having a second opening, and are configured so that, during use, air passes through the first opening to enter inlet conduit 320 and then through condensation chamber 310 and the second opening to enter heating chamber 210. In other words, the first opening is fluidly connected to heating chamber 210, and the second opening is also fluidly connected to external opening 330 on the exterior of aerosol delivery device 100. The widths of condensation chamber 310 and inlet conduit 320 may, for example, be different from or 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 provide, for example, a desired amount of draw or impedance to flow to the user.

[0073] It is recognized that condensate or liquid may collect within the condensation chamber 310 , such as on the interior surfaces of the condensation chamber 310 and the inlet conduit 320 .

[0074] As described in more detail below, various embodiments provide an aerosol delivery device that includes a valve positioned between the airflow chamber and the heating chamber. The valve is configured to ensure that the valve is closed when the user is not using the device (i.e., when not drawing), thereby preventing hot vapor from re-entering the airflow chamber. According to various embodiments, the aerosol delivery device allows for a reduced amount of condensation to accumulate because condensation of the hot vapor is substantially prevented. Furthermore, providing a valve also increases the overall efficiency of the aerosol delivery device because a greater amount of heat is retained within the heating chamber. In particular, heat loss from the heating chamber to the airflow chamber via convection can be reduced. As a result, the heating chamber can remain at a higher temperature for a longer period of time compared to other configurations in which the valve is not present, thereby lowering the overall energy demands on the aerosol delivery device. As a result, less energy needs to be supplied to operate the aerosol delivery device, thereby providing a more efficient aerosol delivery device.

[0075] 7A shows an enlarged cross-sectional view of selected internal components of an aerosol delivery device 100 according to various embodiments that attempt to address the issue of vapor condensation forming condensate in the condensation chamber. The aerosol delivery device 100 includes a heating chamber (not shown) for receiving the aerosol product article 150, an airflow chamber 310a, and an inlet conduit 320.

[0076] Inlet conduit 320 and air flow chamber 310a may have a first (distal) end with a first opening and a second (proximal) end with a second opening, configured so that during use, air passes through the first opening to enter inlet conduit 320 and then through air flow chamber 310a and the second opening to the distal end of article 150 and the heating chamber. The first opening is fluidly connected to the heating chamber, and the second opening is fluidly connected to external opening 330 on the exterior of aerosol delivery device 100.

[0077] The width of the volume within the airflow chamber 310a and inlet conduit 320 may be different from or smaller than the width of the heating chamber, for example. For example, the average width value may be smaller than the average width value of the heating chamber. This may provide a user with, for example, a desired amount of draw or impedance to flow.

[0078] 7A, aerosol delivery device 100 includes valve 340, which is disposed within condensation chamber 310 and functions to separate condensation chamber 310 from the heating chamber. Valve 340 is shown in an open position. An open position in this context means that air can freely flow from external opening 330 through airflow chamber 310a to the heating chamber and the distal end of article 150. Valve 340 includes an upper portion 341 that rests on or against substantially flat portion 311 of airflow chamber 310a when in the closed position. Valve 340 is configured to provide a reversible seal between airflow chamber 310a and the heating chamber.

[0079] 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 flow from the external opening 330 through the condensation chamber 310 and into the heating chamber 210.

[0080] A spacer element 700 may be provided such that the distal end of article 150 abuts spacer element 700 rather than top 341 of valve 340. A stopper 701 or other element may be provided that is configured to prevent top 341 of valve 340 from lifting more than a predetermined distance from substantially flat portion 311 of airflow chamber 310a on which top 341 would otherwise rest when in the closed position. Thus, stopper 701 or other element limits displacement of top 341 of valve. Stopper 701 or other element may be centrally located above top 341 of valve.

[0081] At least a portion of the valve 340 has a static friction coefficient μ staticThe material may be coated with or formed from a material having a tensile strength of <0.30, <0.25, <0.20, <0.15, <0.10 or <0.05.

[0082] Valve 340 may include a one-way valve. In other examples, valve 340 may include a membrane-type valve (not shown). The membrane-type valve may include a flexible membrane including, for example, natural rubber, silicone rubber, ethylene propylene diene monomer rubber, fluororubber, or nitrile rubber. At least a portion of valve 340 may be formed from silicone, polyether ether ketone ("PEEK"), or acrylonitrile butadiene styrene ("ABS").

[0083] Other types of valves may also be used, such as a butterfly valve (not shown). A butterfly valve may comprise a disk attached to a rod such that in a closed position, the disk is rotated to a position that restricts the flow of air and / or steam between the heating chamber and the airflow chamber 310a, and in an open position, the disk is rotated to a position that allows air to flow from the airflow chamber 310a to the distal end of the article 150 and the heating chamber. Other example valves may include ball valves, gate valves, needle valves, pinch valves, plug valves, freely hinged flaps, or check valves.

[0084] Valve 340 may be connected to a mount 352 disposed in external opening 330 via a resilient spring 350. Spring 350 may include, for example, a helical coil spring. Spring 350 may be configured to bias valve 340 to close such that upper portion 341 abuts substantially flat portion 311 of airflow chamber 310a when a user is not inhaling on the proximal end of article 150. In this manner, valve 340 is slidable within airflow chamber 310a between an open position (as shown in FIG. 7A ) and a closed position (as shown in FIG. 7B ). Valve 340 may be configured to slide back and forth along the longitudinal axis of airflow chamber 310a.

[0085] According to various embodiments, the distal end of article 150 may include a cellulose acetate plug that prevents debris from article 150 from interfering with the operation of valve 340, for example, preventing debris from falling below top 341 of valve 340 and thereby affecting the seal formed between airflow chamber 310a and the heating chamber.

[0086] 7B shows valve 340 in a closed position in which air and / or steam cannot flow between the heating chamber and the distal end of article 150 and enter airflow chamber 310a. When valve 340 is in the closed position, top 341 of valve 340 abuts substantially flat portion 311 of airflow chamber 310a due to the biasing force of spring 350, thereby providing a substantially airtight seal.

[0087] 7A, arrows indicate airflow from external opening 330, through airflow chamber 310a, and through or around valve 340 to enter the distal end of article 150. Heat flow into article 150 is also shown. When a user draws air on the proximal end of article 150, air is drawn from external opening 330 into the distal end of article 150.

[0088] Spacer element 700 may be provided so that the distal end of article 150 abuts spacer element 700 rather than top portion 341 of valve 340 .

[0089] In use, when the valve 340 is in its closed position, a user sucks on the proximal end of the article 150, creating a pressure differential ΔP such that the area above the valve 340 is at a lower pressure than the area below the valve 340, which is at substantially ambient pressure. This pressure differential ΔP is sufficient to cause the valve 340 to change from the closed position shown in FIG. 7B to the open position shown in FIG. 7A. In particular, the force on the valve 340 resulting from the pressure differential may be sufficient to overcome the biasing force of the spring 350 that would otherwise maintain the valve 340 in the closed position. As the valve 340 moves against the restoring force of the spring 350, air can pass from the airflow chamber 310a through the valve mechanism to the distal end of the article 150 and into the heating chamber. When a session is initiated, the article 150 is heated by the heating element, which may cause the release of vapor, which can then be entrained in the airflow and consumed by the user.

[0090] When the user stops sucking on the proximal end of article 150, the differential pressure ΔP disappears (or is otherwise significantly reduced). As a result, valve 340, under the biasing or restoring force of spring 350, returns to the closed position, as shown in FIG. 7B. For example, during a draw or puff, valve 340 may be configured to assume a closed position (or a substantially closed position).

[0091] According to various embodiments, the valve 340, as shown in Figures 7A and 7B, can have a relatively large head relative to the widest dimension of the airflow chamber 310a. As a result, the surface area A of the valve 340 at the top 341 is relatively large, and therefore the force F generated on the valve 340 by ΔP is also relatively large. This force can be approximated as F = ΔP · A. Thus, the valve 340 can relatively easily overcome the biasing force of the spring when the user puffs on the proximal end of the article 150.

[0092] The forces acting on the valve 340 cause the total movement of the valve 340 in the upward direction toward the article 150 to be relatively large, e.g., 2.0 mm or more. As a result, the article 150 can be offset from the valve 340 by 2.0 mm or more in the closed position so that the valve 340 does not impact the article 150.

[0093] As explained above, it is recognized that condensate or liquid may collect within the condensation chamber, such as on the interior surfaces of the condensation chamber or inlet conduit, which is undesirable. Condensate may form when hot steam produced from heating the item contacts the cooler interior of the condensation chamber.

[0094] The inclusion of valve 340 ensures that when the user is not using the device (i.e., not drawing), valve 340 prevents hot vapor from re-entering airflow chamber 310a, thereby preventing condensation of the hot vapor and reducing the amount of condensate that accumulates. This simultaneously increases the overall efficiency of aerosol delivery device 100 because a greater amount of heat is retained within the heating chamber and not passed to airflow chamber 310a by convection. Therefore, the overall energy demands on aerosol delivery device 100 may be lower because the heating chamber can remain at a higher temperature for longer compared to a configuration without a valve between the condensation chamber and the heating chamber. As a result, less energy needs to be supplied to the heating element. Therefore, the battery of aerosol delivery device 100 may be depleted at a slower rate.

[0095] According to various embodiments, such as those shown in Figures 7A and 7B, a resilient spring 350 may be used to actuate the valve 340. However, other embodiments are contemplated. For example, according to other embodiments, one or more magnetic mechanisms (not shown) may be configured to open and / or close the valve 340. For example, an electromagnet may be used.

[0096] According to various embodiments, the spring 350 may have a spring constant of <0.05 N / mm, 0.05-0.1 N / mm, 0.1-0.2 N / mm, 0.2-0.3 N / mm, 0.3-0.4 N / mm, 0.4-0.5 N / mm, 0.5-0.6 N / mm, 0.6-0.7 N / mm, 0.7-0.8 N / mm, 0.8-0.9 N / mm, 0.9-1.0 N / mm, 1.0-2.0 N / mm, 2.0-3.0 N / mm, 3.0-4.0 N / mm, 4.0-5.0 N / mm, 5.0-6.0 N / mm, / mm, 6.0-7.0N / mm, 7.0-8.0N / mm, 8.0-9.0N / mm, 9.0-10.0N / mm, 10.0-11.0N / mm, 11.0-12.0N / mm, 12.0-13.0N / mm, 13.0-14.0N / mm, 14.0-15.0N / mm, 15.0-16.0N / mm, 16.0-17.0N / mm, 17.0-18.0N / mm, 18.0-19.0N / mm, 19.0-20.0N / mm or >20.0N / mm.

[0097] The spring 350 can have a length of <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm, 10-11 mm, 11-12 mm, 12-13 mm, 13-14 mm, 14-15 mm, 15-16 mm, 16-17 mm, 17-18 mm, 18-19 mm, 19-20 mm, 20-21 mm, 21-22 mm, 22-23 mm, 23-24 mm, 24-25 mm, 25-26 mm, 26-27 mm, 27-28 mm, 28-29 mm, 29-30 mm, or >30 mm.

[0098] The spring may include a helical spring having <1 turn per cm, 1-2 turns per cm, 2-3 turns per cm, 3-4 turns per cm, 4-5 turns per cm, 5-6 turns per cm, 6-7 turns per cm, 7-8 turns per cm, 8-9 turns per cm, 9-10 turns per cm, or >10 turns per cm.

[0099] 8A shows aerosol delivery device 100 according to a different embodiment, with modified valve 440 shown in the open position. In contrast to the embodiment shown with reference to FIGS. 7A and 7B and described above, no spacer element is provided. Similarly, no stopper is provided above the top of valve 440. As a result, the distal end of article 150 is configured to abut against the top of the housing of airflow chamber 310a (which may also be thought of as forming the base of the heating chamber).

[0100] According to the embodiment shown and described with reference to Figures 8A and 8B, a valve 440 is provided having a smaller surface area at its upper portion 441 compared to valve 340 shown and described with reference to the embodiment shown in Figures 7A and 7B. Valve 440 includes a valve seat 450 disposed within airflow chamber 310a. Valve 440 is configured to be movable relative to valve seat 450 between an engaged position shown and described with reference to Figure 8B and a disengaged position shown and described with reference to Figure 8A. In the engaged (closed) position shown in Figure 8B, upper portion 441 of valve 440 rests on upper portion 451 of valve seat 450. In the disengaged (open) position shown in Figure 8A, upper portion 441 of valve 440 is longitudinally spaced from upper portion 451 of valve seat 450.

[0101] At least a portion of the valve 440 and / or valve seat 450 has a static friction coefficient μ static <0.30, <0.25, <0.20, <0.15, <0.10, or <0.05. At least a portion of the valve 440 and / or valve seat 450 may be formed from silicone, polyetheretherketone (“PEEK”), or acrylonitrile butadiene styrene (“ABS”).

[0102] 8A and 8B, the valve seat 450 may be held within the air flow chamber 310a by an interference fit. In other examples, the valve seat 450 may be secured to the air flow chamber 310a by an adhesive. Alternatively, the valve seat 450 may be integral with the air flow chamber 310a, i.e., the air flow chamber 310a and the valve seat 450 may be formed as a single component.

[0103] 8B, the top 441 of valve 440 abuts against the top 451 of valve seat 450 within airflow chamber 310a due to the biasing force of spring 350. When a user inhales on the proximal end of article 150, air is drawn into inlet conduit 320 and airflow chamber 310a through exterior opening 330. The air flows through airflow chamber 310a, through the gap between valve 440 and valve seat 450, and into the distal end of article 150 and the heating chamber.

[0104] When a user inhales on the proximal end of the article 150, a pressure differential ΔP is generated between the region above the valve 440, which is at a relatively lower pressure than the region below the valve 440. The region below the valve 440 is at substantially ambient pressure when the valve 440 is in its closed position. This pressure differential ΔP is sufficient to move the valve 440 upward toward the distal end of the article 150 from the closed position shown in FIG. 8B to the open position shown in FIG. 8A, thereby overcoming the biasing and restoring forces of the spring 350. As the valve 440 moves upward, air can freely pass from the airflow chamber 310a to the distal end of the article 150 and the heating chamber. When a session is initiated, the article 150 is heated by the heating element, which can cause vapor to be released into the air, which can then be consumed by the user. The flow of heat toward the distal end of the article 150 is also shown in both FIG. 8A and FIG. 8B.

[0105] 8A and 8B has a relatively small cross-sectional area A2 at its upper section 441 compared to the area A of the valve 340 shown and described with reference to FIGS. 7A and 7B. As a result, for the same pressure differential ΔP, the force F2 generated on the valve 440 shown and described with reference to FIGS. 8A and 8B is small compared to the force F generated on the valve 340 shown and described with reference to FIGS. 7A and 7B. This force can be approximated as F2 = ΔP · A2. The force F2 is sufficient to enable the valve 440 to overcome the biasing force of the spring 350 when a user sucks on the proximal end of the article 150.

[0106] When the user stops sucking on the proximal end of article 150, the pressure differential ΔP disappears or is otherwise significantly reduced such that the resulting force F2 is no longer sufficient to overcome the biasing or restoring force of spring 350. As a result, valve 440, subjected to the biasing or restoring force of spring 350, returns to the closed position as shown in FIG. 8B. For example, during a draw or puff, valve 440 returns to the closed position (or substantially closed position).

[0107] Due to the smaller force F2 acting on the valve 440 (relative to the force F on the valve 340 as shown and described with reference to FIGS. 7A and 7B ), the overall movement of the valve 440 in the upward direction toward the article 150 can be reduced compared to the valve 340 (as shown and described with reference to FIGS. 7A and 7B ) for a given biasing force from the spring 350. This effect, associated with the valve 440 being located lower, closer to the external opening 330 due to the presence of the valve seat 450, allows a design to be utilized in which the article 150 does not need to be offset from the valve 440 by a spacer (as is the case with the valve 340 as shown and described with reference to FIGS. 7A and 7B ). This allows a more compact configuration to be realized.

[0108] According to various embodiments, the spring 350 may have a spring constant of <0.05 N / mm, 0.05-0.1 N / mm, 0.1-0.2 N / mm, 0.2-0.3 N / mm, 0.3-0.4 N / mm, 0.4-0.5 N / mm, 0.5-0.6 N / mm, 0.6-0.7 N / mm, 0.7-0.8 N / mm, 0.8-0.9 N / mm, 0.9-1.0 N / mm, 1.0-2.0 N / mm, 2.0-3.0 N / mm, 3.0-4.0 N / mm, 4.0-5.0 N / mm, 5.0-6.0 N / mm, / mm, 6.0-7.0N / mm, 7.0-8.0N / mm, 8.0-9.0N / mm, 9.0-10.0N / mm, 10.0-11.0N / mm, 11.0-12.0N / mm, 12.0-13.0N / mm, 13.0-14.0N / mm, 14.0-15.0N / mm, 15.0-16.0N / mm, 16.0-17.0N / mm, 17.0-18.0N / mm, 18.0-19.0N / mm, 19.0-20.0N / mm or >20.0N / mm.

[0109] The spring 350 can have a length of <1 mm, 1-2 mm, 2-3 mm, 3-4 mm, 4-5 mm, 5-6 mm, 6-7 mm, 7-8 mm, 8-9 mm, 9-10 mm, 10-11 mm, 11-12 mm, 12-13 mm, 13-14 mm, 14-15 mm, 15-16 mm, 16-17 mm, 17-18 mm, 18-19 mm, 19-20 mm, 20-21 mm, 21-22 mm, 22-23 mm, 23-24 mm, 24-25 mm, 25-26 mm, 26-27 mm, 27-28 mm, 28-29 mm, 29-30 mm, or >30 mm.

[0110] The spring may include a helical spring having <1 turn per cm, 1-2 turns per cm, 2-3 turns per cm, 3-4 turns per cm, 4-5 turns per cm, 5-6 turns per cm, 6-7 turns per cm, 7-8 turns per cm, 8-9 turns per cm, 9-10 turns per cm, or >10 turns per cm.

[0111] As explained above, it is recognized that condensation or liquid may collect within the airflow chamber forming the condensation chamber of aerosol delivery device 100, such as on the interior surfaces of the chamber or within inlet conduit 320, and this is generally undesirable. For example, condensation may form if hot steam produced from heating item 150 is allowed to contact the cooler interior of condensation chamber 310.

[0112] The inclusion of valve 440 between airflow chamber 310a and heating chamber 440 ensures that hot vapor is substantially prevented from entering airflow chamber 310a, for example, by diffusion, when the user is not puffing or between puffs. As a result, condensation of hot vapor is prevented, thereby substantially reducing the amount of condensate that accumulates. This also increases the overall efficiency of aerosol delivery device 100, as a greater amount of heat can be retained within the heating chamber and not lost to airflow chamber 310a by convection. Additionally, the overall energy demands on aerosol delivery device 100 can be lower because the heating chamber can remain at a higher temperature for longer compared to a configuration without a valve between the condensation chamber and heating chamber. As a result, less energy needs to be supplied to the heating element, and therefore the battery of aerosol delivery device 100 is depleted at a slower rate.

[0113] 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 essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. a heating chamber configured to receive an aerosol product; an airflow chamber in fluid communication with the heating chamber, the airflow chamber including an air inlet configured to admit air into the airflow chamber; a valve disposed between the heating chamber and the air flow chamber; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein a pressure differential is used to open and / or close the valve.

3. 3. The aerosol delivery device of claim 2, wherein, in use, a user generates the pressure differential when the user inhales or inhales an aerosol product located within the heating chamber.

4. 4. The aerosol delivery device of claim 1, wherein the valve comprises a fixed valve seat and a movable valve member, and in a closed position, the movable valve member is engaged with the fixed valve seat, and in an open position, the movable valve member is disengaged from the fixed valve seat.

5. The aerosol delivery device of claim 4 , wherein the fixed valve seat comprises either a portion of the airflow chamber or a base of the heating chamber.

6. 6. The aerosol delivery device of claim 4 or 5, wherein the fixed valve seat is located within the air flow chamber.

7. At least a portion of the fixed valve seat and / or at least a portion of the movable valve member has a static friction coefficient μ ｓｔａｔｉｃ 7. The aerosol delivery device of claim 4, 5 or 6, coated with or formed from a material having a refractive index of <0.30, <0.25, <0.20, <0.15, <0.10 or <0.

05.

8. 8. The aerosol delivery device of claim 4, wherein at least a portion of the fixed valve seat and / or at least a portion of the movable valve member is formed from silicone, polyetheretherketone ("PEEK"), or acrylonitrile butadiene styrene ("ABS").

9. The aerosol delivery device of any one of claims 1 to 8, further comprising a biasing member configured to open and / or close the valve.

10. The aerosol delivery device of claim 9 , wherein the biasing member comprises one or more springs.

11. The aerosol delivery device of claim 9 or 10, wherein the biasing member includes one or more magnetic mechanisms.

12. 12. The aerosol delivery device of claim 9, 10, or 11, wherein the biasing member comprises one or more elastic elements.

13. The aerosol delivery device of claim 1 , wherein the valve comprises a membrane-type valve.

14. 14. The aerosol delivery device of claim 13, wherein the membrane valve comprises a flexible membrane comprising natural rubber, silicone rubber, ethylene propylene diene monomer rubber, fluororubber, or nitrile rubber.

15. The aerosol delivery device of claim 1 , wherein the valve comprises a butterfly valve.

16. 16. The aerosol delivery device of claim 15, wherein the butterfly valve comprises a disk attached to a rod, and in a closed position, the disk is rotated to a position that restricts the flow of air and / or steam between the heating chamber and the air flow chamber, and in an open position, the disk is rotated to a position that allows air to flow from the air flow chamber to the heating chamber.

17. 10. The aerosol delivery device of claim 1, wherein the valve comprises a ball valve, a gate valve, a needle valve, a pinch valve, or a plug valve.

18. 10. The aerosol delivery device of claim 1, wherein the valve comprises a freely hinged flap or a check valve.

19. 19. The aerosol delivery device of any one of claims 1 to 18, wherein the air inlet and / or the valve are configured to be substantially closed when an aerosol product article is at least partially inserted into the heating chamber and a user is not attempting to inhale aerosol from the aerosol product article.

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

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

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