Heaters for aerosol supply devices

Abstract

A heater for an aerosol supply device (100) configured to heat an article (50) containing an aerosol-generating material is disclosed. The heater (301) includes an elongated housing (302) having a longitudinal axis and a heater element (350) positioned within the elongated housing. The heater element (350) includes a first end and a second end and at least one track (351) of heater material extending between the first end and the second end. At least a portion (604, 606) of the at least one track (351) of heater material includes a section of electrical resistance variation of at least one track.

Description

Technical Field

[0001] The present invention relates to a heater for an aerosol supply device, an aerosol supply device, an aerosol supply system, and a method of generating an aerosol.

Background Art

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

[0003] Aerosol supply systems covering the above-described devices or products are known. A typical system uses a heater to generate an aerosol from a suitable medium, and then the aerosol is inhaled by the user. In many cases, in order to supply different aerosols for inhalation, it is necessary to replace or change the medium used. It is known to use a resistive heating system as a heater for generating an aerosol from a suitable medium. Separately from this, it is known that an induction heating system is used as a heater.

Summary of the Invention

[0004] According to one aspect, there is provided a heater for an aerosol supply device configured to heat an article containing an aerosol-generating material. The heater includes an elongated housing having a longitudinal axis, and a heater element positioned within the elongated housing. The heater element includes a first end and a second end, and at least one track of heater material extending between the first end and the second end. At least a portion of at least one track of heater material includes a change portion of the electrical resistance of the at least one track.

[0005] According to one embodiment, a heater for an aerosol supply device is provided, configured to heat an article containing an aerosol-generating material. The heater comprises an elongated housing having a longitudinal axis, and a heater element positioned within the elongated housing. The heater element comprises a first end and a second end, and a track of heater material. The length of the track of heater material is not divided and includes a section of electrical resistance variation in the track of heater material. If the track of heater material is not divided into two or more tracks, or does not merge with one or more tracks, the length of the track of heater material is not divided.

[0006] The section of the track where the electrical resistance changes may be such that the track has a first electrical resistance on one side of the section where the resistance changes, and a second electrical resistance on the other side of the section where the resistance changes along the longitudinal direction of the track, and the first and second electrical resistances are not equal.

[0007] The section of electrical resistance of the track may be such that, on one side of the section of electrical resistance change, at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, or at least 5 mm of the track from the section of electrical resistance change has a first electrical resistance, and on the other side of the section of electrical resistance change along the longitudinal direction of the track, at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, or at least 5 mm of the track from the section of electrical resistance change has a second electrical resistance, and the first and second electrical resistances are not equal.

[0008] The lengths of the first resistor and the second resistor on either side of the resistance change section may be different.

[0009] The difference between the first electrical resistance and the second electrical resistance may be greater than any expected variation in the electrical resistance of the heating material along that length of the heating material, where the cross-sectional area and shape are uniform along that length of the heating material.

[0010] At least one track of the heating material may be divided into at least two tracks of the heating material over at least a portion of the length of that track.

[0011] At least one track of the heating material may be divided into at least two tracks of the heating material over at least a portion of the length of that track, and then rejoined as a single track at a position spaced apart from the point of division of the track.

[0012] In some embodiments, at least two divided tracks do not merge back into a single track, and one end of the track includes at least two ends of the divided tracks.

[0013] At least one change in the electrical resistance of the track may be positioned on the track such that, when the heater element is activated, the heater element produces a predetermined temperature profile along the length of the track. Activating the heater element involves supplying energy to the heater so that the heater generates an aerosol from the aerosol-generating material.

[0014] The change in electrical resistance of the truck is a result of the change in the cross-sectional area of ​​the truck.

[0015] A change in cross-section may also be a change in the cross-sectional area of ​​the track. In such embodiments, a decrease in cross-sectional area causes an increase in the electrical resistance of the track, resulting in a rise in the temperature reached by the heating material at the locations of increased electrical resistance. An increase in cross-sectional area causes a decrease in the electrical resistance of the track, resulting in a decrease in the temperature reached by the heating material at the locations of decreased electrical resistance.

[0016] There may be at least two points of change in the electrical resistance of the track.

[0017] The track may have at least two variable parts in its electrical resistance, where, as it moves in the same direction from one end to the other, at least one variable part increases the electrical resistance and at least one variable part decreases the electrical resistance.

[0018] At least one of the changes in electrical resistance may be a stepped change at a single location on the track of the heater material. The single location is a very short distance along the track.

[0019] At least one of the changes in electrical resistance may be a continuous change along the length of the track of the resistive material.

[0020] The heating element may further comprise a base material, and tracks of heating material or each track is supported on the base material.

[0021] The base material and the tracks of the heating material, or each track, may be flexible.

[0022] The base material may be elastically flexible.

[0023] The housing may define an internal void, and the heater element is configured such that at least 75%, at least 80%, at least 90%, and 100% of the heater element fits within the internal void. In some embodiments, the proportion of the heater element is measured in a direction parallel to the central axis of the internal void.

[0024] The heater element and the substrate may be configured such that the substrate is on one or more surfaces of the housing defining the inner void and the heater material tracks or biases each track. In some embodiments, the substrate may be rolled or folded into a tube or other shape that conforms to the inner surface of the inner void, and the heater element is on the radially outer surface of the tube or other shape. Rolling or folding the substrate and the substrate material may be such that the substrate has a tendency to reshape itself from a tube or other shape to a more planar configuration.

[0025] The heater may comprise at least one mass of material, the mass of material being positioned within the inner void. At least one mass of material may hold at least a portion of the heater element in a fixed position relative to the housing.

[0026] The inner void may be filled with a mass of material, and the entire heater element positioned within the inner void is held in a fixed position relative to the housing.

[0027] The mass of material may include an adhesive or a potting compound.

[0028] The heater material may be a resistive heater material, and the heater may be a resistive heater.

[0029] The heater may be an induction heating heater.

[0030] The heater element may be an induction heating element.

[0031] According to one aspect, there is provided an aerosol supply device configured to heat an article containing an aerosol-generating material, the aerosol supply device comprising the heater described above. The aerosol supply device may comprise a heating chamber in which the heater is provided.

[0032] The aerosol supply device may comprise a power supply, a controller, and a heating chamber that removably receives the aerosol product. The power supply may be aligned along the longitudinal axis of the heating chamber. The power supply may also be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0033] The aerosol supply device may be configured for wireless charging. The aerosol supply device may be provided with a charging port, such as a USB port, which is used to connect the power supply to an external power source for recharging.

[0034] According to one embodiment, an aerosol supply system is provided, comprising an aerosol supply device as described above and an article containing an aerosol generating material.

[0035] The aerosol supply system may include a charging unit having a cavity for removably receiving an aerosol supply device.

[0036] The charging unit may include a movable lid that covers the aerosol supply device in a closed configuration.

[0037] The charging unit may include a user display.

[0038] The user display is visible to the user when the movable lid is in the closed position, and is partially or completely hidden from view by the lid when the lid is in the open position.

[0039] In another embodiment, a method for generating an aerosol is provided, comprising the steps of: providing an aerosol supply device comprising a heater as described above and a heating chamber including a receiving portion; and inserting an aerosol product at least partially into the receiving portion of the heating chamber.

[0040] The embodiments of the heaters and devices of this disclosure may include, as necessary, one or more of the features or embodiments described above. The embodiments of the methods of this disclosure may include, as necessary, one or more of the features or embodiments described above. Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0041] [Figure 1] This is a perspective view of one embodiment of an aerosol supply system, which includes one embodiment of an aerosol supply device located within a charging unit. [Figure 2] Figure 1 is a schematic cross-sectional view of a portion of the aerosol supply device. [Figure 3] Figure 1 shows a schematic cross-sectional view of a portion of the aerosol supply device and the aerosol products of the aerosol supply system. [Figure 4] This is a perspective view of another aerosol supply device. [Figure 5] Figure 4 is a schematic cross-sectional view of the device. [Figure 6] This is a schematic cross-sectional view of one embodiment of the heater of the device shown in Figure 1 or Figure 4. [Figure 7] This figure shows the first detail of the first embodiment of the heating element of the heater shown in Figure 6. [Figure 8] This figure shows a second detail of the first embodiment of the heating element of the heater shown in Figure 6. [Figure 9] This figure shows the first detail of the second embodiment of the heating element of the heater shown in Figure 6. [Figure 10] This figure shows the second detail of the second embodiment of the heating element of the heater shown in Figure 6. [Figure 11] This figure shows the details of the third embodiment of the heating element of the heater shown in Figure 6. [Modes for carrying out the invention]

[0042] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or components thereof) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0043] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0044] 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), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0045] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0046] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of one or more aerosol-generating materials that can be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises 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.

[0047] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0048] In some embodiments, the non-combustible aerosol supply device may include a region or volume section for receiving consumables, an aerosol generator, an aerosol generating region or volume section, a housing, a mouthpiece, a filter and / or an aerosol modifier.

[0049] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area or volume section, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area or volume section, a housing, packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0050] As used herein, the term “aerosol-generating material” refers to a material that can generate an aerosol when energy is supplied, for example, by heating, irradiation, or any other means. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0051] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0052] The aerosol-generating material may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers 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-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0053] The aerosol-generating material may include an aerosol-generating film, or may be in the form of an aerosol-generating film. The aerosol-generating film may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers may also be present. The aerosol-generating film may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0054] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.5 mm or 0.3 mm.

[0055] The aerosol-generating film may be continuous. For example, the film may or may be a continuous sheet of material. The sheet may be in the form of wrapping paper, may be gathered to form a gathered sheet, or may be shredded to form a shredded sheet. The shredded sheet may contain one or more strands or strips of the aerosol-generating material.

[0056] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of an aerosol-generating material, such as dots, stripes, or lines, which can be supported on a support. In such embodiments, the support may be planar or non-planar.

[0057] An aerosol-generating film can 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 components such as one or more substances to be delivered to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form an aerosol-generating film.

[0058] An aerosol supply device can accept articles containing aerosol-generating material for heating. In this context, “article” refers to a component that contains or is contained with aerosol-generating material at the time of use, and optionally other components at the time of use, which are heated to volatilize the aerosol-generating material. The user can insert the article into or onto the aerosol supply device before it is heated to generate an aerosol, and the user then inhales the aerosol. The article may be of a predetermined or specific size, for example, configured to be placed in or across the heater of a device sized to accept the article.

[0059] 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 supply thermal energy to the aerosol-generating material in order to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0060] Consumables are articles containing or consisting of aerosol-generating materials, some or all of which are intended to be consumed during use by the user. Consumables may also comprise 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, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may include, for example, a flammable material, an electrically conductive material, or a susceptor.

[0061] A susceptor is a heating material that can be heated by penetration due to a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and as a result, penetration of the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and as a result, penetration of the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and as a result, the susceptor can be heated by both heating mechanisms. An aerosol supply device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0062] A non-combustible aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and interchangeable aerosol products. In some implementations, the non-combustible aerosol supply device may include a power source and a controller (i.e., a control circuit). The power source may be an electrical power source, such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol supply device may also include an aerosol generating component. However, in other implementations, the aerosol product may comprise the aerosol generating component partially or entirely.

[0063] Figure 1 shows an aerosol supply system 10 comprising an aerosol supply device 100 and a charging unit 101. The device is shown positioned within the cavity of the charging unit 101. The aerosol supply device 100 is arranged to generate aerosols from an aerosol product (see Figure 3) that can be inserted into the aerosol supply device 100 when in use. In the embodiment, the article forms part of the aerosol supply system 10.

[0064] The aerosol supply device 100 is an elongated structure extending along its longitudinal axis. Furthermore, the aerosol supply device has a proximal end, which is closest to the user (e.g., the user's mouth) when used by the user, and a distal end, which is furthest from the user when used, for inhaling the aerosol produced by the aerosol supply device 100. The proximal end may also be called the “mouthpiece end”. Thus, the aerosol supply device 100 also defines a proximal direction which is directed toward the user when used. Furthermore, the aerosol supply device 100 also defines a distal direction which is directed away from the user when used. The terms proximal and distal applied to the features of the device 100 are explained by referring to the relative positioning of such features relative to each other in the proximal-distal direction along the longitudinal axis. The aerosol supply device 100 has an opening at its distal end that leads into a heating chamber.

[0065] The aerosol supply device 100 may be removably inserted into a charging unit 101 for charging. The charging unit 101 includes a cavity (see Figure 2) for receiving the aerosol supply device 100. The aerosol supply device 100 may be inserted into the cavity through an opening. The cavity may also include a longitudinal opening. A portion of the aerosol supply device 100 may include a first side surface. One or more user-operable control elements, such as a button 106, which can be used to operate the aerosol supply device 100, may be provided on the first side surface of the aerosol supply device 100. The first side surface of the aerosol supply device 100 may be received into a longitudinal opening provided in the charging unit 101.

[0066] In one embodiment, the cavity of the charging unit 101 may have a cross-sectional profile that allows the aerosol supply device 100 to be inserted into the charging unit 101 in only one orientation. According to one embodiment, the outer profile of the aerosol supply device 100 may include a curved portion and a straight portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also include a similar curved portion and a straight portion. The straight portion of the cavity's cross-sectional profile may correspond to a longitudinal opening.

[0067] The charging unit 101 includes a sliding lid 103. When the aerosol supply device 100 is inserted into the charging unit 101 for recharging, the sliding lid 103 may be closed to cover the opening into the aerosol supply device 100. In other embodiments, the charging unit 101 may have an alternative lid configuration, such as a hinged or pivoted lid, or may not have a lid at all.

[0068] The charging unit 101 may include a user interface such as a display 108, which can be installed in any convenient location, such as the position shown in Figure 1.

[0069] Figure 2 shows a cross-sectional view of a portion of the aerosol supply device 100. The aerosol supply device 100 comprises a main housing 200. The main housing 200 defines the device body of the device 100. The device 100 defines a heating chamber 201. A receptacle 205 defines the heating chamber 201. An opening 203 is provided to provide access to the heating chamber 201. The receptacle 205 comprises a wall configuration including a receptacle side wall 205a and a receptacle base 205b. The base 205b is located at the distal end of the receptacle 205. The heating zone 201a is configured to receive at least a portion of an article for heating.

[0070] A heater 301 is provided in a portion of the main housing 200, and the heater 301 extends into or protrudes within the heating chamber 201. The heater 301 may include a base portion 301a that can be positioned in a recess provided in a portion of the body of the device 100. The heater 301 is upright within the heating chamber 201. The heater 301 is upright from its distal end.

[0071] The heater 301 includes an elongated heater in the form of a pin. In other embodiments, the heater 301 includes other elongated configurations such as blades. During use, the heater 301 can be inserted into the distal end of the aerosol product 50 (see Figure 3) which is received in the heating chamber 201 to heat the aerosol product internally.

[0072] The housing comprises a housing wall 200a. The housing wall 200a extends along or parallel to the longitudinal axis of the aerosol supply device 100 and surrounds the heating chamber 201. The housing wall 200a may define, at least partially, the receiving chamber of the aerosol supply device 100 as a volume enclosed within the wall 200a. A housing base 200b is located at the distal end of the housing wall 200a. In the illustrated embodiment, the heater 301 is upright from the housing base 200b. The heater 301 protrudes through the receptacle base 205b. The receptacle base 205b has an aperture 206 through which the heater 301 protrudes. In the embodiment, the heater 301 is mounted on the receptacle base 205b. The heater 301 is upright from the receptacle base 205b.

[0073] The aerosol supply device 100 further comprises a removal mechanism 204 which can be detachably held in the main housing 200 of the aerosol supply device 100. In embodiments, the removal mechanism 204 is omitted. In embodiments, the housing wall 200a defines at least partially the receptacle 205. The removal mechanism 204 may be held in the main housing 200 such that at least a portion of the removal mechanism 204 extends into the heating chamber 201. In this embodiment, the removal mechanism 204 may comprise a longitudinal portion such as a tubular peripheral wall portion 207a and a base wall portion 207b. The wall 207a may have a shape other than tubular and may be any shape that encloses (for example, surrounds) and defines the heating chamber 201 inside.

[0074] In embodiments having a removal mechanism 204, the removal mechanism 204 defines the heating chamber 201. The removal mechanism 204 forms the receptacle 205. In embodiments where the removal mechanism 204 is omitted, other features of the device 100 define the heating chamber 201, such as the housing side wall 200a and the housing base 200b.

[0075] The base portion 207b has an aperture 206 from which the heater 301 can be projected. In order to hold the removal mechanism 204 in the main housing 200, the removal mechanism 204 is pushed distally, i.e., toward the distal end of the main housing 200, to engage with the main housing 200 until the removal mechanism 204 can no longer move distally. In the following description, when the removal mechanism 204 is "held in" the main housing 200, it means that the removal mechanism 204 is engaged with the main housing 200 and cannot move distally any further.

[0076] The peripheral portion 207a and the base portion 207b may together define and enclose an article chamber for receiving the aerosol product 50, as shown in Figure 3. The article chamber has an inner surface configured to contact the aerosol product, the inner surface comprising a longitudinally extending portion provided by the tubular portion 207a and an end portion provided by the base portion 207b. In embodiments, the article chamber and the heating chamber are the same. When the aerosol product 50 is received into the heating chamber, the aerosol product may contact both the longitudinally extending portion and the end portion of the inner surface. In particular, the article chamber (i.e., the peripheral portion 207a and the base portion 207b) may be configured to receive at least a portion of the aerosol product 50, which is in the form of a longitudinally extending cylindrical rod, such that the longitudinal axis of the article is parallel to (optionally aligned in a line with) the longitudinal axis of the aerosol supply device 100 when received into the article chamber.

[0077] The article chamber may also be called the receiving portion. When the removal mechanism 204 is held in the main housing 200, during use, the article chamber of the removal mechanism 204 is positioned at least partially within the heating chamber 201. The heater 301 may be positioned to protrude into the article chamber through an aperture 206 provided in the base portion 207b of the removal mechanism 204. Thus, the removal mechanism 204 is configured to receive at least a portion of the aerosol product during use.

[0078] In this embodiment, the removal mechanism 204 may include a first magnet or magnetizable material 208. The main housing 200 may include a second magnet or magnetizable material 209. During use, the removal mechanism 204 may be magnetically held to the main housing 200 by the interaction between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209.

[0079] In the embodiment, the removal mechanism 204 is completely separable from the main housing 200. The removal mechanism 204 may be held in place by the magnetic attraction between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209. The removal mechanism 204 may be separated from the main housing 200 by overcoming the magnetic force between the first magnet or magnetizable material 208 and the second magnet or magnetizable material 209. In the embodiment, the removal mechanism 204 is removably held in place by the main housing 200 by other means. For example, the removal mechanism 204 may be configured to be removably held in place by an interlocking fit with the main housing.

[0080] The removal mechanism 204 may also comprise an internal element ( comprising a tubular portion 207a and a base portion 207b) and an outer cap portion 210, where, when held in the main housing 200, the outer cap portion 210 encloses (e.g., covers) at least a portion of the main housing, such as the wall 200a of the main housing 200. The tubular portion 207a, the base portion 207b, and the outer cap portion 210 may comprise a single (e.g., one) component (e.g., formed by molding). Alternatively, the tubular portion 207a and the base portion 207b may comprise a first component, and the outer cap portion 210 may comprise a second separate component. The first and second components may then be fixed to each other.

[0081] Figure 4 shows another aerosol supply system 40. System 40 comprises a one-piece aerosol supply device 400 for generating an aerosol from an aerosol-generating material, and an aerosol product 50 containing the aerosol-generating material. Device 400 can be used to heat the aerosol product 50 containing the aerosol-generating material to generate an aerosol or other inhalable medium that can be inhaled by a user of device 400.

[0082] The device 400 includes a housing 500 that surrounds and houses various components of the device 400. The housing 500 is elongated. The device 400 has an opening 504 at one end into which an article 50 can be inserted for heating by the device 400. The article 50 may be fully or partially inserted into the device 400 for heating by the device 400.

[0083] The device 400 may include a user-operable control element 506, such as a button or switch, that operates the device 400 when operated, for example, when pressed. For example, a user may activate the device 400 by pressing the switch 406.

[0084] The device 400 defines a longitudinal axis 509 along which the article 50 may extend when it is inserted into the device 400. The opening 504 is aligned on the longitudinal axis 509.

[0085] Figure 5 shows a schematic cross-sectional view of the aerosol supply system 40. Features described with reference to Figure 5 in the embodiment are applicable to the embodiment described above. The aerosol supply device 400 comprises a power supply 410, a controller 420, and a heating chamber 401 in which the aerosol product 50 is removably received. The heater 301 includes an elongated heater in the form of a pin. In embodiments, the heater 301 includes other elongated configurations such as blades. The heater 301 is housed within a heating chamber. The heater 301 described above with reference to the heater 301 in Figure 5 and Figures 1 to 3 can each be adapted to the details described herein. The heater 301 extends or protrudes within the heating chamber 401.

[0086] The heater 301 can be inserted into the distal end of the aerosol product received in the heating chamber 401 to heat the aerosol product internally during use.

[0087] The aerosol supply devices 100,400 include a heating component 300. The heating component 300 includes a heater 301. The heater includes a heater element 350 (see Figure 6) which is arranged to actuate the heater.

[0088] The heating component 300 is a resistance heating component. The heater 301 is a resistance heating heater. The heater element is at least one track 351 of a resistance heating material, as described later. In such a configuration, the heating assembly comprises a resistance heating generator which includes components for heating the heater element via a resistance heating process. In this case, a current is applied directly to the resistance heater element, which acts as a heating component, and the resulting current flow within the heater element heats the heater element by Joule heating. The resistance heater element includes a resistance material configured to generate heat when a suitable current passes through the resistance heater element, and the heating component comprises electrical contacts for supplying current to the resistance material. In the embodiment, the heater element forms at least a portion of the resistance heater itself. In the embodiment, the resistance heater element transfers heat to the heater, for example, by conduction. By providing a resistance heating component, a compact configuration is possible. Resistance heating provides an efficient configuration.

[0089] Figure 6 shows a heater 301 for use in the aerosol supply device described above. The heating component 300 includes the heater 301. The heater 301 comprises an elongated housing 302 and a heater element 350. The elongated housing 302 is an elongated member that defines a longitudinal axis.

[0090] The housing 302 is formed from a thermally conductive material such as aluminum. Other suitable materials such as stainless steel or ceramics such as aluminum nitride may be used. The elongated housing may include a coating on its outer surface. The elongated housing 302 is configured to transfer heat from the heater element 350 to the heating zone 201a.

[0091] The elongated housing 302 has a base end 303 and a free end 304. The base end 304 is mounted on the device body. The mounting portion 305 of the base end 303 mounts the heater 301. It will be understood that different mounting configurations, such as bonding including fixing, molding, and bonding, may be used. The mounting portion 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0092] The elongated housing 302 comprises a housing body 306, which is tubular in shape. The housing body 306 includes a bore 307, which defines an inner void 308 of the heater 301. The inner void 308 extends in the longitudinal direction. In the embodiment, the inner void 308 is at least partially filled with, for example, a filler. In the embodiment, the inner void 308 is completely filled with, for example, one or more fillers and / or components. In the embodiment, the inner void 308 defines an air gap. An inner surface 309 is defined on the inside of the elongated housing 302. The base end 303 is provided with an open end 310 to the inner void 308.

[0093] The free end 304 of the elongated housing 302 extends toward the proximal end of the heating chamber. The free end 304 of the heating member 301 is closed. The inner gap 308 does not extend through the free end 304. A tip 311 is provided at the free end 304. The tip 311 extends to the apex 312. Other shapes and configurations of the tip 311 may be provided; for example, the tip 311 may define a plane.

[0094] The heater element 350 extends within the heater 301. The heater element 350 extends longitudinally within the elongated housing 302. The heater element 350 is received within the inner void 308. The heater element 350 extends between the base end 303 and the distal end 304. In the embodiment, the heater element 350 partially extends along the length of the inner void 308. In the embodiment, the heater element 350 extends to or beyond the open end 310.

[0095] In the embodiment, the heater element 350 comprises at least one track 351 of resistance heating material. The track 351 of the resistance heating material comprises a resistive member defining the track 351 of the resistance heating material. In the embodiment, the track 351 of the resistance heating material includes an electrical insulating coating, such as ceramic, to electrically insulate the track 351 of the resistance heating material from the elongated housing 302. In the embodiment, the electrical insulating coating is thermally conductive to provide heat transfer from the heater element 350 to the elongated housing 302. In the embodiment, the electrical insulating coating is omitted. In the embodiment, a separate electrical insulating configuration is provided, such as at least one of an electrical insulating member and an electrical insulating filler. In the embodiment, the electrical insulating member and the electrical insulating filler are thermally conductive to provide heat transfer from the heater element 350 to the elongated housing 302.

[0096] Referring to Figures 7 and 8, a first embodiment of the heater element 350 has the form of a track 351 of resistance heating material formed on a helical coil. The track 351 of resistance heating material extends from a first end 600 to a second end 602 of the coil. The track 351 of resistance heating material is formed from a continuous length of resistance heating material. A first portion 608 of the helical coil extends from a first end 600 to a first resistance change position 604. The first portion 608 of the helical coil has a circular cross-sectional profile having a profile with a diameter D1.

[0097] The second portion 610 of the helical coil extends from the first resistance change position 604 to the second resistance change position 606. The second portion 610 of the helical coil has a circular cross-sectional profile having a profile with a diameter D2.

[0098] A third portion 612 of the helical coil extends from a second resistance change position 606 to a second end 602. The third portion 612 of the helical coil has a circular cross-sectional profile having a profile with a diameter D1.

[0099] In some embodiments, diameter D2 is greater than diameter D1, and as a result, the temperatures at which the first and third portions 608,612 of the helical coil are heated are the same as those at which the second portion 610 is heated.

[0100] In some other embodiments, diameter D2 is smaller than diameter D1, and as a result, the temperatures at which the first and third portions 608,612 of the helical coil heat up are the same as those at which the second portion 610 heats up. In some other examples not shown, the third portion 612 has a circular cross-sectional profile with a diameter D3. In some embodiments, D3 is less than D1 and less than D2. This has the effect that the third portion 612 is heated to a higher temperature than the first portion 608, and the first portion 608 is heated to a higher temperature than the second portion 610.

[0101] In the embodiment shown in Figure 7, the change in diameter of the continuous length of the resistance heating material at the first and second resistance change positions 604 and 606 is a stepped change. That is, the change in diameter between D1 and D2 occurs over a very small length of the continuous length of the resistance heating material, for example, less than 1.0 mm.

[0102] In other examples not illustrated, the change between D1 and D2 may be gradual over distances such as at least 1.0 mm, 1.0 mm to 3.0 mm, or 1.0 mm to 5.0 mm.

[0103] In other examples not shown, the first, second, and third portions 608, 610, and 612 of the heating coil 351 each have a rectangular cross-sectional profile. It will be understood that other coil configurations are also possible. In such examples, if the change in cross-section is gradual, the cross-sectional profile at any point along the gradual change may be the same cross-sectional profile as at the ends of the gradual change.

[0104] The heating element 350 includes electrical connection paths 352 and 353. The electrical connection paths 352 and 353 are connected to connectors (not shown) at each end 600 and 602 of the resistance heating material track 351, respectively. The base electrical connection path 352 extends from the distal end of the resistance heating material track 351. The return electrical connection path 353 extends from the proximal end of the resistance heating material track 351. The return electrical connection path 353 extends through the space defined by the helical coil in a direction substantially parallel to the longitudinal axis of the helical coil. The electrical connection paths 352 and 353 are wires that connect to the device and have lower resistance than the resistance heating material track 351 in order to reduce heating of the device electronics.

[0105] In some other examples not shown, the return electrical connection path 353 extends outside the helical coil.

[0106] In some other examples not shown, the body of the elongated housing 302 constitutes at least part of the return electrical connection path 353.

[0107] In embodiments not shown, the electrical connection path is formed integrally with the track 351 of the resistance heating material, for example, as a single wire.

[0108] Track 351 of the resistance heating material is formed from a resistance material such as a nickel / chromium alloy such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0109] The heater element 350 can be positioned within the inner void 308 of the elongated housing 302, and the connection paths 352 and 353 are configured to extend out of the inner void 308 through the suction end 310 of the housing 302.

[0110] Referring to Figure 8, the heater element 350 is fixed in place within the inner void 308 by the mass of the filler material 360. The mass of filler material extends between the inner surfaces of the housing body 306 and surrounds a portion of the heater element 350. The mass of filler material 360 may be a potting compound.

[0111] In some other examples not shown, a single lump of filler material is present, filling the portion of the inner void not occupied by the heater element 350 and any electrical connection paths.

[0112] Referring to Figures 9 and 10, a second embodiment of the heater element 350 includes a substrate 700, on which a continuous track 351 of resistance heating material is supported on the main surface 702 of the substrate 700. Figure 8 shows the substrate 700 in a flat configuration.

[0113] The track 351 of the resistance heating material extends from a first end 704 to a second end 706. The track 351 of the resistance heating material is formed from a plurality of alpha portions 708 and a plurality of beta portions 710, where the alpha portions and beta portions 708,710 alternate along the length of the track 351 of the resistance heating material (for clarity, not all of the alpha portions and beta portions 708,710 are labeled). The alpha portions 708 have a quadrilateral, e.g., square cross-sectional profile with cross-sectional area A1. The beta portions 710 have a rectangular cross-sectional profile with cross-sectional area A2. Cross-sectional area A1 is greater than cross-sectional area A2, and as a result, the temperature heated by the alpha portions 708 is lower than the temperature heated by the beta portions 710.

[0114] In Figure 9, the change in the cross-sectional area of ​​the resistance heating material track 351 at the intersection of the alpha and beta portions is a stepped change. That is, the change in cross-sectional area between regions A1 and A2 occurs over a very short length of the track, for example, less than 1.0 mm.

[0115] In other examples not shown, the change between cross-sectional areas A1 and A2 may be gradual, for example, over a distance of at least 1.0 mm, 1.0 mm to 3.0 mm, or 1.0 mm to 5.0 mm.

[0116] In other examples not shown, the alpha and beta portions 708, 710 each have circular or other shaped cross-sectional profiles. It will be understood that other configurations of the continuous length of the resistance heating material 351 are also possible.

[0117] The heating element 350 includes electrical connection paths 352 and 353. The electrical connection paths 352 and 353 are connected to connectors (not shown) at each end 704 and 706 of the track 351 of the resistance heating material. The connection paths are not supported on the substrate 700.

[0118] In embodiments not shown, the electrical connection path is formed integrally with the track 351 of the resistive heating material, for example, as a single ribbon of the resistive material, and is supported on the substrate 700.

[0119] Track 351 of the resistance heating material is formed from a resistance material such as a nickel / chromium alloy such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0120] The base material 700 is rolled onto the tube (as shown in Figure 10) with its surface 702 on the radially inner surface of the tube, and the portion of the base material 700 adjacent to the edge 714 overlapping with the portion of the base material adjacent to the edge 712. The connecting paths 352 and 353 extend from the end of the tube.

[0121] The tube can be positioned within the inner void 308 of the elongated housing 302, and the connection paths 352 and 353 are configured to extend out of the inner void 308 through the suction end 310 of the housing 302.

[0122] In some other examples not shown, where the connection path is integrally formed with the track 351 of the resistance heating material, a portion of the tube of the base material 700 may protrude from the inner void 308.

[0123] Referring to Figure 11, a third embodiment of the heater element 350 includes a base material 700, on which a continuous track 351 of resistance heating material is supported on the main surface 702 of the base material 700. The base material 700 is rectangular with opposing side edges 712 and 714 and opposing side edges 716 and 718.

[0124] The track 351 of the resistance heating material extends from a first end 704 to a second end 706. The track 351 of the resistance heating material is formed from first and second alpha portions 708A, 708B and a plurality of beta portions 710. The alpha portion 708 has a quadrilateral cross-sectional profile with a cross-sectional area A1, for example, a square. The beta portion 710 has a different quadrilateral cross-sectional profile with a cross-sectional area A2, for example, a rectangular. The cross-sectional area A1 is larger than the cross-sectional area A2, and as a result, the temperature heated by the alpha portion 708 is lower than the temperature heated by the beta portion 710.

[0125] In some other examples not shown, the cross-sectional area A1 is smaller than the cross-sectional area A2, and as a result, the temperature at which the alpha portion 708 heats is higher than the temperature at which the beta portion 710 heats.

[0126] The first and second ends 704 and 705 of the track 351 of the resistance heating material are located adjacent to the edge 716 of the base material 700, close to but spaced apart from the edges 714 and 712, respectively. The alpha portion 708A extends from the first end 704 in a direction substantially parallel to the edge 714 to a position 720 that is close to but spaced apart from the edge 718. The alpha portion 708A then extends in a direction substantially parallel to the edge 718 to position 722. Multiple beta portions 710 extend from a joint 724 located in part of the alpha portion 708A between positions 720 and 722.

[0127] The alpha portion 708B extends from the second end 706 toward the edge 714 in a direction substantially parallel to the edge 716, but stops at position 728 before intersecting with the alpha portion 708A. The alpha portion 708B includes a plurality of joints 726 between the alpha portion 708B and the beta portion 710.

[0128] In Figure 11, the change in the cross-sectional area of ​​the track 351 of the resistance heating material at the joints 724 and 726 between the alpha and beta portions is a stepped change. That is, the change in cross-sectional area between areas A1 and A2 occurs over a very short distance, for example, less than 1.0 mm from the first end 704, with the cross-sectional area of ​​joint 724 decreasing and the cross-sectional area of ​​joint 726 increasing.

[0129] In other examples not shown, the change between cross-sectional areas A1 and A2 may be gradual, for example, over a distance of at least 1.0 mm, 1.0 mm to 3.0 mm, or 1.0 mm to 5.0 mm.

[0130] In other examples not shown, the alpha and beta portions 708, 710 each have circular or other shaped cross-sectional profiles. It will be understood that other configurations of the continuous length of the resistance heating material 351 are also possible.

[0131] The heating element 350 includes electrical connection paths 352 and 353. The electrical connection paths 352 and 353 are connected to connectors (not shown) at each end 704 and 706 of the track 351 of the resistance heating material. The connection paths are not supported on the substrate 700.

[0132] In embodiments not shown, the electrical connection path is formed integrally with the track 351 of the resistive heating material, for example, as a single ribbon of the resistive material, and is supported on the substrate 700.

[0133] Track 351 of the resistance heating material is formed from a resistance material such as a nickel / chromium alloy such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0134] In the same manner as described in relation to the embodiments shown in Figures 9 and 10, the substrate 700 is rolled into a tube (again, as shown in Figure 10) such that the surface 702 of the substrate 700 is on the radially inner surface of the tube, and the portion of the substrate 700 adjacent to the edge 714 of the substrate overlaps with the portion of the substrate adjacent to the edge 712 of the substrate. Connection paths 352, 353 extend from the end of the tube.

[0135] The tube can be positioned within the inner void 308 of the elongated housing 302, and the connection paths 352 and 353 are configured to extend out of the inner void 308 through the suction end 310 of the housing 302.

[0136] In some other examples not shown, where the connection path is integrally formed with the track 351 of the resistance heating material, a portion of the tube of the base material 700 may protrude from the inner void 308.

[0137] In the embodiments described above, the heating element is a resistance heating element. Other types of heating elements, such as induction heating, are used in the embodiments. The device configuration is substantially as described above, so a detailed description is omitted.

[0138] An induction heating system comprises various components for heating the aerosol-generating material of an article by an induction heating process. Induction heating is a process of heating a conductive heating element (such as a susceptor) by electromagnetic induction. An induction heating system may comprise an induction element, for example, one or more inductor coils, and a device for passing a fluctuating current, such as an alternating current, through the induction element. The fluctuating current within the induction element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor (heating element) that is appropriately positioned relative to the induction element. Compared to heating by conduction, for example, induction heating generates heat inside the susceptor, enabling rapid heating. Furthermore, it does not require any physical contact between the induction element and the susceptor, increasing the freedom of construction and application.

[0139] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0140] In the embodiment, the heater of the aerosol supply system is part of the aerosol product, rather than part of the aerosol supply device. The heating element may be a resistive heating element, for example, in the form of a resistive coil as described above, provided as part of the aerosol product. Electrical connections may allow current to flow through the resistive heating element.

[0141] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A heater for an aerosol supply device configured to heat an article containing an aerosol generating material, An elongated housing having a longitudinal axis, A heater element positioned within the elongated housing, comprising a first end and a second end, and at least one track of heater material extending between the first end and the second end, A heater comprising, wherein at least a portion of at least one track of the heater material includes a portion of the at least one track that changes the electrical resistance.

2. The heater according to claim 1, wherein the at least one track of the heater material is divided into at least two tracks of the heater material with respect to at least a portion of the length of the track.

3. The heater according to claim 1 or 2, wherein the at least one variable portion of the electrical resistance of the track is positioned on the track such that when the heater element is activated, the heater element produces a predetermined temperature profile along the length of the track.

4. The heater according to any one of claims 1 to 3, wherein the change in the electrical resistance of the track is the result of a change in the cross-section of the track.

5. The heater according to any one of claims 1 to 4, wherein the track has at least two variable parts of the electrical resistance.

6. The heater according to any one of claims 1 to 5, wherein the at least one change in electrical resistance is a stepped change at a single position on the track of the heater material.

7. The heater according to any one of claims 1 to 6, wherein the at least one variable portion of the electrical resistance is a continuous variable portion over the length of the track of the resistive material.

8. The heater according to any one of claims 1 to 7, wherein the heater element further comprises a base material, and the tracks or each track of the heater material are supported on the base material.

9. The heater according to claim 8, wherein the base material and the tracks or each track of the heater material are flexible.

10. The heater according to claim 8 or 9, wherein the base material is elastically flexible.

11. The heater according to any one of claims 1 to 10, wherein the housing defines an internal void, and the heater element is configured such that at least 75%, at least 80%, at least 90%, and 100% of the heater element fits into the internal void.

12. The heater according to claim 11, as dependent on any one of claims 8 to 10, wherein the heater element and the substrate are configured such that the substrate biases the track or each track of the heater material with respect to one or more of the surfaces of the housing that define the inner void.

13. The heater according to claim 11 or 12, wherein the heater comprises at least one mass of material, the mass of material is positioned within the hollow bore, and the at least one mass of material holds at least a portion of the heater element in a fixed position relative to the housing.

14. The heater according to any one of claims 11 to 13, wherein the hollow bore is filled with a mass of the material, and the entire heater element positioned within the hollow bore is held in a fixed position relative to the housing.

15. The heater according to claim 13 or 14, wherein the mass of the material comprises an adhesive or a potting compound.

16. The heater according to any one of claims 1 to 15, wherein the heater material is a resistance heater material and the heater is a resistance heater.

17. An aerosol supply device configured to heat an article for generating an aerosol, comprising a heater according to any one of claims 1 to 16.

18. A system comprising a heater according to any one of claims 1 to 16 and an article containing an aerosol-generating material.

19. A method for generating an aerosol, comprising the steps of: providing an aerosol supply device comprising a heater according to any one of claims 1 to 16 and a heating chamber including a receiving portion; and inserting an aerosol product at least partially into the receiving portion of the heating chamber.

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