Heaters for aerosol supply devices

Abstract

A heater (301) for an aerosol supply device (100) configured to heat an article (50) containing an aerosol generating material is disclosed. The heater (301) includes a substrate (600) and a heating element including at least one track (612) of the heating material. The substrate (600) has a first main surface (604) and a second main surface (606), and at least one track (612) of the heating material is supported on the first main surface (604). The substrate (600) is elongated and configured as a roll.

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 generate tobacco smoke by burning tobacco during use. 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 devices or products are known. A common 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 a base material and a heating element including at least one track of a heating material. The base material has a first main surface and a second main surface, and at least one track of the heating material is supported on the first main surface. The base material is elongated and configured as a roll.

[0005] The roll may include folds. The roll may be a folded roll.

[0006] The first and second main surfaces of the substrate may be the surfaces of the substrate having the maximum surface area.

[0007] The base material roll may have a cylindrical or substantially cylindrical form. The base material roll may have a cylindrical or substantially cylindrical form formed by winding or rotating the base material around or around itself without folding the base material.

[0008] A roll of substrate containing one or more folds may be similar to a roll of substrate, with the difference being that one or more folds are introduced into the substrate with each winding or rotation, with the effect that the cross-section of the roll containing one or more folds is non-circular. The cross-section of the roll containing one or more folds may be approximately triangular, approximately square, approximately rectangular, or approximately polygonal.

[0009] The heating material track may include a continuous length of heating material formed on or supported on the first main surface of the substrate.

[0010] The track may extend between a first track end and a second track end. The track may include a single path for heating material between the first track end and the second track end.

[0011] The base material may be a sheet material.

[0012] According to one embodiment, a heater for an aerosol supply device configured to heat an article containing an aerosol-generating material is provided, comprising a substrate and a heating element including at least one track of heater material. The substrate has a first principal surface and a second principal surface, and at least one track of heating material is supported on the first principal surface. At least a first portion of the substrate is in contact with and overlaps with at least one of the second portion of the substrate.

[0013] At least a first portion of the substrate may be in contact with a second portion of the substrate. At least a first portion of the substrate may overlap with a second portion of the substrate. At least a first portion of the substrate may be in contact with and overlap with a second portion of the substrate.

[0014] The base material may be in a rolled configuration.

[0015] The rolled structure may include folds.

[0016] The base material may include a sheet of metal or a metal alloy. The metal may be aluminum or an aluminum alloy.

[0017] The substrate may be configured to be insertable into the aerosol product.

[0018] The substrate may be rolled up to a number of times sufficient to allow the created roll to have structural strength that enables it to press the substrate into the aerosol product without damaging or deforming the substrate.

[0019] The substrate may be rolled and folded a number of times sufficient to ensure that the resulting roll has structural strength that allows it to press the substrate into the aerosol product without damaging or deforming the substrate.

[0020] At least one track of the resistive material may comprise a core of heating material that is at least partially surrounded by an electrically insulating material.

[0021] The substrate may define a hollow bore. The substrate may be rolled or folded around the hollow bore.

[0022] At least a large portion of the hollow bore may be surrounded by one layer of the substrate.

[0023] At least a large portion of the hollow bore may be surrounded by two or more layers of the substrate.

[0024] The heater may comprise a support element. The support element may occupy a hollow bore.

[0025] Rolling or folding the substrate forms the outer surface of the substrate on at least a part of the first major surface of the substrate.

[0026] Rolling or folding the substrate may form the outer surface of the substrate on at least a part of the second major surface of the substrate.

[0027] The first major surface of the substrate may comprise a support portion. At least one track of the heating material may be supported on the support portion.

[0028] The outer periphery of the support portion may be the shortest line on the first major surface that extends around the track of the heating material or surrounds the entire track.

[0029] The first and second major surfaces of the substrate may be rectangular. The outer periphery of the support portion may be bounded by a rectangle that extends around the track of the heating material or encloses the entire track and has sides parallel to the edges of the first and second major surfaces of the substrate.

[0030] The support portion may comprise at least 75% of the area of the first major surface.

[0031] The support portion may comprise at least 80% of the area of the first major surface.

[0032] The support portion may comprise at least 90% of the area of the first major surface.

[0033] The support portion may comprise at least 95% of the area of the first major surface.

[0034] The support portion may comprise the area of the first major surface.

[0035] The first main surface of the substrate may have at least one clear portion in which no track of heating material is supported, the support portion covers the support area of ​​the first main surface, at least one clear portion covers the clear area of ​​the first main surface, and the support area is greater than or equal to the clear area. In such embodiments, the clear area is the cumulative total area of ​​the clear portions if there are two or more clear portions.

[0036] The first main surface of the substrate may have at least one clear portion in which no track of heating material is supported, the support portion covers the support area of ​​the first main surface, at least one clear portion covers the clear area of ​​the first main surface, and the support area is smaller than the clear area. In such embodiments, the clear area is the cumulative total area of ​​the clear portions if there are two or more clear portions.

[0037] The clear portion may be configured to extend at least once around the support portion when the substrate is configured as a roll or a folded roll.

[0038] The heater may be a resistance heater, and the heater material may be a resistance heater.

[0039] The heater may be an induction heater.

[0040] The track for the heating material may be an induction heating element.

[0041] According to one embodiment, an aerosol supply device is provided which is configured to heat an article containing an aerosol generating material, and which includes the heater described above.

[0042] The aerosol supply device may include a heating chamber equipped with a heater.

[0043] The aerosol supply device may comprise a power supply, a controller, and a heating chamber in which the aerosol product is removably received.

[0044] The power supply may be aligned along the longitudinal axis of the heating chamber.

[0045] The power supply may be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0046] The aerosol supply device may be configured for wireless charging.

[0047] 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.

[0048] The aerosol supply system may include a charging unit having a cavity for removably receiving an aerosol supply device.

[0049] The charging unit may include a movable lid that covers the aerosol supply device in a closed configuration.

[0050] The charging unit may include a user display.

[0051] 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.

[0052] In another embodiment, a method for generating an aerosol is provided, comprising the steps of: providing an aerosol supply device equipped with a heater as described above; and inserting at least partially the aerosol product into a receiving portion of a heating chamber.

[0053] The embodiments of the heaters and devices of the present disclosure described above may, as necessary, include one or more, all, or combinations of the features or embodiments described above. The embodiments of the methods of the present disclosure may, as necessary, include one or more, all, or combinations of the features or embodiments described above.

[0054] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0055] [Figure 1] This is a perspective view of an aerosol supply system, including 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 figure shows a schematic embodiment of a substrate that forms part of the heater of the device shown in Figure 1 or Figure 4. [Figure 7] This is a schematic diagram of a first embodiment of the heater of the device shown in Figure 1 or Figure 4. [Figure 8] This is a schematic diagram of the first part of a second embodiment of the heater of the device shown in Figure 1 or Figure 4. [Figure 9] This is a schematic diagram of the second part of a second embodiment of the heater of the device shown in Figure 1 or Figure 4. [Modes for carrying out the invention]

[0056] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the constituent aerosol-generating materials (or components of those materials) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0057] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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), and may or may not contain active substances and / or flavorings.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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 base portion 301a may have a smaller cross-sectional profile than the rest of the heater 301, for example, a smaller diameter. As a result, the effect of heat conduction from the body of the heating member 301 through the base end of the heating member 301 mounted on the mounting portion 305 is reduced, suppressed, or mitigated. Consequently, the flow of heat or thermal energy from the heating member 301 to the mounting portion 305 is reduced. Therefore, the reduced cross-sectional profile can be considered to function as a thermal break-off portion that reduces heat release from the heating member 301 to the mounting portion 305.

[0085] The heater 301 is upright inside the heating chamber 201. The heater 301 is upright from its distal end.

[0086] The heater 301 includes an elongated heater in the form of a roll of substrate 600 (see Figure 6). 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.

[0087] The housing comprises a housing wall 200a. The housing wall 200a extends along 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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 comprises a power supply 410, a controller 420, and a heating chamber 401 in which the aerosol product 50 is removably received.

[0101] The one-piece device in Figure 5 shows a power supply 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of the one-piece aerosol generating device, the power supply is aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0102] The heater 301 includes an elongated heater in the form of a roll of the substrate 600 (see Figure 6). The heater 301 is located within the 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.

[0103] The heater 301 can be inserted into the distal end of the aerosol product 50, which is received in the heating chamber 401, to heat the aerosol product internally during use.

[0104] The aerosol supply devices 100 and 400 include a heating component 300. The heating component 300 includes a heater. The heater 301 acts as a heater.

[0105] The heating component 300 is a resistance heating component. The heater is a resistance heating heater. The track of heating material is a resistance heating element, as described later. In such a configuration, the heating assembly comprises a resistance heating generator which includes components for heating the heating element via a resistance heating process. In this case, a current is applied directly to the resistance heating element, which acts as a heating component, and the resulting current flow within the heating element heats the heating element by Joule heating. The resistance heating element includes a resistance material configured to generate heat when a suitable current passes through the resistance heating element, and the heating component comprises electrical contacts for supplying current to the resistance material. In the embodiment, the heating element forms at least a part of the resistance heater itself. In the embodiment, the resistance heating element transfers heat to the heater 301, for example, by conduction. By providing a resistance heating component, a compact configuration is possible. Resistance heating provides an efficient configuration.

[0106] The resistive material may be, for example, a nickel / chromium alloy such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0107] Figure 6 shows an embodiment of the base material 600 of the heating element 301 for use in the aerosol supply device described above. The base material 600 comprises first and second main surfaces 604, 606 and is shown in Figure 6 before being formed into a roll or folded roll.

[0108] The first main surface 604 includes a support region (also called a support portion) 608 defined by a boundary 610. A track 612 of resistive material is supported on the support region 608. The track 612 extends from a first connector 614 to a second connector 616 via a meandering path. The meandering path comprises a plurality of long track elements 612A and a plurality of short track elements 612B (for clarity, not all of the long track elements 612A and short track elements 612B are labeled). In some embodiments, the track is surrounded by a layer of electrical insulating material, such as dielectric material. This is preferable as it helps ensure that there are no short circuits between the heating material and the housing or between separate parts of the track.

[0109] An electrical connection path 352 is connected to the first connector 614, and an electrical connection path 353 is connected to the second connector 614.

[0110] The first main surface 604 also includes a clear region (also called a clear portion) 618 which is part of the first main surface 604 and not a support region 608.

[0111] Referring to Figures 6 and 7, to form the first embodiment of the heater 301, the base material 600 is formed into a roll, and the base material 600 is rolled around its edge 620 around a hollow bore 621, with the first main surface 604 facing radially inward within the roll. The relative sizes of the support region 608 and the clear region 618 are such that the clear region 618 overlaps once around the rolled portion of the base material 600, including the support region 608. Alternatively, the edge 626 of the base material 600 covers the edge 628 of the support region 608.

[0112] The first main surface 604 further includes a second portion 629 that at least partially covers the first portion 627 on the second main surface 606 when the substrate 600 is formed into a roll.

[0113] Connection paths 352,353 extend from the first end 622 of the roll. The first end 622 of the roll is adapted to mount a heater such that the heater extends into the heating chambers 201,401.

[0114] A tip 602 is attached to the second end 624 of the roll. The tip 602 is configured to facilitate the insertion of the heater 301 into the distal end of the aerosol product 50 to be received in the heating chambers 201,401. This allows the heater 301 to heat the aerosol product internally.

[0115] The tip portion 602 is configured to cover the edge of the base material 600 that forms the end portion 624. This prevents the insertion of the heater 301 from damaging the edge of the base material.

[0116] In some alternative embodiments not shown, the substrate 600 may be rolled such that the second main surface faces radially inward within the roll of the substrate.

[0117] In some alternative, not-illustrated embodiments, the relative sizes of the support region 608 and the clear region 618 are such that the clear region 618 overlaps multiple times with at least a portion of the rolled portion of the substrate 600 containing the support region 608.

[0118] In some alternative, not-illustrated embodiments, the tip portion 602 is absent.

[0119] Referring to Figures 8 and 9, to form a second embodiment of the heater 301, the substrate 600 of Figure 6 is formed into a roll having a fold 636 around the support element 630. The substrate 600 is rolled around the stem 632 of the support element 630, with the edge 620 of the substrate 600 initiating the roll. The fold 636 is introduced into the roll as the substrate 600 extends around the corner 634 of the stem 632.

[0120] The roll is formed such that the first main surface 604 of the roll faces radially outward.

[0121] The relative sizes of the support area 608 and the clear area 618 are such that the clear area 618 overlaps the outer circumference of the roll-shaped portion of the base material 600, which includes the support area 608, approximately twice.

[0122] The connecting paths 352 and 353 extend from the first end 622 of the roll.

[0123] The first end 638 of the stem 632 is adapted to mount a heater so that the roll extends into the heating chamber 201,401.

[0124] The second end 640 of the stem 632 is formed into a tip 602. The tip 602 is configured to facilitate the insertion of the heater 301 into the distal end of the aerosol product 50 to be received in the heating chambers 201,401.

[0125] The tip portion 602 is configured to cover the edge of the base material 600 that forms the end portion 624. This prevents the insertion of the heater 301 from damaging the edge of the base material.

[0126] In some alternative embodiments not shown, the substrate 600 may be rolled such that the second main surface 606 faces radially outward within the roll of the substrate.

[0127] In some alternative, not-illustrated embodiments, the relative sizes of the support region 608 and the clear region 618 are such that the clear region 618 overlaps at least one or more times with the periphery of the rolled portion of the substrate 600 containing the support region 608.

[0128] An advantage of such an embodiment is that the clear area of ​​the substrate provides a support area, and therefore the track of the heating material supported on the support area is protected from damage caused by external forces and general wear on the outer surface of the substrate.

[0129] In some alternative, not-illustrated embodiments, the tip portion 602 is absent.

[0130] The support element 630 is formed from a material with low thermal mass so as to absorb little of the thermal energy generated by the track of the resistive material when electricity flows along the track.

[0131] Referring to the embodiment of the heater 301 shown in Figures 6 to 9, the heating component 300 includes electrical connection paths 352 and 353. The electrical connection paths 352 and 353 extend from connections 614 and 616 at both ends of the heating element 350.

[0132] In embodiments not shown, the electrical connection path is formed integrally with the heating material track 612, for example, as a single wire.

[0133] 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.

[0134] 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 heater (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 member) that is appropriately positioned relative to the induction element. In induction heating, compared to heating by conduction, for example, heat is generated inside the susceptor, enabling rapid heating. Furthermore, no physical contact is required between the induction element and the susceptor, increasing the freedom of construction and application.

[0135] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the track of the heating material.

[0136] 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.

[0137] 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, The device comprises a base material and a heating element including at least one track of a heating material, The substrate has a first main surface and a second main surface, At least one track of the heating material is supported on the first main surface, A heater in which the aforementioned base material is long and narrow and configured as a roll.

2. The heater according to claim 1, wherein the roll includes a fold.

3. A heater for an aerosol supply device configured to heat an article containing an aerosol generating material, The device comprises a base material and a heating element including at least one track of heating material, The substrate has a first main surface and a second main surface, At least one track of the heating material is supported on the first main surface, A heater in which at least a first portion of the substrate is in contact with and overlaps with at least one of the second portion of the substrate.

4. The heater according to claim 3, wherein the base material has a roll-like configuration.

5. The heater according to claim 3 or 4, wherein the roll-shaped configuration includes folds.

6. The heater according to any one of claims 1 to 5, wherein the base material includes a sheet of metal or a metal alloy.

7. The heater according to any one of claims 1 to 6, wherein the substrate is configured to be insertable into the aerosol product.

8. The heater according to any one of claims 1 to 7, wherein at least one track of the resistive material comprises a core of heater material at least partially surrounded by an electrical insulating material.

9. The heater according to any one of claims 1 to 8, wherein the substrate defines a hollow bore, and the substrate is rolled or folded around the hollow bore.

10. The heater according to claim 9, wherein at least a large portion of the hollow bore is surrounded by one layer of the substrate.

11. The heater according to claim 9, wherein at least a large portion of the hollow bore is surrounded by two or more layers of the base material.

12. The heater according to any one of claims 9 to 11, wherein the heater comprises a support element, and the support element occupies the hollow bore.

13. The heater according to any one of claims 1 to 12, wherein forming the base material into a roll shape or folding it causes at least a portion of the first main surface of the base material to form the outer surface of the base material.

14. The heater according to any one of claims 1 to 12, wherein forming the base material into a roll shape or folding it causes at least a portion of the second main surface of the base material to form the outer surface of the base material.

15. The heater according to any one of claims 1 to 14, wherein the first main surface of the base material is provided with a support portion, and at least one track of the heating material is supported on the support portion.

16. The heater according to claim 15, wherein the support portion includes one of at least 75%, at least 80%, at least 90%, at least 95%, and 100% of the area of ​​the first main surface.

17. The heater according to claim 15, wherein the first main surface of the substrate comprises at least one clear portion, and no track for the heating material is supported in any of the clear portions, the support portion covers the support region of the first main surface, the at least one clear portion covers the clear region of the first main surface, and the support region is greater than or equal to the clear region.

18. The heater according to claim 15, wherein the first main surface of the substrate comprises at least one clear portion, and no track for the heating material is supported in any of the clear portions, the support portion covers a support area of ​​the first main surface, the at least one clear portion covers a clear area of ​​the first main surface, and the support area is smaller than the clear area.

19. The heater according to claim 18, wherein the clear portion is configured to extend at least once around the support portion when the base material is configured as a roll, a folded roll, or in a folded state.

20. The heater according to any one of claims 1 to 19, wherein the heater is a resistance heating heater and the heater material is a resistance heating material.

21. An aerosol supply device configured to heat an aerosol product for generating an aerosol, comprising a heater according to any one of claims 1 to 20.

22. A system comprising the aerosol supply device according to claim 21 and an article containing an aerosol generating material.

23. A method for generating an aerosol, comprising the steps of providing an aerosol supply device comprising a heating chamber including a receiving portion and a heater according to any one of claims 1 to 20, and inserting an aerosol product at least partially into the receiving portion of the heating chamber.

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