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 an elongated housing (302) having a longitudinal axis and a heating element (350) comprising a continuous length of heating material (351). The continuous length of heating material (351) follows a meandering path.

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 for 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-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 exchange 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 comprising an elongated housing having a longitudinal axis and a heating element including a continuous length of heating material. The continuous length of heating material follows a meandering path. It should be understood that the meandering path is a non-linear path including one or more changes in the direction of the center line of the path.

[0005] ]A meandering path may include two or more changes in direction.

[0006] A continuous length of heating material may include multiple parts and multiple intersections of length, the intersections extending between longitudinally adjacent parts, and the parts and intersections alternating along the length of the heating material. All parts and intersections may form part of a single continuous length of heating material.

[0007] Each of the parts may be linear, and each part extends at least partially in a direction parallel to the longitudinal axis of the elongated housing.

[0008] Each of the parts may be curved, and each part extends at least partially in a direction parallel to the longitudinal axis of the elongated housing.

[0009] At least one of the parts may be straight, and at least one of the parts may be curved. Each part may extend at least partially in a direction parallel to the longitudinal axis of the elongated housing.

[0010] At least one intersection may be a curved link extending between adjacent ends in the longitudinal direction of adjacent portions of the length of the heating material. The length of the curved link may be shorter than the length of any portion between which the curved link extends.

[0011] At least one intersection may consist of a linear link extending between adjacent ends in the longitudinal direction of adjacent portions of the length of the heated material. The length of the linear link may be shorter than the length of any portion between which the linear link extends.

[0012] The length of a straight or curved link may be at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% shorter than the length of any portion in which the straight or curved link extends.

[0013] At least one intersection may be configured such that the angle between the intersection between adjacent parts and the projected longitudinal axes of a portion of the longitudinally adjacent part intersecting the intersection is between 0 and 45 degrees.

[0014] At least one intersection may be configured such that the angle between the intersection between longitudinally adjacent portions and the projected longitudinal axis of a portion of the adjacent portion intersecting it is greater than 45 degrees and less than or equal to 90 degrees.

[0015] Each intersection may have the same configuration.

[0016] Each intersection may be configured such that the angle between the intersection between adjacent parts and the projected longitudinal axis of a longitudinally adjacent part intersecting the intersection is one of 0 degrees, 45 degrees, and 90 degrees.

[0017] The heater may include a base material. At least a portion of a continuous length of heating material may be supported on the surface of the base material.

[0018] The heating material, which is a continuous length, may be an electrical resistance material. The heater may be a resistance heater.

[0019] The housing has a base end and a free end. The free end may be configured to penetrate an article containing aerosol-generating material.

[0020] A continuous length of heating material may have a first end and a second end. The intersection closest to the first end of the continuous length of heating material in the longitudinal direction and the intersection closest to the second end of the continuous length of heating material in the longitudinal direction may both be closer to the free end of the housing than to the base end of the housing. In this regard, the longitudinal direction is based on the continuous length of heating material.

[0021] The housing may define a bore that extends in the longitudinal direction. The base end of the housing may define the open end of the bore. At least a portion of the continuous length of heating material may be positioned within the bore.

[0022] At least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or 100% of the continuous length of heating material is positioned within the bore.

[0023] The heater may include at least one mass of material. The at least one mass may be configured to hold at least a portion of the continuous length of heating material in a fixed position relative to the housing.

[0024] The mass of material may be configured such that the entire continuous length of heating material is held in a fixed position relative to the housing.

[0025] The mass of material may be an adhesive or a potting compound.

[0026] The heater may be an induction heating heater.

[0027] The continuous length of heating material may be an induction heating element.

[0028] According to one aspect, there is provided an aerosol supply device configured to heat an article containing an aerosol-forming material, the aerosol supply device comprising the heater described above.

[0029] The aerosol supply device may comprise a heating chamber in which the heater is provided.

[0030] The aerosol supply device may comprise a power source, a controller, and a heating chamber in which the aerosol-forming article is removably received.

[0031] The power source may be aligned along the longitudinal axis of the heating chamber.

[0032] The power supply may 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.

[0034] 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.

[0035] 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.

[0036] The aerosol supply system may include a charging unit having a cavity for removably receiving an aerosol supply device.

[0037] The charging unit may include a movable lid that covers the aerosol supply device in a closed configuration.

[0038] The charging unit may include a user display.

[0039] 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.

[0040] 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.

[0041] The heating and device embodiments of this disclosure may, as necessary, include one or more of the features or embodiments described above. The method embodiments of this disclosure may, as necessary, include one or more of the features or embodiments described above.

[0042] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0043] [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 details of the first embodiment of the heating element of the heater shown in Figure 6. [Figure 8] This figure shows the first detail of the second embodiment of the heating element of the heater shown in Figure 6. [Figure 9] This figure shows the second detail of the second embodiment of the heating element of the heater shown in Figure 6. [Figure 10] This figure shows the details of the third embodiment of the heating element of the heater shown in Figure 6. [Figure 11] This figure shows the details of the second embodiment of the heating element of the heater shown in Figure 6. [Modes for carrying out the invention]

[0044] 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.

[0045] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] The heater 301 comprises an elongated heating element in the form of a pin. In other embodiments, the heater 301 includes other elongated components 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.

[0074] The housing comprises a housing wall 200a. The housing wall 200a extends 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] The aerosol supply devices 100,400 include a heating component 300. The heating component 300 includes a heater 301. The heater 301 includes a heating element 350 (see Figure 6), such as a resistance heating material of a certain length, which is arranged to actuate the heater 301.

[0092] The heating component 300 is a resistance heating component. The heater is a resistance heating heater. Heating elements such as heating coils, described later, are resistance heating elements. In such a configuration, the heating assembly comprises a resistance heating generator which includes components for heating the heating elements via a resistance heating process. In this case, 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 portion of the resistance heating member itself. In the embodiment, the resistance heating element transfers heat to the heating element, for example, by conduction. Providing a resistance heating component enables a compact configuration. Resistance heating provides an efficient configuration.

[0093] 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 heating element 350. The elongated housing 302 is an elongated member defining the longitudinal axis A.

[0094] 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 heating element 350 to the heating zone 201a.

[0095] 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.

[0096] The elongated housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body 306 comprises a bore 307. The bore 307 defines an inner void 308 of the heater 301. The inner void 308 extends longitudinally in the direction of axis A. 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.

[0097] The free end 304 of the elongated housing 302 extends toward the proximal end of the heating chamber. The free end 304 of the heater 301 is closed. The inner gap 308 does not extend through the free end 304. A tip 311 is provided on 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.

[0098] The heating element 350 extends within the heater 301. The heating element 350 extends longitudinally within the elongated housing 302. The heating element 350 is received within the inner void 308. The heating element 350 extends between the base end 303 and the distal end 304. In the embodiment, the heating element partially extends along the length of the inner void 308. In the embodiment, the heating element 350 extends to or beyond the open end 310.

[0099] Referring to Figure 7, a first embodiment of the heating element 350 includes a continuous length of heating material 351 following a meandering path. The continuous length of heating material 351 includes a resistive member or resistive heating material defining the continuous length of heating material 351. In the embodiment, the continuous length of heating material 351 includes an electrical insulating coating, such as ceramic or other dielectric material, to electrically insulate the continuous length of heating material 351 from 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 continuous length of heating material 350 to the elongated housing 302.

[0100] A continuous length heating material 351 is a resistance heater. The continuous length heating material 351 includes multiple sections 600 and multiple intersections 602 of length, the intersections 602 extending between longitudinally adjacent sections 600 (relative to the centerline of the continuous length heating material 351), and the sections 600 and intersections 602 alternate along the length of the heating material 351. All sections and intersections form part of a single continuous length heating material.

[0101] In the embodiment shown in Figure 7, each portion 600 is linear, and each portion 600 extends substantially in a direction parallel to the longitudinal axis A of the elongated housing 302. Each intersection 602 is a continuous length of heating material 351 that extends between longitudinally adjacent portions 600 with respect to the centerline of the continuous length of heating material 351. The intersection 602 extends at an angle of about 90 degrees to the portion 600.

[0102] Each of the sections 600 is substantially parallel to one another and spaced apart from one another such that they can be considered to be circumferentially spaced apart from one another around a circle in a plane perpendicular to all of the sections 600. That circle is dimensioned so that a continuous length of heating material 351 can be seated within the inner gap 308 of the housing 302 when it is configured along its meandering path.

[0103] In some alternative embodiments not shown, each of the portions 600 is curved, and each portion 600 extends at least partially in a direction parallel to the longitudinal axis A of the elongated housing 302.

[0104] In some alternative embodiments not shown, at least one of the portions 600 is straight, at least one of the portions 600 is curved, and each portion 600 extends at least partially in a direction parallel to the longitudinal axis.

[0105] Referring to Figures 8 and 9, a second embodiment of the heating element 350 includes a continuous length heating material 351 supported on the surface of a substrate 604. The continuous length heating material 351 follows a meandering path across the surface of the substrate 604. The continuous length heating material 351 includes a resistive member or resistive heating material defining the continuous length heating material 351. In the embodiment, the continuous length heating material 351 includes an electrical insulating coating, such as ceramic or other dielectric material, to electrically insulate the continuous length heating material 351 from 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 a continuous length of heating material 351 to an elongated housing 302.

[0106] The base material 604 is a flexible electrical insulating material.

[0107] A continuous length heating material 351 is a resistance heater. The continuous length heating material 351 includes a plurality of sections 600 and a plurality of intersections 602, the intersections 602 extending between longitudinally adjacent sections 600 (with respect to the centerline of the continuous length heating material 351), and the sections 600 and intersections 602 alternate along the length of the heating material 351.

[0108] In the embodiments shown in Figures 8 and 9, each portion 600 is linear, and each portion 600 extends substantially in a direction parallel to the longitudinal axis A of the elongated housing 302. In the illustrated embodiments, each intersection 602 is further a continuous length of heating material 351 that extends between longitudinally adjacent portions 600 with respect to the centerline of the continuous length of heating material 351. The portions 602 extend at an angle of about 90 degrees to the portions 600.

[0109] The base material 604 is formed into a tube as shown in Figure 9. When the base material 604 is formed into the tube in Figure 9, the edges 608, 608 of the base material are configured to abut or overlap, and the tube is dimensioned so that the tube can seat within the inner void 308 of the housing 302. In some embodiments, the surface of the base material 604 on which a continuous length of heating material 351 is supported faces radially outward when the base material 604 is formed into a tube. This causes the portions 600 to be circumferentially spaced apart from each other around the radially outer surface of the tube. In some embodiments, the base material 604 is elastically deformable, and the edges 606, 608 of the base material are not fixed to each other when the base material is formed into a tube. In such embodiments, the tube is positioned within the inner void 308, and the elastic properties of the base material cause the base material 604 to expand the tube into contact with the surface of the housing 302 defining the inner void. This helps to create efficient heat transfer from the heating material 351 to the housing 302 in a continuous length.

[0110] In some alternative, not-illustrated embodiments, each of the portions 600 is curved, and each portion extends at least partially in a direction parallel to the longitudinal axis A of the elongated housing 302.

[0111] In some alternative embodiments not shown, at least one of the portions 600 is straight, at least one of the portions 600 is curved, and each portion 600 extends at least partially in a direction parallel to the longitudinal axis.

[0112] Referring to Figure 10, a third embodiment of the heating element 350 includes a continuous length of heating material 351 following a meandering path. The continuous length of heating material 351 includes a resistive member or resistive heating material defining the continuous length of heating material 351. In the embodiment, the continuous length of heating material 351 includes an electrical insulating coating, such as ceramic or other dielectric material, to electrically insulate the continuous length of heating material 351 from the elongated housing 302. The electrical insulating coating in the embodiment is thermally conductive to provide heat transfer from the continuous length of heating material 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. The electrical insulating member and electrical insulating filler in the embodiment are thermally conductive to provide heat transfer from the continuous length of heating material 350 to the elongated housing 302.

[0113] A continuous length heating material 351 is a resistance heater. The continuous length heating material 351 includes a plurality of sections 600 and a plurality of intersections 602, where the intersections 602 are parts of the continuous length heating material 351 between longitudinally adjacent sections 600 (with respect to the center line of the continuous length heating material 351), and the sections 600 and intersections 602 alternate along the length of the heating material 351.

[0114] In the embodiment shown in Figure 10, each portion 600 is curved, and each portion 600 extends in a direction that includes a component parallel to the longitudinal axis A of the elongated housing 302. Furthermore, in the illustrated embodiment, each intersection 602 is a joint between two portions 600 that are longitudinally adjacent to each other with respect to the centerline of a continuous length of heating material 351. The angle included between the portions 600 on either side of the intersection 602 is less than 45 degrees. In other embodiments, the included angle may be greater than 0 degrees and less than 90 degrees, depending on the desired density of the portion / the total length of the continuous length of heating material 351.

[0115] The continuous length heating material 351 is configured such that each of its intersections 602 can be considered to lie on one or the other of the virtual circle 610. As a result, the continuous length heating material 351 can be considered to have its ends substantially located on the surface of a virtual cylinder defined by the virtual circle 610. The continuous length heating material 351 is dimensioned so that it can seat in the inner gap 308 of the housing 302 along its meandering path.

[0116] In some alternative, not-illustrated embodiments, each of the portions 600 is linear, and each portion extends at least partially in a direction parallel to the longitudinal axis A of the elongated housing 302.

[0117] In some alternative embodiments not shown, at least one of the portions 600 is straight, at least one of the portions 600 is curved, and each portion 600 extends at least partially in a direction parallel to the longitudinal axis.

[0118] Referring to Figure 11, a fourth embodiment of the heating element 350 includes a continuous length heating material 351 supported on the surface of a substrate 604. The continuous length heating material 351 follows a meandering path across the surface of the substrate 604. The continuous length heating material 351 includes a resistive member or resistive heating material defining the continuous length heating material 351. In the embodiment, the continuous length heating material 351 includes an electrical insulating coating, such as ceramic or other dielectric material, to electrically insulate the continuous length heating material 351 from 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 a continuous length of heating material 351 to an elongated housing 302.

[0119] The base material 604 is a flexible electrical insulating material.

[0120] A continuous length of heating material 351 is a resistance heater. The continuous length of heating material 351 includes multiple sections 600 and multiple intersections 602 (for clarity, not all sections 600 or intersections 602 are labeled), where the intersections 602 extend between longitudinally adjacent sections 600 (relative to the centerline of the continuous length of heating material 351), and the sections 600 and intersections 602 alternate along the length of the heating material 351.

[0121] In the embodiment shown in Figure 11, each of the portions 600 is linear, and each portion 600 extends substantially perpendicular to the longitudinal axis A of the elongated housing 302. In the illustrated embodiment, each intersection 602 is further a continuous length of heating material 351 that extends between longitudinally adjacent portions 600 with respect to the centerline of the continuous length of heating material 351. The portions 602 extend at an angle of about 90 degrees to the portions 600.

[0122] The substrate 604 in Figure 11 is formed into a tube so that it can be inserted into the elongated housing 302 in a manner similar to that described above in relation to Figure 9.

[0123] In the embodiments shown in Figures 7, 8, 9, 10, and 11, the continuous length heating material 351 has a rectangular cross-sectional profile. It will be understood that other profiles are also possible. In the embodiments, the continuous length heating material 351 has a circular cross-sectional profile. In the embodiments, the heating structure 300 comprises two or more continuous length heating materials 351.

[0124] The heating element 300 includes electrical connection paths 352 and 353. The first and second electrical connection paths 352 and 353 extend from the first and second ends of a continuous length heating material 351, respectively. The electrical connection paths 352 and 353 are formed integrally with the continuous length heating material 351, for example, as a single wire. In embodiments, connectors 280 and 382 connect the electrical connection paths to the continuous length heating material 351. The continuous length heating material 351 is formed from a resistive 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.

[0125] In the embodiments described above, the heating element is a resistance heating element. In the embodiments, other types of heating elements, such as induction heating elements, are used. The device configuration is substantially as described above, so a detailed description is omitted.

[0126] An induction heating configuration 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 or heater (such as a susceptor) by electromagnetic induction. An induction heating configuration 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. In induction heating, compared to heating by conduction, for example, heat is generated inside the susceptor, enabling rapid heating. Furthermore, no physical contact between the induction element and the susceptor is required, increasing the freedom of construction and application.

[0127] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0128] In the embodiment, the heating element of the aerosol supply system is not part of the aerosol supply device but part of the aerosol product. 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.

[0129] 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 heating element containing a heating material of continuous length, A heater comprising the aforementioned continuous length of heating material following a meandering path.

2. The heater according to claim 1, wherein the heating material of a continuous length includes a plurality of portions and a plurality of intersections of the length, the intersections extending between longitudinally adjacent portions, and the portions and intersections alternating along the length of the heating material.

3. The heater according to claim 2, wherein each of the aforementioned parts is linear, and each of the aforementioned parts extends at least partially in a direction parallel to the longitudinal axis.

4. The heater according to claim 2, wherein each of the aforementioned parts is curved, and each of the aforementioned parts extends at least partially in a direction parallel to the longitudinal axis.

5. The heater according to claim 2, wherein at least one of the portions is straight, at least one of the portions is curved, and each portion extends at least partially in a direction parallel to the longitudinal axis.

6. The heater according to claim 2, wherein each of the aforementioned parts is linear, and each of the aforementioned parts extends at least partially in a direction perpendicular to the longitudinal axis.

7. The heater according to claim 2, wherein each of the aforementioned parts is curved, and each of the aforementioned parts extends at least partially in a direction perpendicular to the longitudinal axis.

8. The heater according to claim 2, wherein at least one of the portions is straight, at least one of the portions is curved, and each portion extends at least partially in a direction perpendicular to the longitudinal axis.

9. The heater according to any one of claims 2 to 8, wherein at least one intersection is a curved link extending between adjacent ends in the longitudinal direction of adjacent portions of the heating material of the length, the length of the curved link is shorter than the length of any of the portions between which the curved link extends.

10. The heater according to any one of claims 2 to 8, wherein at least one intersection is composed of a linear link extending between adjacent ends in the longitudinal direction of adjacent portions of the heating material of the length, the length of the linear link being shorter than the length of any of the portions between which the linear link extends.

11. The heater according to claim 9 or 10, wherein the length of the straight or curved link is at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% shorter than the length of any portion in which the straight or curved link extends.

12. The heater according to any one of claims 2 to 11, wherein at least one intersection is configured such that the angle included between the projected longitudinal axes of a portion of the longitudinally adjacent portion intersecting the intersection between the adjacent portions is either 0 degrees or more and 45 degrees or greater than 45 degrees and 90 degrees or less.

13. The heater according to any one of claims 2 to 11, wherein each intersection has the same configuration, and optionally each intersection is configured such that the angle contained between the projected longitudinal axes of the longitudinally adjacent portion intersecting the intersection between the adjacent portions is one of 0 degrees, 45 degrees, and 90 degrees.

14. The heater according to any one of claims 1 to 13, wherein the heater comprises a base material, and at least a portion of the continuous length of heating material is supported on the surface of the base material.

15. The heater according to any one of claims 1 to 14, wherein the continuous length of heating material is an electrical resistance material, and the heater is a resistance heater.

16. The heater according to any one of claims 1 to 15, wherein the housing has a base end and a free end, and the free end is configured to penetrate the article containing the aerosol-generating material.

17. The heater according to claim 16, wherein the continuous length heating material has a first end and a second end, and the intersection closest in the longitudinal direction to the first end of the continuous length heating material and the intersection closest in the longitudinal direction to the second end of the continuous length heating material are both closer to the free end of the housing than to the base end of the housing.

18. The heater according to claim 16 or 17, wherein the housing defines a longitudinally extending bore, the base end of the housing defines an open end of the bore, and at least a portion of the continuous length of heating material is positioned within the bore.

19. The heater according to claim 18, wherein at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or 100% of the continuous length of the heating material is located within the bore.

20. The heater according to any one of claims 1 to 19, wherein the heater further comprises at least one mass of material, the at least one mass configured to hold at least a portion of the continuous length of heating material in a fixed position relative to the housing, and optionally the mass of material configured to hold the entire continuous length of heating material in a fixed position relative to the housing.

21. An aerosol supply device configured to heat an article containing an aerosol-generating material, comprising a heater according to any one of claims 1 to 20.

22. An aerosol supply system comprising a heater according to any one of claims 1 to 20 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 heater according to any one of claims 1 to 20 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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