Heaters for aerosol supply devices

Abstract

A heater (350) for an aerosol supply device (100) configured to heat an article (50) containing an aerosol-generating material is disclosed. The heater includes an elongated housing (302) having a first end (303) and a second end (304). A heating coil (351) within the elongated housing (302) has the first end and the second end and a return electrical path (353) extending from the first end of the heating coil (351) toward the second end of the coil (351). The return electrical path (353) comprises a first portion (362) and a second portion (366). The first portion (362) of the return electrical path (353) extends radially inward of the coil (351), and the second portion (366) of the return electrical path (353) extends radially outward of the coil (351).

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 combustion. Examples of such products include so-called "non-combustion heating-type" products, or tobacco heating devices or products, which release compounds by heating a material without burning it. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] An aerosol supply system covering the above-described devices or products is 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 embodiment, a heater for an aerosol supply device is provided, configured to heat an article containing an aerosol-generating material. The heater comprises an elongated housing having a first end and a second end; a heating coil within the elongated housing having the first end and the second end; and a return electrical path extending from the first end of the heating coil toward the second end of the coil. The return electrical path comprises a first portion and a second portion. The first portion of the return electrical path extends radially inward of the coil, and the second portion of the return electrical path extends radially outward of the coil. The first and second portions of the return electrical path are part of the length of the return electrical path.

[0005] A coil can be thought of as the length of a material such that its length includes multiple turns or loops around a central axis extending in the longitudinal direction, with the ends of each loop displaced from one another in a direction parallel to the central axis, i.e., the ends of a single turn spaced apart from one another in the longitudinal direction. Examples of such coils are wires, or other elongated materials such as tapes or ribbons that follow a helical path. A coil can also be thought of as having a radially outer surface facing away from the central axis and a radially inner surface facing toward the central axis. A coil can also be thought of as partially enclosing or defining an inner space, and the coil can be thought of as forming a virtual envelope that encloses that inner space.

[0006] The heater may include a second return electrical path extending from the second end of the coil.

[0007] One or both of the first and second return electrical paths may be configured to electrically connect the coil to a resistance heating generator which includes components that can generate heat in the coil via a resistance heating process. The coil may be activated when those components cause heat to be generated in the coil.

[0008] The first and second parts of the return electrical path may be connected by a transitional part of the return electrical path, which extends through the coil / envelope. When the transitional part extends through the coil, it passes from the inner space to the space outside the coil, or from the space outside the coil to the inner space.

[0009] The transition portion may be oriented in different directions with respect to one or both of the ends of the first and second portions that extend from either end of the transition portion.

[0010] The transition section may extend through the coil and be separated from any part of the coil.

[0011] At least the transition portion of the return electrical path may be surrounded by a non-conductive coating.

[0012] At least the return electrical path may be surrounded by a non-conductive coating.

[0013] At least the coil may be surrounded by a non-conductive coating.

[0014] The first portion of the return electrical path may extend from the first end of the coil or a connector connected thereto.

[0015] The connector may be configured to electrically connect the coil to a return electrical path or a second return electrical path.

[0016] The second portion of the return electrical path may extend from the first portion of the return electrical path or the trading portion, and extend toward the second end of the coil. When the second portion extends from the end of the transition portion, it extends from the end of the transition portion that is away from the end to which the first portion extends.

[0017] The second portion of the return electrical path may extend from the first end of the coil or a connector attached thereto.

[0018] The first portion of the return electrical path may extend from the second portion or trading portion of the return electrical path toward the second end of the coil. The first portion extends from the end of the transition portion toward the end of the transition portion toward the end of the transition portion toward the end of the second portion toward the first end of the coil.

[0019] The first portion of the return electrical path may be continuous. The second portion of the return electrical path may be continuous.

[0020] If there is only one such section along the entire length of the return electrical path, then the portion of the return electrical path is continuous. Thus, if both the first and second portions of the return electrical path are continuous, the entire return electrical path consists of (i) two parts extending from one of the ends of the return electrical path, where the first part is the first portion and the second part is the second portion, or (ii) three parts extending from one of the ends of the return electrical path, where the first part is the first portion, the second part is a transitional portion, and the third part is the second portion.

[0021] The first part of the return electrical path may be continuous, and the second part of the return electrical path may be discontinuous.

[0022] If there are two or more such parts along the entire length of the return electrical path, then the first or second part of the return electrical path is discontinuous. Thus, for example, if the second part of the return electrical path is discontinuous, then there are two or more parts of the return electrical path extending radially outward from the coil. In such embodiments, the second parts adjacent to each other along the return electrical path are connected by (i) the first part, or (ii) proceeding from one second part to the other second part, a transition part, the first part, and a transition part.

[0023] The first part of the return electrical path may be discontinuous, and the second part of the return electrical path may be continuous.

[0024] The first part of the return electrical path may be discontinuous, and the second part of the return electrical path may be discontinuous.

[0025] The housing may comprise a base end. The second end of the coil may be close to the base end.

[0026] The housing may comprise a free end. The first end of the coil may be close to the free end.

[0027] The housing may include an inner void. At least a part of the coil may be within the inner void. The heater may further comprise at least one mass of material positioned within the inner void, and the at least one mass may hold at least a part of the coil in a fixed position relative to the housing.

[0028] The inner void may be filled with a mass of material. At least a part of the coil and the coil within the housing may be held in a fixed position relative to the housing.

[0029] The mass of material may be an adhesive or a potting compound.

[0030] The base end of the housing may define an opening through which access to the inner void is possible.

[0031] The heater may be a resistive heater. The heating element may be a resistive heating element. The heating element may be a resistive heating coil.

[0032] The heater may be an induction heating heater. The heating element may be an induction heating element. The coil may be an induction coil.

[0033] According to one aspect, there is provided an aerosol supply device configured to heat an article containing an aerosol-generating material, the aerosol supply device comprising a heater as described above.

[0034] The aerosol supply device may include a heating chamber equipped with a heater.

[0035] The aerosol supply device may comprise a power supply, a controller, and a heating chamber in which the aerosol product is removably received.

[0036] The power supply may be aligned along the longitudinal axis of the heating chamber.

[0037] The power supply may be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0038] The aerosol supply device may be configured for wireless charging.

[0039] 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.

[0040] 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.

[0041] The aerosol supply system may include a charging unit having a cavity for removably receiving an aerosol supply device.

[0042] The charging unit may include a movable lid that covers the aerosol supply device in a closed configuration.

[0043] The charging unit may include a user display.

[0044] 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.

[0045] In another embodiment, a method for generating an aerosol is provided, comprising the steps of: providing an aerosol supply device comprising a heating chamber including a receiving portion and a heater as described above; and inserting an aerosol product at least partially into the receiving portion of the heating chamber.

[0046] 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.

[0047] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0048] [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 is a schematic cross-sectional view of a part of the aerosol supply device and a schematic cross-sectional view of one embodiment of the aerosol product of the aerosol supply system. [Figure 4] This is a perspective view of another embodiment of the 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] Figure 6 is a schematic detail diagram of the first embodiment of the heater. [Figure 8] Figure 6 is a schematic detail view of the second embodiment of the heater. [Figure 9] Figure 6 is a schematic detail diagram of the third embodiment of the heater. [Modes for carrying out the invention]

[0049] 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.

[0050] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] The heater 301 includes an elongated heater in the form of a pin. In other embodiments, the heater 301 includes other elongated configurations such as blades. During use, the heater 301 can be inserted into the distal end of the aerosol product 50 (see Figure 3) which is received in the heating chamber 201 to heat the aerosol product internally.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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 coil, which is arranged to operate to heat the heater.

[0097] The heating component 300 is a resistance heating component. The heater 301 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 resistive 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 resistive 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, for example, by conduction. Providing a resistance heating component enables a compact configuration. Resistance heating provides an efficient configuration.

[0098] 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 that defines a longitudinal axis.

[0099] The elongated housing 302 is formed from a thermally conductive material such as stainless steel. 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.

[0100] 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.

[0101] The elongated housing 302 comprises a housing body 306, which is tubular in shape. The housing body 306 includes a bore 307, which defines an inner void 308 of the heater 301. The inner void 308 extends longitudinally. In some embodiments, the inner void 308 is at least partially filled with a filler 360, such as an adhesive or potting compound. In some embodiments, the inner void 308 is completely filled with the filler 360 and / or components such as a coil 351. In embodiments, 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.

[0102] 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.

[0103] 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.

[0104] Referring to Figure 7, the heating element 350 in the embodiment includes a first embodiment of the heating coil 351. The heating coil 351 comprises a resistive member that defines the heating coil 351. The heating coil 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.

[0105] In the embodiment, the heating coil 351 includes an electrical insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302 and itself. The electrical insulating coating in the embodiment is thermally conductive to provide heat transfer from the heating coil 351 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 the electrical insulating filler in the embodiment are thermally conductive to provide heat transfer from the heating coil 351 to the elongated housing 302.

[0106] The heating coil 351 is a resistance heating coil. The heating coil 351 has a rectangular cross-sectional profile. It will be understood that other coil configurations are also possible. In this embodiment, the heating coil 351 has a circular cross-sectional profile.

[0107] The heating coil 351 is a helical coil with a variable radius, where the coil loop or turn, having its maximum radius around the longitudinal axis of the coil, is adjacent to the base end 303 of the elongated housing 302. The radius of the coil decreases to its minimum radius at the end of the coil 351 closest to the free end 304 of the elongated housing.

[0108] The heating element 300 includes electrical connection paths 352 and 353. The electrical connection paths 352 and 353 are connected to the respective ends of the heating element 350. The base electrical connection path 352 extends from the distal end of the heating element 350. The return electrical connection path 353 is connected to the proximal end of the heating element 350. Connectors 380 and 382 connect the heating element 350 to the base electrical connection path 352 and the return electrical connection path 353, respectively.

[0109] In the illustrated embodiment, the material of the electrical connection paths 352 and 353 is different from the material of the coil 351.

[0110] In alternative embodiments not shown, the electrical connection paths 352, 353 and the coil 351 are integrated with one another.

[0111] The return electrical connection path 353 comprises a first portion 362, a second portion 366, and a transition portion 364.

[0112] The second portion 366 extends from connector 382 to position 370 on the return electrical connection path 353, radially outward of coil 351, or outside the envelope defined by coil 351. The transition portion 364 extends from position 370 to position 372 on the return electrical connection path 353, passing through the adjacent coil loop or the coil between turns 374 and 376.

[0113] The first portion 362 of the return electrical connection path 353 extends from position 372 toward the base end 303 through the open end 310 of the elongated housing 302 and extends radially inward of the coil 351.

[0114] Referring to Figure 8, the heating element 350 in the embodiment includes a second embodiment of the heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. The heating coil 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.

[0115] In the embodiment, the heating coil 351 includes an electrical insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302 and itself. The electrical insulating coating in the embodiment is thermally conductive to provide heat transfer from the heating coil 351 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 the electrical insulating filler in the embodiment are thermally conductive to provide heat transfer from the heating coil 351 to the elongated housing 302.

[0116] The heating coil 351 is a resistance heating coil. The heating coil 351 has a rectangular cross-sectional profile. It will be understood that other coil configurations are also possible. In this embodiment, the heating coil 351 has a circular cross-sectional profile.

[0117] The heating coil 351 is a helical coil having a variable radius, with a loop or turn of coil having a first radius adjacent to or closest to the base end 303 of the elongated heater 302, and a second radius adjacent to or closest to the free end 304 of the elongated heater 302. The radius of the coil increases from the first radius to a position 384 approximately midway between the base end 303 and the free end 304, respectively. The radius of coil 351 also increases from the second radius to position 384.

[0118] The heating element 300 includes electrical connection paths 352 and 353. The electrical connection paths are connected to each end of the heating element 350. The base electrical connection path 352 is connected to the distal end of the heating element 350. The return electrical connection path 353 is connected to the proximal end of the heating element 350. Connectors 380 and 382 connect the heating element 350 to the base electrical connection path 352 and the return electrical connection path 353, respectively.

[0119] The return electrical connection path 353 comprises a first section 362, first and second parts 366A and 366B of a second section 366, and transition sections 364 and 365.

[0120] The first part 366A of the second part 366 extends from the connector 382 to position 370 on the return electrical connection path 353 and extends radially outward from the coil 351.

[0121] The transition section 364 extends from position 370 to position 372 on the return electrical connection path 353, passing through the adjacent coil loop or coil 351 between turns 374 and 376.

[0122] The first portion 362 of the return electrical connection path 353 extends from position 372 toward the base end 303 of the elongated housing 302 to position 386, and extends radially inward of the coil 351.

[0123] The transition section 365 extends from position 386 to position 388 on the return electrical connection path 353, passing through the adjacent coil loop or coil 351 between turns 390 and 392.

[0124] The second part 366B of the second section 366 extends from position 388 toward the base end 303 through the elongated opening end 310 of the housing radially outward of the coil 351.

[0125] The coil 351 is held in place within the elongated housing 302 by three lumps of filler material 360. The filler material extends between the bores 307 and surrounds a portion of the coil 351. Between the lumps of filler material 360 are air spaces 361. The air spaces 361 are in fluid communication with each other via bore 363A. The air space 361 closest to the base end 303 is in fluid communication with the open end 310 via bore 363B.

[0126] Referring to Figure 9, the heating element 350 in the embodiment includes a third embodiment of the heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. The heating coil 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.

[0127] In the embodiment, the heating coil 351 includes an electrical insulating coating, such as ceramic, to electrically insulate the heating coil 351 from the elongated housing 302 and itself. The electrical insulating coating in the embodiment is thermally conductive to provide heat transfer from the heating coil 351 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 the electrical insulating filler in the embodiment are thermally conductive to provide heat transfer from the heating coil 351 to the elongated housing 302.

[0128] The heating coil 351 is a resistance heating coil. The heating coil 351 has a rectangular cross-sectional profile. It will be understood that other coil configurations are also possible. In this embodiment, the heating coil 351 has a circular cross-sectional profile.

[0129] The heating coil 351 is a helical coil having a variable radius, with a loop or turn of coil 351 having a first radius adjacent to or closest to the base end 303 of the elongated heater 302, and a second radius adjacent to or closest to the free end 304 of the elongated heater 302. The radius of coil 351 increases from the first radius to position 384 on coil 351 approximately midway between the base end 303 and the free end 304, respectively. The radius of coil 351 also increases from the second radius to position 384. The envelope defined by coil 351 is shown by a dashed line 394.

[0130] The heating element 300 includes electrical connection paths 352 and 353. The electrical connection paths extend from each end of the heating element 350. The base electrical connection path 352 is connected to the distal end of the heating element 350. The return electrical connection path 353 is connected to the proximal end of the heating element 350. Connectors 380 and 382 connect the heating element 350 to the base electrical connection path 352 and the return electrical connection path 353, respectively.

[0131] The return electrical connection path 353 comprises a first portion 362 and a second portion 366. The boundary between the first portion 362 and the second portion 366 is where the return electrical connection path 353 passes through the envelope 394.

[0132] The second portion 366 of the return electrical connection path 353 extends from the connector 382 to the intersection with the envelope 394 and extends radially outward from the coil 350 or the envelope 394.

[0133] The return electrical connection path 353 passes through coil 351 or envelope 394 between adjacent coil loops or turns 374 and 376, and then separates from those coils or loops.

[0134] The first portion 362 extends from the intersection with the envelope 394 toward the base end 303 through the elongated opening end 310 of the housing radially inward of the coil 351 or the envelope 394.

[0135] The coil 351 is held in place within the bore 307 by a mass of filler material 360. The filler material substantially fills the portion of the inner space 308 defined by the bore 307 that is not occupied by the coil 351 or the return electrical connection path 353.

[0136] 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.

[0137] An induction heating system comprises various components for heating the aerosol-generating material of an article by an induction heating process. Induction heating is a process of heating a conductive heating element (such as a susceptor) by electromagnetic induction. An induction heating system may comprise an induction element, for example, one or more inductor coils, and a device for passing a fluctuating current, such as an alternating current, through the induction element. The fluctuating current within the induction element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor (heating element) that is appropriately positioned relative to the induction element. Compared to heating by conduction, for example, induction heating generates heat inside the susceptor, enabling rapid heating. Furthermore, it does not require any physical contact between the induction element and the susceptor, increasing the freedom of construction and application.

[0138] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0139] 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.

[0140] 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 first end and a second end, A heating coil in the elongated housing having a first end and a second end, A return electrical path extending from the first end of the heating coil toward the second end of the coil, Equipped with, The return electrical path comprises a first part and a second part, The first portion of the return electrical path extends radially inward of the coil, The second portion of the return electrical path extends radially outward from the coil, Heater.

2. The heater according to claim 1, wherein the first and second portions of the return electrical path are connected by a transition portion of the return electrical path, the transition portion extending through the coil.

3. The heater according to claim 1 or 2, wherein the first portion of the return electrical path extends from the first end of the coil.

4. The heater according to claim 1 or 2, wherein the second portion of the return electrical path extends from the first end of the coil.

5. The heater according to claim 3 or 4, wherein the other of the first or second portion of the return electrical path extends from the first or second portion or transition portion of the return electrical path toward the second end of the coil.

6. The heater according to any one of claims 1 to 5, wherein the first portion of the return electrical path is continuous and the second portion of the return electrical path is continuous.

7. The heater according to any one of claims 1 to 5, wherein the first portion of the return electrical path is continuous and the second portion of the return electrical path is discontinuous.

8. The heater according to any one of claims 1 to 5, wherein the first portion of the return electrical path is discontinuous and the second portion of the return electrical path is continuous.

9. The heater according to any one of claims 1 to 5, wherein the first portion of the return electrical path is discontinuous, and the second portion of the return electrical path is discontinuous.

10. The heater according to any one of claims 1 to 9, wherein the housing has a base end, and the second end of the coil is close to the base end.

11. The heater according to any one of claims 1 to 10, wherein the housing has a free end, and the first end of the coil is close to the free end.

12. The heater according to any one of claims 1 to 11, wherein the housing comprises an inner void, at least a portion of the coil is located within the inner void, and the heater further comprises at least one mass of filler positioned within the inner void, the at least one mass holding at least a portion of the coil in a fixed position relative to the housing.

13. The heater according to claim 12, wherein the inner void is filled with the mass of the filler and at least a portion of the coil, and the coil in the housing is held in a fixed position relative to the housing.

14. The heater according to claim 12 or 13, wherein the lump of filler is an adhesive or a potting compound.

15. The heater according to any one of claims 1 to 14, wherein the heater is a resistance heater.

16. An aerosol supply device comprising a heater according to any one of claims 1 to 15, configured to heat an aerosol product for generating an aerosol.

17. A system comprising the aerosol supply device according to claim 16 and an article containing an aerosol generating material.

18. A method for generating an aerosol, A step 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 15, The steps include: inserting the aerosol product at least partially into the receiving portion of the heating chamber; Methods that include...

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