Heaters for aerosol supply devices

Abstract

A heater for an aerosol supply device, comprising an elongated housing defining a longitudinal axis, a first heater coil located within the housing, and a second heater coil located within the housing. The first heater coil and the second heater coil are not aligned in the direction of the longitudinal axis.

Description

Technical Field

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

Background Art

[0002] Smoking articles such as cigarettes and cigars generate tobacco smoke by burning tobacco during use. Attempts have been made to provide alternatives to these articles by creating products that release compounds without burning. Examples of such products include so-called "non-combustion heating type" products, 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] Aerosol supply systems covering the above-described devices or products are known. A common system uses a heater to generate an aerosol from a suitable medium, and then the aerosol is inhaled by the user. Often, in order to supply different aerosols for inhalation, it is necessary to replace or change the medium used. Resistance heating systems are known to be used as heaters for generating aerosols from suitable media. Separately, induction heating systems are known to be used as heaters.

Summary of the Invention

[0004] According to one aspect, there is provided a heater for an aerosol supply device, comprising an elongated housing defining a longitudinal axis, a first heater coil located within the housing, and a second heater coil located within the housing, wherein the first heater coil and the second heater coil do not coincide in the direction of the longitudinal axis.

[0005] According to various embodiments, a heater for an aerosol supply device is provided, comprising two heater coils. The heater coils may occupy different volumes in the inner cavity of an elongated housing. According to various embodiments, an opening may be provided on the side of the elongated housing. The two heater coils may be inserted into the inner cavity, and conductive pins may be positioned below the side. The two heater coils may be heated separately.

[0006] According to various embodiments, two heater coils or heating coils may occupy different volumes within the inner cavity to facilitate electrical connection to each of the heater coils. In particular, embodiments are conceivable in which the two heater coils may be inserted at different insertion depths within the inner cavity. According to one embodiment, two or more heater coils may be displaced longitudinally from each other, resulting in no longitudinal overlap or, alternatively, only slight and partial longitudinal overlap. For example, an embodiment is conceivable in which the first heater coil has a longitudinal length L1 and the second heater coil has a longitudinal length L2. The two heater coils may be spaced longitudinally by a distance of at least 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, or more than 10 mm. According to one embodiment, the two coils may overlap longitudinally by a distance of less than 5% or less than 10% of the length L1 or L2.

[0007] Embodiments are conceivable in which the two heater coils may be coaxial. Other embodiments are conceivable in which the two heater coils have parallel and non-overlapping longitudinal axes.

[0008] According to one embodiment, a heater for an aerosol supply device is provided, comprising: an elongated housing defining a longitudinal axis extending in the longitudinal direction; a first heater coil located within the housing and having a first position in the longitudinal direction; and a second heater coil located within the housing and having a second position in the longitudinal direction different from the first position.

[0009] The elongated housing may have an internal cavity. The elongated housing may be configured to provide access to the internal cavity via a surface extending longitudinally through the housing during at least part of the heater manufacturing process.

[0010] According to various embodiments, the first heater coil and the second heater coil do not overlap in the longitudinal direction.

[0011] According to an alternative embodiment, the first and second heater coils may overlap at least partially in the longitudinal direction. However, embodiments are conceivable in which the degree of overlap is less than 5% of the longitudinal length of one or both heater coils.

[0012] The first heater coil and the second heater coil may have the same configuration as each other.

[0013] In another embodiment, an aerosol supply device is provided which is configured to heat an article containing an aerosol-generating material, the device comprising the heater described above.

[0014] The aerosol supply device may further include one or more controllers for controlling the operation of the first heater coil and the second heater coil.

[0015] One or more controllers may be arranged to control the first heater coil independently of the second heater coil.

[0016] One or more controllers may be arranged to control a first heater coil to have a first heating profile and a second heater coil to have a second different heating profile.

[0017] The controller may be configured to control the first heater coil and the second heater coil in parallel with each other.

[0018] In another embodiment, a system is provided comprising the above-described aerosol supply device and an article containing an aerosol generating material.

[0019] In another embodiment, a method for manufacturing or assembling a heater for an aerosol supply device configured to heat an aerosol product containing an aerosol generating material, A step of providing an elongated housing that defines the longitudinal axis, The steps include positioning the first heater coil within the housing, The steps include positioning the second heater coil so that it is located inside the housing, and A method is provided which includes the first heater coil and the second heater coil not being aligned in the direction of the longitudinal axis.

[0020] According to one embodiment, a method for manufacturing or assembling a heater for an aerosol supply device configured to heat an aerosol product containing an aerosol generating material, A step of providing an elongated housing that defines a longitudinal axis extending in the longitudinal direction, The steps include positioning or inserting a first heater coil at a first longitudinal position within the housing, The steps include positioning or inserting a second heater coil at a second longitudinal position within the housing that is different from a first position, and A method is provided that includes this.

[0021] The method may include the step of accessing the internal void through a longitudinally extending surface of the housing to position at least one of the first heater coil and the second heater coil within the housing.

[0022] According to another embodiment, The steps include providing the aerosol supply device described above, The steps include: inserting an aerosol product containing an aerosol generating material at least partially into an aerosol supply device; A method for generating an aerosol is provided, which includes

[0023] The method may further include the step of operating an aerosol supply device.

[0024] The heater may be a resistively heated heater. The heating member may be a resistive heating member. The heating element may be a resistive heating element. The coil may be a resistively heated heater coil.

[0025] The heater may be an inductively heated heater. The heating element may be an inductive heating element. The coil may be an induction coil.

[0026] According to one aspect, an aerosol supply device configured to heat an article containing an aerosol generating material is provided, and the device includes the heater described above. The aerosol supply device may include a heating chamber provided with the heater.

[0027] The aerosol supply device may include a power source, a controller, and a heating chamber in which an aerosol generating article is removably received. The power source may be aligned along the longitudinal axis of the heating chamber. The power source may be aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0028] The aerosol supply device may be configured for wireless charging.

[0029] According to one aspect, an aerosol supply system is provided, which includes the aerosol supply device described above and an article containing an aerosol generating material.

[0030] The aerosol supply system may include a charging unit having a cavity for removably receiving an aerosol supply device. The charging unit may include a movable lid that covers the aerosol supply device in a closed configuration. The charging unit may include a user display. The user display may be visible to the user when the movable lid is in the closed position, and may be partially or completely hidden or obscured by the lid when the lid is in the open position.

[0031] In another embodiment, a method for generating an aerosol is provided, comprising the steps of providing the aerosol supply device described above and inserting the aerosol product at least partially into the receiving portion of a heating chamber.

[0032] Next, various embodiments will be described as mere examples, with reference to the attached drawings. [Brief explanation of the drawing]

[0033] [Figure 1] This is a perspective view of an aerosol supply system that includes 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 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 the heater of the device shown in Figure 1 or Figure 4. [Figure 7] This figure shows heaters according to various embodiments, in which two heater coils are located within an inner cavity of an elongated housing, and the two heater coils are not aligned in the direction of their longitudinal axes. [Figure 8(a)]This figure shows an embodiment in which the two heater coils are positioned so that they do not coincide in the direction of their longitudinal axes. [Figure 8(b)] This figure shows an embodiment in which the two heater coils are positioned so that they do not coincide in the direction of their longitudinal axes. [Figure 8(c)] This figure shows an embodiment in which two heater coils are positioned so as to partially overlap in the direction of their longitudinal axes. [Figure 8(d)] This diagram shows an arrangement where two heating coils have different lengths, with the smaller heating coil located within the volume of the larger heating coil. [Figure 9] This figure shows a method for manufacturing or assembling a heater according to various embodiments. [Modes for carrying out the invention]

[0034] 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.

[0035] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0036] 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.

[0037] 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.

[0038] 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 in the form of, for example, 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.

[0039] 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.

[0040] In some embodiments, the non-flammable aerosol supply device may include a region for receiving consumables, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter and / or an aerosol modifier.

[0041] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, packaging material, a filter, a suction nozzle, and / or an aerosol modifier.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] The aerosol-generating film may be continuous. For example, the film may include a continuous sheet of material, or may be a continuous sheet of material. The sheet may be in the form of packaging material, may be gathered to form a gathered sheet, or may be shredded to form a shredded sheet. The shredded sheet may include one or more strands or strips of the aerosol-generating material.

[0048] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of 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.

[0049] The aerosol-generating film may be formed by combining a binder such as a gelling agent with a solvent such as water, an aerosol-forming agent, and one or more other 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 the aerosol-generating film.

[0050] 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 on a heater of a device sized to accept the article.

[0051] 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.

[0052] Consumables are articles comprising or consisting of aerosol-generating material, 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.

[0053] 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.

[0054] 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 electrical 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.

[0055] 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 an aerosol 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.

[0056] 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 that is directed toward the user when used. Furthermore, the aerosol supply device 100 also defines a distal direction that 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.

[0057] The aerosol supply device 100 may be removably inserted into the charging unit 101 for charging. The charging unit 101 includes a cavity 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 have a first side. 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 of the aerosol supply device 100. The first side of the aerosol supply device 100 may be received by a longitudinal opening provided in the charging unit 101.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] Figure 2 shows a partial cross-sectional view 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 structure including a receptacle side wall 205a and a receptacle base 205b. The base 205b is at the distal end of the receptacle 205. The heating zone 201a consists of at least a portion of the article for heating.

[0062] A heating element 301 is provided in part of the main housing 200, and the heating element 301 extends into or protrudes into the heating chamber 201. The heating element 301 may include a base portion 301a that can be located in a recess provided in part of the body of the device 100. The heating element 301 stands upright within the heating chamber 201. The heating element 301 stands upright from its distal end.

[0063] The heating element 301 comprises an elongated heating element in the form of a pin. In other embodiments, the heating element 301 comprises other elongated components such as a blade. The heating element 301 may be inserted into the distal end of the aerosol product 50 (see Figure 3) received in the heating chamber 201 in order to heat the aerosol product 50 internally during use.

[0064] 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, at least partially, define the receiving chamber of the aerosol supply device 100 as a volume enclosed within the wall 200a. The housing base 200b is at the distal end of the housing wall 200a. In the illustrated embodiment, the heating member 301 stands upright from the housing base 200b. The heating member 301 protrudes through the receptacle base 205b. The receptacle base 205b has an aperture 206 from which the heating member 301 protrudes. In the embodiment, the heating member 301 is attached to the receptacle base 205b. The heating member 301 stands upright from the receptacle base 205b.

[0065] 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. The removal mechanism 204 is omitted in the embodiment. In the embodiment, the housing wall 200a defines the receptacle 205 at least partially. The removal mechanism 204 may be held in the main housing 200, so 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 which encloses (e.g., surrounds) and defines the heating chamber 201 inside.

[0066] 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.

[0067] The base portion 207b has an aperture 206 from which the heating element 301 can protrude. 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.

[0068] The peripheral portion 207a and the base portion 207b may both 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 50 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.

[0069] The article chamber may also be called the receiving portion. When the removal mechanism 204 is held in the main housing 200, the article chamber of the removal mechanism 204 is positioned at least partially within the heating chamber 201 during use. The heating member 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.

[0070] 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.

[0071] 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.

[0072] The removal mechanism 204 may 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.

[0073] Figure 4 shows another aerosol supply system 40. System 40 comprises an integrated aerosol supply device 400 for generating aerosols from 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.

[0074] The device 400 comprises 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.

[0075] 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, the user may activate the device 400 by pressing the switch 406.

[0076] 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.

[0077] Figure 5 shows a schematic cross-sectional view of the aerosol supply system 40. Features described with reference to Figure 5 in the embodiments are applicable to the embodiments 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.

[0078] The integrated device in Figure 5 shows a power supply 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of the integrated aerosol generation device, the power supply is aligned along a second longitudinal axis parallel to the longitudinal axis of the heating chamber.

[0079] The heating element 301 comprises an elongated heating element in the form of a pin. In embodiments, the heating element 301 comprises other elongated components such as blades. The heating element 301 is provided within a heating chamber. The heating element 301 of Figure 5 and the heating element 301 described above with reference to Figures 1 to 3 can be applied to each other as described in detail herein. The heating element 301 extends into or protrudes into the heating chamber 401.

[0080] The heating element 301 may be inserted into the distal end of the aerosol product 50, which is received in the heating chamber 401, in order to heat the aerosol product 50 internally during use.

[0081] The aerosol supply devices 100 and 400 include a heating component 300. The heating component 300 includes a heater. The heating element 301 functions as a heater. The heater includes a heating element 350 (see Figure 6), such as a resistance heating coil, which is arranged to operate to heat the heating element 301.

[0082] 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 component, the heating assembly includes a resistance heating generator which includes components for heating the heating elements via a resistance heating process. In this case, a current is applied directly to the resistance heating element, and the resulting flow of current within the heating element acts as a heating component, heating the heating element by Joule heating. The resistance heating element includes a resistive material configured to generate heat when an appropriate current passes through the resistance heating element, and the heating component includes electrical contacts for supplying current to the resistive 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 member, for example, by conduction. By providing a resistance heating component, a compact configuration is possible. Resistance heating provides an efficient configuration.

[0083] Figure 6 shows a heating element 301 for use in the aerosol supply device described above. The heating element 301 acts as a heater or forms at least part of a heater. The heating component 300 comprises the heating element 301. The heating element 301 comprises an elongated housing 302 and a heating element 350. The elongated housing 302 is an elongated member that defines a longitudinal axis.

[0084] The elongated housing 302 is formed from a thermally conductive material such as aluminum. Other materials such as stainless steel may be used. The elongated housing may have 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.

[0085] The elongated housing 302 has a base end 303 and a free end 304. The base end 304 is attached to the device body. A mount 305 on the base end 303 attaches the heating element 301. It will be understood that different mounting configurations, such as fixing, molding, and joining including adhesive, may be used. The mount 305 may be a separate component or may be formed integrally with the elongated housing 302.

[0086] The groove 302a or the region with reduced cross-sectional diameter may be provided within the elongated housing 302, toward the base end 303 of the elongated housing 302. As will be described in more detail below, the heating coil 351 is located within the inner gap 308 of the heating member 301. The groove 302a or the region with reduced cross-sectional diameter may be located, for example, along the length of the elongated housing 302, at a longitudinal position intermediate between a first longitudinal position corresponding to the longitudinal position of the end of the heating coil 351 closest to the base end 303 and a second longitudinal position corresponding to the longitudinal position where the base end of the elongated housing 302 is attached to, abuts against, or otherwise secured to the mount 305.

[0087] It will be understood that the groove 302a or the region with a reduced cross-sectional diameter reduces, limits, or reduces the effect of heat conduction from the body of the heating member 301 to the base end of the heating member 301 attached to the mount 305. As a result, the flow of heat or thermal energy from the heating member 301 to the mount 305 is reduced. Therefore, the groove 302a or the region with a reduced cross-sectional diameter can be considered to function as a thermal barrier that reduces thermal bleed from the heating member 301 to the mount 305 or more generally to the mounting point.

[0088] Further embodiments are conceivable in which the elongated housing may be provided with two or more grooves or regions with reduced cross-sectional diameter to act as a thermal barrier (not shown). The groove 302a or region with reduced cross-sectional diameter comprises an annular recess, which is shown in Figure 6 as having a rectangular cross-sectional profile, but other embodiments are conceivable in which the annular recess may have a different cross-sectional profile, such as a V-notch or a W-notch. Further embodiments are conceivable in which one or more grooves or regions with reduced cross-sectional diameter may be provided on the inner surface of the elongated housing 302.

[0089] The elongated housing 302 comprises a housing body 306, which is tubular. The housing body 306 includes a bore 307, which defines an inner cavity 308 of the heating element 301. The inner cavity 308 extends longitudinally. In the embodiment, the inner cavity 308 is at least partially filled with, for example, a filler. In the embodiment, the inner cavity 308 is completely filled with, for example, one or more fillers and / or components. In the embodiment, the inner cavity 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 cavity 308.

[0090] The free end 304 of the elongated housing 302 extends toward the proximal end of the heating chamber. The free end 304 of the heating member 301 is closed. The inner gap 308 does not penetrate the free end 304. The 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.

[0091] The heating element 350 extends within the heating member 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 extends partially along the length of the inner void 308. In the embodiment, the heating element 350 extends to or beyond the open end 310.

[0092] In the embodiment, the heating element 350 comprises a heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. 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. In the embodiment, the electrical insulating coating is thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In the embodiment, the electrical insulating coating is omitted. In the embodiment, a separate electrical insulating component 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 heating element 350 to the elongated housing 302.

[0093] The heating coil 351 is a resistance heating coil. The heating coil 351 is a helical coil. The heating coil 351 has a rectangular cross-sectional profile. It will be understood that other coil configurations are also possible. In the embodiment, the heating coil 351 has a circular cross-sectional profile. In the embodiment, the heating component 300 comprises two or more heating coils.

[0094] The heating element 300 includes electrical connection paths. The electrical connection paths extend from each end 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 extends from the proximal end of the heating element 350. The return electrical connection path overlaps the longitudinal range of the heating element 350. The electrical connection paths 352, 352 are formed integrally with the heating element 350, for example, as a single wire. In embodiments, a connector connects the electrical connection paths 352, 353 to the heating element 350. The heating coil 351 is formed of 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.

[0095] Figure 7 shows a heating member 301 for use in the aerosol supply device described above according to various embodiments. The heating member 301 acts as a heater, i.e., a heating component 300, or forms at least a part thereof. The heating member 301 comprises an elongated housing 302 and a heating element 350. The elongated housing 302 is an elongated member defining a longitudinal axis extending in the longitudinal direction.

[0096] A heater for an aerosol supply device is disclosed comprising an elongated housing defining a longitudinal axis, a first heater coil located within the housing, and a second heater coil located within the housing. The first and second heater coils are not aligned in the direction of the longitudinal axis.

[0097] According to various embodiments, a heater for an aerosol supply device is provided, comprising two heater coils. The heater coils may occupy different volumes in the inner cavity of an elongated housing. According to various embodiments, an opening may be provided on the side of the elongated housing. The two heater coils may be inserted into the inner cavity, and conductive pins may be positioned below the side. The two heater coils may be heated separately to achieve a more uniform heating profile across each heater coil.

[0098] As a result, the heater can be configured to heat the aerosol product during use to provide the user with an improved experience.

[0099] The elongated housing 302 is formed from a thermally conductive material such as aluminum. Other materials such as stainless steel may be used. According to another embodiment, the housing 302 may be formed from ceramic. 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 303 is attached to the device body. A mount 305 on the base end 303 attaches the heating element 301. It will be understood that different mounting configurations, such as fixing, molding, and joining including adhesive, may be used. The mount 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. The housing body 306 includes a bore 307, which defines an inner void 308 of the heating member 301. The inner void 308 extends longitudinally. 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.

[0102] The elongated housing 302 may be configured to provide access to the inner void 308 via a longitudinally extending surface of the housing body 306 during at least part of the manufacturing process of the heater 300.

[0103] The free end 304 of the elongated housing 302 extends toward the proximal end of the heating chamber. The free end 304 of the heating member 301 is closed. The inner gap 308 does not penetrate the free end 304. The 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.

[0104] The heating element 350 extends longitudinally within an elongated housing 302. The heating element 350 is received within an inner void 308. The heating element 350 extends between a base end 303 and a distal end 304. In embodiments, the heating element extends partially along the length of the inner void 308. In embodiments, the heating element 350 (or at least one heater coil of it) extends to or beyond an open end 310.

[0105] The heating element 350 comprises a first heater coil 351a and a second heater coil 351b. The first heater coil 351a is located in a first longitudinal position within the housing 302. The second heater coil 351b is located in a second longitudinal position within the housing 302. The first and second positions are different (do not coincide) such that one of the first heater coil 351a and the second heater coil 351b extends more longitudinally than the other (one coil occupies a certain position in the longitudinal direction, while the other does not). According to various embodiments, the first heater coil 351a and the second heater coil 351b are separated from each other in the longitudinal direction, i.e., the first heater coil 351a and the second heater coil 351b do not overlap in the longitudinal direction.

[0106] By arranging two or more heater coils within the inner cavity of an elongated housing, electrical connections to the heater coils can be made easier while the heater is being assembled or manufactured. Furthermore, this configuration facilitates the formation of novel heater shapes that conform to customized heating profiles.

[0107] However, in other embodiments, the first heater coil 351a and the second heater coil 351b may overlap at least partially in the longitudinal direction. For example, the first heater coil 351a may overlap the second heater coil 351b by less than 20%, less than 15%, less than 10%, less than 5%, or less than 1% of the longitudinal length of the first and / or second heater coils 351a and 351b.

[0108] By providing multiple heater coils 351 (at least a first heater coil 351a and a second heater coil 351b) at different longitudinal positions within the elongated housing 302, more uniform heating of the heater 300 may be possible compared to providing a single larger heater coil within the elongated housing 302. In this regard, multiple smaller coils at different longitudinal positions may provide a heating element of the same overall size as a single larger coil. However, smaller coils can be manufactured with greater uniformity compared to a larger coil (and / or good uniformity can be achieved with lower complexity / cost) so that the overall uniformity of the temperature profile provided by multiple coils may be greater compared to the temperature profile provided by a single larger coil.

[0109] In particular, by arranging two heater coils 351a and 351b within the inner cavity 308 of the elongated housing, the same effect as providing a single long heater coil can be provided according to various embodiments. Thus, by utilizing two or more heater coils 351a and 351b, various heating configurations can be formed. For example, each heater coil 351a and 351b may have a length of less than 50% of the longitudinal length of the inner cavity 308.

[0110] The first heater coil 351a and the second heater coil 351b may have the same configuration (i.e., shape and / or size) as each other. This may allow the construction of a heater 300 using multiple heater coils 351 manufactured to the same specifications and / or tolerances, thereby simplifying manufacturing. As a result, a novel heater shape can be formed using a single type of heater coil. This allows for more complex heating profiles to be obtained while reducing manufacturing costs by utilizing a single type of heater coil.

[0111] However, in other embodiments, the first heater coil 351a and the second heater coil 351b may have different configurations. By using heater coils with different configurations, for example, the shape of the elongated housing 302 along the longitudinal axis can be arbitrarily varied.

[0112] The first heater coil 351a may be radially aligned with the second heater coil 352b, that is, the first heater coil 351a and the second heater coil 352 may have the same corresponding position in the radial direction perpendicular to the longitudinal direction. By providing the first heater coil 351a with a radial position that at least partially overlaps with the radial position of the second heater coil 352b, more uniform heating of the elongated housing 302 may be possible. However, according to other embodiments, the first heater coil 351a may be radially offset from the second heater coil 351b, for example, the first heater coil 351a may have a radial position that does not coincide with the second heater coil 351b. By providing the first heater coil 351a radially offset from the second heater coil 351b, electrical access to the different coils may be facilitated.

[0113] According to various embodiments, the heating element 350 may have two heater coils. However, in other embodiments, the heating element 350 may have three, four, five, six, seven, eight, nine, ten, or more than ten heater coils. Each heater coil may comprise less than 50%, less than 40%, less than 30%, less than 20%, or less than 10% of the internal length of the inner cavity.

[0114] Each (or each) heating coil of the plurality of heating coils 351 (e.g., the first heating coil 351a and / or the second heating coil 351b) may be provided with a resistive member defining the heating coil. The heating coils 351 may include an electrically insulating coating, such as ceramic, to electrically insulate the heating coil 351a from the elongated housing 302. In embodiments, the electrically insulating coating is thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302. In embodiments, the electrically insulating coating is omitted. In embodiments, a separate electrically insulating component is provided, such as at least one of an electrically insulating member and an electrically insulating filler. In embodiments, the electrically insulating member and the electrically insulating filler are thermally conductive to provide heat transfer from the heating element 350 to the elongated housing 302.

[0115] The heater coil 351 of the heating element 350 may be a resistance heater coil. The heater coil 351 may be a helical coil. The heater coil 351 may have, for example, a rectangular cross-sectional profile or a circular cross-sectional profile. The heater coil 351 may be formed of a resistance material such as a nickel / chromium alloy such as nichrome 80 / 20 (80% nickel, 20% chromium), an iron / chromium / aluminum alloy, or a copper / nickel alloy.

[0116] The heater (heating component) 300 may be provided with an electrical connection path. The heater 300 may have separate electrical connection paths for each of the first heater coil 351a and the second heater coil 351b, or the first heater coil 351a and the second heater coil 351b may share an electrical connection path. In an embodiment in which the first heater coil 351a and the second heater coil 351b share an electrical connection path, the distal end of one heater coil may have an electrical connection path to the proximal end of the other heater coil.

[0117] The heater 300 may have separate electrical connection paths for the first and second heater coils 351a and 351b. The base electrical connection path 370b may be connected to the proximal end of the first heater coil 351a. The return electrical path 370a may be connected to the distal end of the first heater coil 351a. The base electrical connection path 360a may be connected to the proximal end of the second heater coil 351b. The return electrical path 360b may be connected to the distal end of the second heater coil 351b. Embodiments are conceivable in which the return electrical connection path overlaps the longitudinal range of the heating element 350. The electrical connection path may be formed integrally with the heating element 350, for example, as a single wire. In embodiments, connectors may connect the electrical connection path to the heater coils 351a and 351b.

[0118] The aerosol supply device may comprise the heater 300 described above with reference to Figure 7, and a controller (e.g., a control circuit / electrical circuit). The aerosol supply device may be configured to heat the aerosol product to generate an aerosol. The controller may be configured to control the operation of a plurality of heater coils 351 (e.g., a first heater coil 351a and a second heater coil 351b). The controller may control the operation of the heater coils via an electrical connection path for the heater coils.

[0119] The controller may be configured to control the first heater coil 351a independently of the second heater coil 351b. The controller may be configured to control the first heater coil 351a to have a first heating profile and the second heater coil 351b to have a second different heating profile. The controller may be configured to control the first heater coil 351a and the second heater coil 351b in parallel (i.e., simultaneously). The controller may be configured to control the first heater coil 351a and the second heater coil 351b independently in order to provide a uniform temperature profile across the elongated housing 302.

[0120] By controlling the first heater coil 351a independently of the second heater coil 351b, a more uniform heating profile overall of the heating element 350 may be possible. For example, the heater coils may be controlled independently to counteract existing temperature gradients along the elongated housing 302. The heater coils may also be controlled independently, either additionally or otherwise, to take into account differences in the coils and / or their positions (e.g., based on manufacturing tolerances). However, in embodiments, this may also, or instead, allow different heater coils to operate (power and provide heat) at different times, or to intentionally provide a non-uniform heating profile of the heating element 350.

[0121] The controller may include one or more temperature sensors. The temperature sensors may measure the temperature of the aerosol product in the elongated housing 302 and / or the aerosol supply device. The controller may be configured to control the heater coils based on the temperature sensors. In one embodiment, each of the multiple heater coils has a temperature sensor.

[0122] Figure 8(a) shows an embodiment in which two heater coils 351a and 351b are positioned so as not to coincide in the direction of their longitudinal axes. The two heater coils 351a and 351b are coaxial. Figure 8(b) shows an embodiment in which two heater coils 351a and 351b are positioned so as not to coincide in the direction of their longitudinal axes. The two heater coils 351a and 351b are arranged to be non-coaxial. Figure 8(c) shows an embodiment in which two heater coils 351a and 351b are positioned so as to partially overlap by less than 5% in the direction of their longitudinal axes. Figure 8(d) shows an arrangement in which two heater coils 351a and 351b have different lengths, and the smaller heater coil 351b is located within the volume of the larger heater coil 35a.

[0123] Figure 9 shows a method for manufacturing a heater for an aerosol supply device according to various embodiments. The method includes providing an elongated housing defining a longitudinal axis extending in the longitudinal direction (step 901), and then positioning a first heater coil within the housing at a first longitudinal position (step 902). The method further includes positioning a second heater coil within the housing at a second longitudinal position (step 903). According to various embodiments, the first position is different from the second position; that is, the first and second heater coils are positioned so as not to coincide in the direction of the longitudinal axis.

[0124] The method may further include the step of accessing the inner gap through a longitudinally extending surface of the housing to position the first and / or second heater coils within the housing. This may allow for easier and / or more precise positioning of the first and / or second heater coils. For example, the method may include the step of inserting the first and / or second heater coils through a gap on the longitudinal side of the housing. Part of the housing may be movable (e.g., sliding or rotatable) to open and / or close the gap.

[0125] A method for generating an aerosol is also disclosed, comprising the steps of providing the aerosol supply device described above, inserting an aerosol product containing an aerosol generating material at least partially into the aerosol supply device, and operating the aerosol supply device.

[0126] In the embodiments described above, the heating element is a resistance heating element. Other types of heating elements, such as induction heating elements, are used in the embodiments. The device configuration is generally as described above, so a detailed explanation is omitted.

[0127] 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) 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.

[0128] In induction heating, heat is generated within the susceptor (heating element), while in resistance heating, heat is generated within the coil (heating element).

[0129] 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.

[0130] 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, A long, slender housing that defines the longitudinal axis, A first heater coil located within the housing, A second heater coil located within the housing and A heater comprising the first heater coil and the second heater coil not coinciding in the direction of the longitudinal axis.

2. The heater according to claim 1, wherein the elongated housing includes an internal void.

3. The heater according to claim 2, wherein the elongated housing is configured to provide access to the inner void via a surface extending longitudinally of the housing during at least part of the manufacturing process of the heater.

4. The heater according to any one of claims 1 to 3, wherein the first heater coil and the second heater coil do not overlap in the longitudinal direction.

5. The heater according to any one of claims 1 to 3, wherein the first heater coil and the second heater coil overlap at least partially in the longitudinal direction.

6. The heater according to any one of claims 1 to 5, wherein the first heater coil and the second heater coil have the same configuration as each other.

7. 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 6.

8. The aerosol supply device according to claim 7, further comprising one or more controllers for controlling the operation of the first heater coil and the second heater coil.

9. The aerosol supply device according to claim 8, wherein one or more controllers are arranged to control the first heater coil independently of the second heater coil.

10. The aerosol supply device according to claim 8 or 9, wherein one or more controllers are arranged to control the first heater coil to have a first heating profile and the second heater coil to have a second different heating profile.

11. The aerosol supply device according to claim 8, wherein the controller controls the first heater coil and the second heater coil in parallel with each other.

12. A system comprising an aerosol supply device according to any one of claims 7 to 11 and an article containing an aerosol generating material.

13. A method for manufacturing or assembling a heater for an aerosol supply device configured to heat an aerosol product containing an aerosol generating material, A step of providing an elongated housing that defines the longitudinal axis, The steps include positioning the first heater coil within the housing, The steps include positioning the second heater coil so that it is located within the housing, A method comprising the first heater coil and the second heater coil not being aligned in the direction of the longitudinal axis.

14. The steps of providing an aerosol supply device according to any one of claims 7 to 11, The steps include: inserting an aerosol product containing an aerosol generating material into the aerosol supply device, at least partially; A method for generating an aerosol containing [a specific substance].

15. The method according to claim 14, further comprising the step of activating the aerosol supply device.

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