Apparatus for heating an aerosolizable material and method for arranging the apparatus - Patents.com

Abstract

Provided is a device 1 for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user. The device 1 includes a heating arrangement 23 having an elongated heating zone 29 for receiving and heating the aerosolizable material, a power supply zone for mounting a power source 27 that provides heating power for heating the heating zone 29, and a control circuit 25 for controlling the heating power. The power supply zone and control circuit 25 are sequentially arranged in a direction substantially parallel to the longitudinal axis of the device 1, and the elongated heating zone 29 is arranged adjacent to and substantially parallel to the power supply zone and control circuit 25.

Description

[Technical field]

[0001] The present invention relates to an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and a method for configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. 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 heat-to-burn" products, or tobacco heating devices or products, that release compounds by heating a material rather than by burning it. The material may be, for example, tobacco, or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] A first aspect of the invention provides a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, the device comprising a heating arrangement having an elongated heating zone for receiving and heating the aerosolizable material, a power supply zone for locating a power source providing heating power for heating the heating zone, and control circuitry for controlling the heating power, the power supply zone and control circuitry being sequentially arranged in a direction substantially parallel to a longitudinal axis of the device, and the elongated heating zone being arranged adjacent to and substantially parallel to the power supply zone and control circuitry.

[0004] In an exemplary embodiment, the longitudinal axis of the device is the main axis of the device. In an exemplary embodiment, the longitudinal axis of the device is parallel to the longitudinal axis of the elongated heating zone.

[0005] In an exemplary embodiment, the longitudinal axis of the elongated heating zone is disposed parallel to the longitudinal axis of each of the power supply zone and the control circuitry.

[0006] In an exemplary embodiment, an elongated heating zone is disposed on one side of the power source and on one side of the power circuit.

[0007] In an exemplary embodiment, an elongated heating zone is disposed within the power supply and control circuitry in a direction substantially parallel to the longitudinal axis of the elongated heating zone.

[0008] In an exemplary embodiment, one end of the power source is located closer to the proximal end of the device than one end of the elongated heating zone is to the proximal end of the device.

[0009] In an exemplary embodiment, one end of the control circuit is connected to one end of the elongated heating zone of the device.

[0010] In an exemplary embodiment, the device includes an opening for receiving an aerosolizable material, and the power zone is disposed closer to the opening than the control circuitry is disposed at the opening.

[0011] In an exemplary embodiment, the control circuitry comprises a plurality of printed circuit boards (PCBs) arranged substantially parallel in a direction substantially perpendicular to the longitudinal axis of the device. In an exemplary embodiment, each PCB has a depth parallel to the depth of the device. In an exemplary embodiment, each of the plurality of PCBs is electrically connected. In an exemplary embodiment, the plurality of PCBs is provided as a split PCB. In an exemplary embodiment, one of the plurality of PCBs comprises an electrical connection port for electrical connection between the device and an external power source. In an exemplary embodiment, the electrical connection port is located at an end opposite the opening for receiving the aerosolizable material, and the electrical connection port faces outward in a direction substantially perpendicular to the longitudinal axis of the device. In an exemplary embodiment, the direction substantially perpendicular to the longitudinal axis of the device is a lateral direction.

[0012] In an exemplary embodiment, the power supply zone is disposed alongside the heating zone and along only a portion of the length of the heating zone.

[0013] In an exemplary embodiment, the control circuitry is positioned alongside the heating zone and along only a portion of the length of the heating zone.

[0014] In an exemplary embodiment, the power supply zone is disposed along a first portion of the length of the heating zone and the control circuitry is disposed along a second portion of the length of the heating zone, the size of the first portion being greater than the size of the second portion.

[0015] In an exemplary embodiment, each PCB has substantially the same length.

[0016] In an exemplary embodiment, each PCB is substantially planar.

[0017] In an exemplary embodiment, each PCB has a length that is less than the length of the power zone. In an exemplary embodiment, the length of each PCB is greater than half the length of the power zone.

[0018] In an exemplary embodiment, each PCB has a length between 30 mm and 40 mm. In an exemplary embodiment, the length is between 35 mm and 38 mm. In an exemplary embodiment, the length is between 36 mm and 37 mm. In an exemplary embodiment, the length is approximately 36.6 mm.

[0019] In an exemplary embodiment, the depth of at least one of the PCBs is between 1 mm and 2 mm. In an exemplary embodiment, the depth is between 1 mm and 1.5 mm. In an exemplary embodiment, the depth is about 1.2 mm.

[0020] In an exemplary embodiment, the apparatus includes a first chassis for independently supporting the power supply zones and a second chassis for independently supporting the heating elements and the control circuitry.

[0021] In an exemplary embodiment, the power supply zone has a volume that is greater than the volume of the control circuitry and the volume of the elongated heating zone. In an exemplary embodiment, the volume of the elongated heating zone is greater than the volume of the control circuitry.

[0022] In an exemplary embodiment, the depth of the power supply zone is greater than the depth of the control circuitry and the depth of the elongated heating zone. In an exemplary embodiment, the width of the power supply zone is greater than the depth of the elongated heating zone.

[0023] In exemplary embodiments, the aerosolizable material includes tobacco and / or is reconstituted and / or is in the form of a gel and / or includes an amorphous solid.

[0024] A second aspect of the invention provides a method for configuring a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, the method comprising the steps of providing a heating arrangement with an elongated heating zone for receiving and heating the aerosolizable material, and sequentially arranging a power supply zone and control circuitry in a direction substantially parallel to a longitudinal axis of the device, the power supply zone for accommodating a power source for providing heating power for heating the heating zone, the elongated heating zone being arranged adjacent to and substantially parallel to the power supply zone and the control circuitry.

[0025] In an exemplary embodiment, the arranging step includes sequentially arranging the power sources and control circuits of the power zone in a direction substantially parallel to a longitudinal axis of the device.

[0026] In an exemplary embodiment, the method includes installing a power source in a power zone.

[0027] In exemplary embodiments, the aerosolizable material includes tobacco, and / or is reconstituted, and / or is in the form of a gel, and / or includes an amorphous material.

[0028] Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, made with reference to the accompanying drawings, in which:

[0029] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0030] [Figure 1] FIG. 1 is a schematic perspective view of an example of an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the apparatus being shown with a consumable containing the aerosolizable material inserted therein. [Diagram 2] 2 is a schematic front view of the exemplary device of FIG. 1 with a consumable inserted. [Diagram 3] FIG. 2 is a schematic right side view of the exemplary device of FIG. 1 with a consumable inserted. [Figure 4] FIG. 2 is a schematic left side view of the exemplary device of FIG. 1 with a consumable inserted. [Diagram 5] 5 is a schematic cross-sectional front view of the exemplary device of FIG. 1 with a consumable inserted, taken along line AA shown in FIG. 4. [Figure 6] 2 is a schematic cross-sectional front view of the exemplary device of FIG. 1 without a consumable inserted therein; [Figure 7] 1 is a flow diagram illustrating an example method of configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] As used herein, the term "aerosolizable material" includes materials that upon heating provide volatilized components, typically in the form of a vapor or aerosol. An "aerosolizable material" may be a non-tobacco-containing material or a tobacco-containing material. An "aerosolizable material" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. An "aerosolizable material" may be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, amorphous, gelled sheet, powder, or mass, etc. An "aerosolizable material" may also include other non-tobacco products, and may or may not contain nicotine, depending on the product. An "aerosolizable material" may include one or more humectants, such as glycerol or propylene glycol. The term "aerosol-generating material" may also be used interchangeably herein with the term "aerosolizable material."

[0032] As noted above, the aerosolizable material may comprise an "amorphous body," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." An amorphous body is a solid material that may hold some fluid therein, such as a liquid. In some cases, the aerosolizable material comprises about 50 wt%, 60 wt%, or 70 wt% amorphous body to about 90 wt%, 95 wt%, or 100 wt% amorphous body. In some cases, the aerosolizable material consists of amorphous body.

[0033] As used herein, the term "sheet" means an element having a width and length that is substantially greater than its thickness. A sheet can be, for example, a strip.

[0034] As used herein, the term "heating material" or "heater material" refers, in some instances, to a material that is heatable by penetration by a varying magnetic field, for example, when an aerosolizable material is heated by an inductive heating arrangement.

[0035] Other forms of heating the heating material include resistive heating, which involves an electrical resistive heating element that heats up when an electrical current is applied to the electrical resistive heating element, thereby transferring heat by conduction to the heating material.

[0036] Referring to Figure 1, a schematic perspective view of a device 1 according to an embodiment of the present invention is shown. The device 1 is for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user. In this embodiment, the aerosolizable material includes tobacco and the device 1 is a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device). The device 1 is a handheld device for inhalation of the aerosolizable material by a user of the handheld device.

[0037] The device 1 comprises a first end 3 and a second end 5 opposite the first end 3. The first end 3 may be referred to herein as the oral or proximal end of the device 1. The second end 5 may be referred to herein as the distal end of the device 1. The device 1 has an on / off button 7 to enable the device 1, as a whole, to be switched on and off as desired by a user of the device 1.

[0038] Generally speaking, the device 1 is configured to generate an aerosol to be inhaled by a user by heating an aerosol-generating material. In use, the user inserts an article 21 into the device 1 and activates the device 1, for example using the button 7, so that the device 1 begins to heat the aerosol-generating material. The user then sucks on the mouthpiece 21b of the article 21 near the first end 3 of the device 1 to inhale the aerosol generated by the device 1. When the user sucks on the article 21, the generated aerosol flows through the device 1 along a flow path towards the proximal end 3 of the device 1.

[0039] In an example, vapor is generated which then at least partially condenses to form an aerosol before exiting the device 1 to be inhaled by the user.

[0040] In this regard, it should first be noted that, in general, a vapor is a substance in the gas phase that is below its critical temperature, meaning that, for example, a vapor can be condensed into a liquid by increasing its pressure without lowering its temperature. On the other hand, in general, an aerosol is a colloid of fine solid particles or liquid droplets in air or another gas. A "colloid" is a substance that has microscopically dispersed insoluble particles suspended throughout another substance.

[0041] For reasons of convenience, the term aerosol, as used herein, should be taken to mean an aerosol, a vapor, or a combination of aerosol and vapor.

[0042] The device 1 includes a casing 9 for arranging and protecting the various internal components of the device 1. The casing 9 is thus an outer housing for containing the internal components. In the illustrated embodiment, the casing 9 includes a sleeve 11 that circumscribes the device 1 and is fitted with a top panel 17 at the first end 3 that generally defines a "top" of the device 1, and a bottom panel 19 at the second end 5 (see Figures 2-5) that generally defines a "bottom" of the device 1.

[0043] The sleeve 11 comprises a first sleeve 11a and a second sleeve 11b. The first sleeve 11a is provided at an upper portion of the device 1, shown as the upper portion of the device 1, and extends away from the first end 3. The second sleeve 11b is provided at a lower portion of the device 1, shown as the lower portion of the device 1, and extends away from the second end 5. The first sleeve 11a and the second sleeve 11b each surround the periphery of the device 1. That is, the device 1 includes a longitudinal axis in the Y-axis direction, and the first sleeve 11a and the second sleeve 11b each surround an internal component in a radial direction to the longitudinal axis. The longitudinal axis is the main axis of the device 1.

[0044] In this embodiment, the first sleeve 11a and the second sleeve 11b are removably engaged with one another. In this embodiment, the first sleeve 11a is engaged with the second sleeve 11b in a snap-fit ​​arrangement that includes a groove and a recess.

[0045] In some embodiments, top panel 17 and / or bottom panel 19 may be removably secured to corresponding first and second sleeves 11a, 11b, respectively, to allow easy access to the interior of device 1. In some embodiments, sleeve 11 may be "permanently" secured to top panel 17 and / or bottom panel 19, for example, to prevent a user from accessing the interior of device 1. In one embodiment, panels 17 and 19 are made of a flexible material, including, for example, glass-filled nylon formed by injection molding, and sleeve 11 is made of aluminum, although other materials and manufacturing processes may be used.

[0046] The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which a consumable 21 containing an aerosolizable material is inserted into and removed from the device 1 by a user during use. In this embodiment, the consumable 21 functions as a mouthpiece for a user to place between the user's lips. In other embodiments, an external mouthpiece can be provided through which at least one volatile component of the aerosolizable material is drawn. When an external mouthpiece is used, no aerosolizable material is placed within the external mouthpiece.

[0047] In this embodiment, the opening 20 is opened and closed by a lid 4. In the embodiment shown, the lid 4 is movable between a closed position and an open position, and when in the open position allows for the insertion of a consumable 21 into the device 1. The lid 4 is configured to move bidirectionally along the X-axis direction.

[0048] A connection port 6 is shown at the second end 5 of the device 1. The connection port 6 is for connection to a cable and power source 27 (shown in FIG. 6) for charging the power source 27 of the device 1. The connection port 6 extends in the Z-axis direction from the front side of the device 1 to the rear side of the device 1. As shown in FIG. 3, the connection port 6 is accessible on the right side of the device 1 at the second end 5 of the device 1. Advantageously, the device 1 can be stood up at the second end 5 while charging or to enable a data connection through the connection port 6. In the illustrated embodiment, the connection port 6 is a Universal Serial Bus (USB) socket.

[0049] Referring to FIG. 2, the first sleeve 11a comprises a surface at the first end 3 of the device 1 that is tapered. The tapered surface has a first angle α with respect to a surface of the second sleeve 11b at the second end 5. In this embodiment, the surface of the second sleeve 11b at the second end 5 is substantially parallel to the X-axis direction. Thus, as shown, the consumable 21 can be inserted through an opening 20 (shown in FIG. 1) at the proximal portion of the first end 3. Where the first sleeve 11a and the second sleeve 11b meet at the junction 11c, a second angle β is formed with respect to the X-axis direction. The second angle β is shown to be greater than the first angle α.

[0050] Figures 3 and 4 respectively show the right and left sides of the device 1. Here, the consumable 21 is shown in a laterally central position because the opening 20 through which the consumable 21 is inserted is located at the midpoint of the device along the Z axis and is also off-centre.

[0051] 5 and 6 show schematic cross-sectional views from the front of the device 1 shown in FIG. 4 along line AA with the consumable inserted and extracted, respectively.

[0052] As shown in FIG. 6, in the casing 9, a heater arrangement 23, a control circuit 25 and a power supply 27 are arranged or fixed. In this embodiment, the control circuit 25 is part of the electronics compartment and comprises two printed circuit boards (PCBs) 25a, 25b. The control circuit 25 thus comprises electrical components for controlling the heating of the heating arrangement 23. In this embodiment, the control circuit 25 and the power supply 27 are laterally adjacent to the heater arrangement 23 (i.e. adjacent when viewed from the end), and the control circuit 25 is located below the power supply 27. This advantageously allows the device 1 to be compact in the lateral direction corresponding to the X-axis direction.

[0053] In this embodiment, control circuitry 25 includes a controller, such as a microprocessor arrangement, constructed and arranged to control the heating of aerosolizable material within consumable 21, as described further below.

[0054] In this embodiment, the power source 27 is a rechargeable battery. In other embodiments, a non-rechargeable battery, a capacitor, or a battery-capacitor hybrid may be used, or a connection to an electrical mains supply may be used. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (such as nickel cadmium batteries), alkaline batteries, and / or the like. The battery 27 is electrically connected to the heater arrangement 23 to provide power when needed and to heat the aerosolizable material in the consumable under the control of the control circuitry 25 (to volatilize the aerosolizable material without burning the aerosolizable material, as described above).

[0055] An advantage of locating the power supply 27 laterally adjacent to the heater arrangement 23 is that a physically larger power supply 27 can be used without the device 1 as a whole becoming too long. As will be appreciated, a physically larger power supply 27 will have a higher capacity (i.e., total electrical energy that can be delivered, often measured in ampere-hours or the like) and therefore the battery life of the device 1 may be longer.

[0056] In one embodiment, the heater configuration 23 is generally in the form of a hollow cylindrical tube having a hollow inner heating chamber 29 into which the consumable 21, including the aerosolizable material, is inserted for heating during use. Generally speaking, the heating chamber 29 is a heating zone for receiving the consumable 21. Different configurations for the heater configuration 23 are possible. In some embodiments, the heater configuration 23 may comprise a single heating element or may be formed of multiple heating elements aligned along the longitudinal axis of the heater configuration 23. The or each heating element may be annular or tubular about its circumference, or at least partially annular or partially tubular. In one embodiment, the or each heating element may be a thin film heater. In another embodiment, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which may be layered and sintered. Other heater components are also possible, including induction heating, infrared heater elements that heat by emitting infrared radiation, or resistive heating elements formed, for example, by resistive electrical windings.

[0057] In this embodiment, the heater construction 23 is supported by a stainless steel support tube 75 and comprises a heater 71. In one embodiment, the heater 71 comprises a substrate on which at least one conductive element is formed. The substrate may take the form of a sheet and may comprise, for example, a flexible layer. In a preferred embodiment, this layer is a polyimide layer. The conductive element or elements may be printed or separately applied to the substrate layer. The conductive element or elements may be encapsulated within or coated by the substrate.

[0058] The support tube 75 is a heating element that transfers heat to the consumable 21. Thus, the support tube 75 is made of a heating material. In this embodiment, the heater material is stainless steel. In other embodiments, other metallic materials may be used as the heating material. For example, the heating material may include a metal or a metal alloy. The heating material may include one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, ferritic stainless steel, molybdenum, copper, and bronze.

[0059] The heater arrangement 23 is dimensioned such that when the consumable 21 is inserted into the device 1, substantially the entirety of the aerosolizable material is heated in use.

[0060] In some embodiments, the or each heating element may be arranged so that selected zones of aerosolizable material are heated independently, e.g., sequentially (over time), or together (simultaneously), as desired.

[0061] In this embodiment, the heater arrangement 23 is surrounded by a vacuum region 31 along at least a portion of its length. The vacuum region 31 helps reduce heat transfer from the heater arrangement 23 to the outside of the device 1, thereby helping to keep the power requirements of the heater arrangement 23 low, as it reduces heat loss overall. The vacuum region 31 also helps to keep the outside of the device 1 cool during operation of the heater arrangement 23. In some embodiments, the vacuum region 31 may be surrounded by a double-walled sleeve, with the region between the two walls of the sleeve evacuated to provide a low pressure region to minimize heat transfer by conduction and / or convection. In other embodiments, a different insulating arrangement may be used in addition to or instead of the vacuum region, for example using a thermal insulating material, including for example a suitable foam type material.

[0062] The casing 9, also referred to as the housing, may further comprise an internal support structure 37 (best seen in FIG. 6) for supporting all the internal components and the heater arrangement 23.

[0063] The device 1 further comprises a collar 33 that extends around and projects from the opening 20 into the inside of the housing 9, and an expansion element 35 located between the collar 33 and one end of the vacuum region 31. The expansion element 35 is funnel-shaped to form an expansion chamber 40 at the mouth end 3 of the device 1. The collar 33 is a retainer for holding the consumable 21 (best seen in FIG. 5). In this embodiment, the retainer is removably removable from the device 1.

[0064] One end of the expansion element 35 connects to and is supported by the first sleeve 11a, and the other end of the expansion element 35 connects to and is supported by one end of the cassette 51. A first sealing element 55, shown as an O-ring, is disposed between the expansion element 35 and the first sleeve 11a, and a second sealing element 57, shown as an O-ring, is disposed between the expansion element 35 and the cassette 51. Each O-ring is made of silicone, although other elastomeric materials may be used to provide a seal. The first and second sealing elements 55, 57 prevent the migration of gas into the surrounding components of the device 1. A sealing element is also provided at the distal end to prevent fluid ingress and egress at the distal end.

[0065] As best seen in FIG. 6, the collar 33, extension element 35 and vacuum region 31 / heater arrangement 23 are coaxially arranged such that when the consumable 21 is inserted into the device 1, the consumable extends through the collar 33 and extension element 35 into the heating chamber 29, as best seen in FIG.

[0066] As mentioned above, in this embodiment, the heater arrangement 23 is generally in the form of a hollow cylindrical tube. The heating chamber 29 formed by this tube is in fluid communication with the opening 20 at the mouth end 3 of the device 1 via an expansion chamber 40.

[0067] In this embodiment, the expansion element 35 comprises a tubular body having a first open end adjacent the opening 20 and a second open end adjacent the heating chamber 29. The tubular body comprises a first section extending approximately halfway along the tubular body from the first open end and a second section extending approximately halfway along the tubular body to the second open end. The first section comprises a flared portion that widens away from the second section. Thus, the first section has an inner diameter that narrows outwardly toward the open first open end. The second section has a substantially constant inner diameter.

[0068] As best seen in Fig. 6, in this embodiment, the extension element 35 is disposed within the housing 9 between the collar 33 and the vacuum region 31 / heater arrangement 23. More specifically, at a second open end of the extension element 35, the extension element 35 is disposed between an end portion of the support tube 75 of the heater arrangement 23 and the inside of the vacuum region 31, such that the second open end engages the support tube 75 and the inside of the vacuum region 31. At a first open end, the extension element 35 receives the collar 33 such that the legs 59 of the collar 33 protrude into the expansion chamber 40. Thus, the inner diameter of the first section of the extension element 35 is greater than the outer diameter of the legs when the consumable 21 is received within the device 1 (see Fig. 5) and when the consumable 21 is not present.

[0069] As best seen in Figure 5, the inner diameter of the first section of the expansion element 35 is larger than the outer diameter of the consumable 21. Thus, when the consumable 21 is inserted into the device 1 over at least a portion of the length of the expansion element 35, a gap 36 exists between the expansion element 35 and the consumable 21. The gap 36 is around the entire circumference of the consumable 21 in that region.

[0070] As best seen in FIG. 6, the collar 33 includes a number of legs 59. In this embodiment, there are four legs 59, with only three visible in the perspective of FIG. 6. However, in other embodiments, the legs 59 may be more or less than four. The legs 59 are equally spaced circumferentially on the inner surface of the collar 33 and are disposed within the expansion chamber 40 when the device 1 is assembled. In this embodiment, the legs 59 are equally spaced circumferentially on the periphery of the opening 20 when installed in the device 1. In one embodiment, there are four legs 59, and in other embodiments, there may be more or less than four legs 59. Each of the legs 59 extends in the Y-axis direction, parallel to the longitudinal axis of the expansion chamber 40, and protrudes into the opening 20. The legs 59 also extend radially toward the expansion element 35 at the tips 59a of the legs 59, such that the tips 59a are angled away from each other. The tip 59a of each leg 59 allows for better passage of the consumable 21 to avoid damage to the consumable 21 when inserting and / or removing it from the device 1. Collectively, the legs 59 provide a gripping section that grips the consumable 21 to properly position and hold the consumable 21 within the expansion chamber 40 when the consumable 21 is in the device 1. Between them, the legs 59 lightly squeeze or pinch the consumable 21 in the area of ​​the consumable contacted by the legs 59.

[0071] The legs 59 may be made of an elastic material (or may be elastic in some other way), so that when the consumable 21 is inserted into the device 1, they slightly deform (e.g., compress) in order to better grip the consumable 21, but then regain their original shape when the consumable 21 is removed from the device 1, since the legs 59 are biased to the rest position shown in FIG. 6. Thus, the legs 59 are reversibly movable from a first position, which is a rest position, to a second position, which is a deformed position shown in FIG. 5, whereby the consumable 21 is gripped. In this embodiment, the legs 59 are integrally formed with the main body of the collar 33. However, in some embodiments, the legs 59 may be separate components attached to the body of the collar 33. The inner diameter of the space formed between the legs 59 in the first position, which is a rest position, is, for example, 4.8 mm to 5 mm, preferably 4.9 mm. The legs 59 occupy space within the opening 20 such that the open area of ​​the opening 20 with the legs 59 in place is less than the open area of ​​the opening 20 without the legs 59 .

[0072] For example, the expansion element 35 may be formed of a flexible material including, for example, polyetheretherketone (PEEK), which has a relatively high melting point compared to most other thermoplastics and is highly resistant to thermal degradation.

[0073] 6, in this embodiment, the heating chamber 29 communicates with a region 38 of reduced inner diameter towards the distal end 5. This region 38 defines a cleaning chamber 39 formed by a cleaning tube 41. The cleaning tube 41 is a hollow tube that provides an end stop for the consumables 21 (see FIG. 5) that have passed through an opening at the oral end 3. The cleaning tube 41 is configured to support and position the heater arrangement 23.

[0074] The device 1 further comprises a lid 61 at the distal end 5 of the device 1, which opens and closes an opening in the bottom panel 19 to allow access to the heating chamber 29 so that it can be cleaned. The lid 61 pivots about a hinge 63. Such access through the lid 61 allows, among other things, a user to clean the heater arrangement 23 and the inside of the heating chamber 29 at the distal end 5. When the lid 61 is open, a straight through hole is provided through the entire device 1 between the opening 20 at the mouth end 3 and an opening at one end of the cleaning chamber at the distal end 5 of the device 1. Thus, the user can easily clean substantially the entire interior of the hollow heating chamber 29. Thus, the user can access the heating chamber 29 through either end of the device 1 as he prefers. The user may use one or more of a variety of cleaning devices for this purpose, including, for example, a traditional pipe cleaner or a brush or the like.

[0075] 6, the top panel 17 generally forms the first end 3 of the housing 9 of the device 1. The top panel 17 supports a collar 33 that defines an insertion point in the form of an opening 20 through which a consumable 21 is removably inserted into the device 1 during use.

[0076] The collar 33 extends around the opening 20 and projects therefrom into the interior of the housing 9. In this embodiment, the collar 33 is a separate element from the top panel 17 and is attached to the top panel 17 through a fastener such as a bayonet locking mechanism. In other embodiments, adhesive or screws may be used to bond the collar 33 to the top panel 17. In other embodiments, the collar 33 may be integral with the top panel 17 of the housing 9, such that the collar 33 and top panel 17 form a single piece.

[0077] 5 and 6, the open space defined by adjacent pairs of legs 59 of the consumable 21 and collar 33 form air passages 20a around the outside of the consumable 21. Such air passages 20a allow hot steam escaping from the consumable 21 to flow out of the device 1 and also allow cool air to flow into the device 1 around the consumable 21. In this embodiment, four air passages are located around the periphery of the consumable 21, which provides ventilation for the device 1. In other embodiments, more or fewer such air passages 20a may be provided.

[0078] Referring again in particular to FIG. 5, in this embodiment, the consumable 21 is in the form of a cylindrical rod, which has or contains aerosolizable material 21a at its rear end in the section of the consumable 21 that is within the heater arrangement 23 when the consumable 21 is inserted into the device 1. The front end of the consumable 21 extends from the device 1 and serves as a mouthpiece 21b, which is an assembly that includes one or more of a filter for filtering the aerosol and / or a cooling element 21c for cooling the aerosol. The filter / cooling element 21c is spaced from the aerosolizable material 21a by a space 21d and also from the tip of the mouthpiece assembly 21b by a further space 21e. The consumable 21 is circumferentially coated with an outer layer (not shown). In this embodiment, the outer layer of the consumable 21 is permeable to allow some heated volatile components from the aerosolizable material 21a to escape from the consumable 21.

[0079] During operation, the heater arrangement 23 heats the consumable 21 to volatilize at least one component of the aerosolizable material 21a.

[0080] The primary flow path of the heated volatile components from the aerosolizable material 21a is axially through the consumable 21, through space 21d, filter / cooling element 21c, and further space 21e before entering the user's mouth through the open end of mouthpiece assembly 21b. However, some of the volatile components may leak out of the consumable 21, through its permeable outer covering, and into the space 36 surrounding the consumable 21 in the expansion chamber 40.

[0081] It is undesirable for the user to inhale volatile components that flow from the consumable 21 into the expansion chamber 40 because these components have not passed through the filter / cooling element 21c and therefore have not been filtered or cooled.

[0082] Advantageously, the volume of air surrounding the consumable 21 within the expansion chamber 40 cools at least a portion of the volatile components that escape from the consumable 21 through its outer layer, causing them to condense on the inner walls of the expansion chamber 40, preventing them from being inhaled by the user.

[0083] This cooling effect may be aided by cooling air that may enter the space 36 surrounding the consumable 21 in the expansion chamber 40 from outside the device 1 via the air passage 20a that allows fluid to flow into and out of the device. A first air passage is defined between a pair of adjacent legs 59 of the collar 33 to provide ventilation around the outside of the consumable 21 at the insertion point. A second air passage is provided between a second pair of adjacent legs 59 to allow at least one heated volatile component to flow from the consumable 21 at the second location. Thus, ventilation is provided around the outside of the consumable 21 at the insertion point by the first and second air passages. Furthermore, heated volatile components that escape from the consumable 21 through its outer covering may safely flow out of the device 1 via the air passage 20a without condensing on the inner walls of the expansion chamber 40 and being inhaled by the user. Both the expansion chamber 40 and the venting aid in reducing the temperature and content of the water vapor composition that is released into the heated volatile components from the aerosolizable material.

[0084] The device 1 is fitted with a thermal liner 13 towards the first end 3 of the device 1. As shown in FIG. 6, the thermal liner 13 is bonded to the first sleeve 11a. The thermal liner 13 is a heat diffuser that helps manage heat distribution and helps protect the first sleeve 11a from thermal stress by distributing the internal heat generated by use of the device 1 over a larger area. The thermal liner 13 is made from a metallic material such as aluminum to be lightweight and to dissipate heat well around the proximal end 3. This helps avoid localized hot spots and increases the life of the first sleeve 11a. The liner 13 distributes heat by conduction. The liner 13 is not configured to insulate or reflect heat by radiation.

[0085] As shown in FIG. 6, the support tube 75 is coated on the outside with a heater 71. In this example, the heater 71 is a thin film heater comprising polyimide and conductive elements. The heater 71 can comprise multiple heating regions that are independently controlled and / or multiple heating regions that are simultaneously controlled. In this example, the heater 71 is formed as a single heater. However, in other embodiments, the heater 71 may be formed with multiple heaters aligned along the longitudinal axis of the heating chamber 29. In some embodiments, multiple temperature sensors may be used to detect the temperature of the heater 71 and / or the support tube. In this embodiment, the support tube 75 is made of stainless steel to conduct heat from the heater 71 toward the consumable 21 when the consumable 21 is inserted into the heating zone (the heating zone is defined by the heat conducting area of ​​the support tube 75). In other embodiments, the support tube 75 may be made of a different material, so long as the support tube 75 is thermally conductive. Other heating elements 75 may be used in other embodiments. For example, the heating element may be a susceptor that is inductively heatable.In this embodiment, the support tube 75 serves as an elongated support for supporting the article 21 containing the aerosolizable material, in use.

[0086] In this embodiment, the heater 71 is disposed outside the support tube 75. However, in other embodiments, the heater 71 may be disposed inside the support tube 75. In this embodiment, the heater 71 passes outside the support tube 75 and includes a portion referred to herein as a heater tail 73. The heater tail 73 extends beyond the heating chamber 29 and is configured for electrical connection to the control circuitry 25. In the illustrated embodiment, the heater tail 73 physically connects to one PCB 25a. Electrical current may be provided to the heater 71 by the power supply 27 through the control circuitry 25 and the heater tail 73.

[0087] Because a connection between the heating chamber 29 and the control circuitry 25 is required, it may be difficult to prevent airflow (or any other fluid flow) between the heating chamber 29 and the electronics compartment. In this embodiment, a gasket 15 is used to prevent such fluid flow, as shown in FIG. 6. The gasket 15 includes a first seal 15a and a second seal 15b. The gasket 15 surrounds the heater tail 73 and is clamped together by the base 53 and the cassette 51. In the illustrated embodiment, four fasteners 43 are used to provide sufficient force to clamp the base 53 and the cassette 51 together, sealing access to and from the chamber 29 at this point. The fasteners 43 are screws that are tightened to a predetermined torque. In other embodiments, different fasteners 43, such as bolts, may be used.

[0088] 6, the heating arrangement 23 of the device 1 is disposed in a first volume of the device 1. The heating zone 29 is located in the first volume. In the illustrated embodiment, the heating zone 29 is elongated to receive an elongated article including an aerosolizable material through the opening 20. Thus, the elongated heating zone 29 is for receiving and heating the aerosolizable material.

[0089] The power supply zone is disposed laterally adjacent to the heating zone 29 of the heating device 23 in the X-axis direction. That is, the power supply zone is disposed in a direction substantially parallel to the longitudinal axis BB (shown by a dashed line) of the elongated heating zone. In this embodiment, the longitudinal axis BB of the elongated heating zone 29 is parallel to the longitudinal axis of the device 1. In the illustrated embodiment, the power supply zone is disposed to the right of the heating zone 29.

[0090] The power supply zone is a second space for installing the power supply 27. That is, the power supply 27 occupies the second space. Thus, the power supply 27 can be installed in a compartment of the device, the compartment defining the second space.

[0091] In the embodiment shown in FIG. 6, the device 1 comprises a chassis that is an internal support structure 37 of the device 1. The power source 27 is combinable with and attached to the chassis to independently support the power source 27. The chassis defines a power source zone as a second space. The chassis defines the aforementioned compartment. The power source 27 provides heating power to heat the heating zone 29 such that the aerosolizable material can be heated when the aerosolizable material is within the heating zone 29.

[0092] The control circuit 25 is arranged laterally adjacent to the heating zone 29 of the heating device 23 in the X-axis direction. That is, the control circuit 25 is arranged in a direction substantially parallel to the longitudinal axis BB of the elongated heating zone. Furthermore, the control circuit 25 is longitudinally adjacent (Y-axis direction) to the power source 27 and the power source zone. That is, the power source zone and the control circuit are arranged in sequence in the longitudinal direction of the elongated heating zone 29. In the embodiment provided, the control circuit 25 is arranged below the power source zone, and the control circuit 25 is arranged closer to the distal end 5 of the device 1 than the power source zone. As mentioned above, the control circuit 25 is for controlling the power for heating.

[0093] Both the control circuitry 25 and the heating arrangement 23 are mounted on another chassis shown as the bottom panel 19. The bottom panel defines a space for housing the control circuitry 25. The bottom panel 19 supports the heating arrangement 23 and the control circuitry 25 independently.

[0094] As shown in Fig. 6, the elongated heating zone 29 of the heating device 23 is disposed transversely to both the power supply zone and the control circuit 25. In the longitudinal direction (Y-axis direction), the elongated heating zone 29 overlaps with a portion of the power supply zone and a portion of the control circuit 25. Fig. 6 shows an elongated heating zone 29 with a longitudinal axis BB extending in the Y-axis direction. Thus, the power supply zone and the control circuit 25 are disposed sequentially in a direction substantially parallel to the longitudinal axis BB of the elongated heating zone 29. That is, the power supply zone and the control circuit 25 are disposed consecutively (sequentially) in the Y-axis direction, with the power supply zone being above the control circuit 25 and closer to the proximal end 3 of the device 1 than the control circuit 25.

[0095] The power supply zone is disposed closer to the opening 20 of the device 1 than the control circuitry is disposed at the opening 20 of the device. When the consumable 21 is inserted into the heating zone 29, a proximal end of the consumable 21 passes longitudinally along the power supply zone before passing longitudinally along the control circuitry 25. When fully inserted, the consumable 21 is proximate to both the power supply zone and the control circuitry 25, as shown in FIG. 5. In the illustrated embodiment, when the consumable 21 is fully inserted, the majority of the length of the consumable 21 is adjacent to the power supply zone and a short portion is adjacent to the control circuitry 25. That is, one end of the heating zone 29 is disposed to the side of the control circuitry 25 rather than the power supply zone, as the power supply zone is disposed longitudinally above one end of the heating zone 29.

[0096] As shown in Figures 5 and 6, the two PCBs 25a, 25b of the device 1 are arranged one after the other in the lateral direction (X-axis direction). The two PCBs 25a, 25b are shown as split PCBs in that the two PCBs 25a, 25b are electrically connected. The first PCB 25a is arranged farther away from the heating zone 29 than the second PCB 25b is arranged relative to the heating zone 29. In the illustrated embodiment, the first PCB 25a is electrically connected to the power source 27 and the second PCB 25b is electrically connected to the heater 71, particularly the heater tail 73. In other embodiments, the electrical connections to the PCBs 25a, 25b may be reversed. The first PCB 25a is electrically connected to a connection port 6, such as a USB port, for electrically connecting the device 1 to an external power source (not shown). The connection port 6 is arranged at an opposite end to the opening 20 for receiving the aerosolizable material. The electrical connection port 6 faces outwards in the lateral direction (X-axis direction) of the device 1 .

[0097] 5 and 6, each printed circuit board 25a, 25b has the same length in the Y-axis direction. This allows the control circuit 25 to be compact and the overall length of the device 1 to be shortened. The power supply zone is longer than the control circuit 25 but shorter than the heating device 23.

[0098] The length (Y direction) of each PCB 25a, 25b is 36.6 mm. In some embodiments, the length of each PCB 25a, 25b may be 36 mm to 37 mm. The depth (X direction) of each PCB 25a, 25b is 1.2 mm. Thus, the depth may be referred to as the thickness. In some embodiments, the depth of each PCB 25a, 25b is 1 mm to 1.5 mm. A gap is shown between each PCB 25a, 25b. In this embodiment, the gap is about twice the depth of the PCBs 25a, 25b.

[0099] Referring to Figure 7, a flow diagram is shown illustrating one example of a method 100 of configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. The method is suitable for the apparatus 1 shown in Figures 1-6.

[0100] The method 100 includes the steps of providing a heating device 101 with an elongated heating zone for receiving and heating an aerosolizable material, and arranging 102 a power supply zone and a control circuit in sequence in a direction substantially parallel to a longitudinal axis of the device, the power supply zone for mounting a power supply for providing heating power to heat the heating zone, the elongated heating zone being arranged adjacent to and substantially parallel to the power supply zone and the control circuit, i.e., the power supply zone and the control circuit are stacked on top of each other. When arranged, the elongated heating zone is transverse to the power supply zone and the control circuit.

[0101] In some embodiments, the arranging step 102 includes sequentially arranging the power sources and control circuits in the power source zone in a direction substantially parallel to the longitudinal axis of the device. In some embodiments, the method 100 includes installing a power source in the power source zone.

[0102] In some embodiments, the aerosolizable material includes tobacco. However, in other embodiments, the aerosolizable material may consist of tobacco, consist substantially entirely of tobacco, include tobacco and aerosolizable materials other than tobacco, include aerosolizable materials other than tobacco, or may not include tobacco. In some embodiments, the aerosolizable material may include a vapor, or an aerosol-forming agent, or a humectant, such as glycerol, propylene glycol, triacetin, or diethylene glycol.

[0103] In some embodiments, the aerosolizable material is a non-flowable aerosolizable material and the device is for heating the non-flowable aerosolizable material to volatilize at least one component of the aerosolizable material.

[0104] Once all, or substantially all, of the one or more volatile components of the aerosolizable material in the consumable item 21 have been consumed, the user may remove the item 21 from the device 1 and discard the item 21. The user may subsequently reuse the device 1 with another item 21. However, in other embodiments, the item may be non-consumable, and once the one or more volatile components of the aerosolizable material have been consumed, the device and the item may be discarded together.

[0105] In the embodiment described herein, the consumable 21 includes a mouthpiece assembly 21b. However, it should be understood that in other embodiments, the exemplary device as described herein may include a mouthpiece. For example, the device 1 may include a mouthpiece that is integral with the device, or in other embodiments, the device may include a mouthpiece that is removably attached to the device 1. In an example, the device 1 may be configured to receive an aerosolizable material to be heated. The aerosolizable material may be included in a consumable that does not include a mouthpiece portion. A user may suck on the mouthpiece of the device 1 to inhale the aerosol generated by the device by heating the aerosolizable material.

[0106] In some embodiments, article 21 is sold, supplied, or provided separately from the device 1 in which article 21 can be used. However, in some embodiments, device 1 and one or more of articles 21 may be provided together as a system, such as a kit or assembly, possibly with additional components such as a cleaning implement.

[0107] To address various problems and advance the art, the entirety of this disclosure illustrates, by way of illustration and example, various embodiments in which the claimed invention may be practiced and which provide an improved heating element for use with an apparatus for heating an aerosolizable material, a method for forming a heating element for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and a system comprising a heating element that can be heated by such an apparatus. The advantages and features of the present disclosure are merely of a representative sample of embodiments and are not exhaustive and / or exclusive. They are presented solely to aid in understanding and to teach the claimed and otherwise disclosed features. It is to be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limitations on the disclosure as defined by the claims, or limitations on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. The present disclosure may include other inventions that may be claimed in the future, but are not currently claimed.

Claims

1. 1. An apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, comprising: a heating arrangement comprising an elongated heating zone for receiving and heating the aerosolizable material; a power supply zone for installing a power supply that supplies heating power for heating the heating zone; A control circuit for controlling the power for heating; Equipped with the power supply zones and the control circuitry are arranged in sequence in a direction substantially parallel to a longitudinal axis of the device; the elongated heating zone is disposed adjacent to and substantially parallel to the power supply zone and the control circuit; the control circuit comprises a plurality of printed circuit boards (PCBs) arranged substantially parallel in a direction substantially perpendicular to a longitudinal axis of the device; Device.

2. an opening for receiving the aerosolizable material; The apparatus of claim 1 , wherein the power zone is disposed closer to the opening than the control circuitry is disposed at the opening.

3. The device of claim 2 , wherein one of the PCBs comprises an electrical connection port for electrical connection between the device and an external power source.

4. 4. The device of claim 3, wherein the electrical connection port is located at an end opposite the opening for receiving the aerosolizable material, and the electrical connection port faces outward in a direction substantially perpendicular to a longitudinal axis of the device.

5. An apparatus according to any preceding claim, wherein the power supply zone is disposed alongside the heating zone and along only a portion of the length of the heating zone.

6. An apparatus according to any preceding claim, wherein the control circuitry is disposed alongside the heating zone and along only a portion of the length of the heating zone.

7. 7. The apparatus of claim 1, wherein the power supply zone is disposed along a first portion of the length of the heating zone and the control circuitry is disposed along a second portion of the length of the heating zone, the size of the first portion being greater than the size of the second portion.

8. The apparatus of claim 1, wherein each of the PCBs has substantially the same length.

9. The apparatus of claim 1, wherein each of the PCBs has a length that is shorter than the length of the power supply zone.

10. The apparatus of claim 9 , wherein a length of each of the PCBs is greater than half a length of the power zone.

11. 11. Apparatus according to any one of claims 1 to 10, comprising a first chassis for independently supporting the power supply zone and a second chassis for independently supporting the heating arrangement and the control circuitry.

12. 1. A method for configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, comprising: providing a heating arrangement comprising an elongated heating zone for receiving and heating the aerosolizable material; sequentially arranging power zones and control circuits in a direction substantially parallel to a longitudinal axis of the device; Including, The power supply zone is for installing a power supply that supplies heating power for heating the heating zone, the elongated heating zone is disposed adjacent to and substantially parallel to the power supply zone and the control circuitry; The method, wherein the control circuitry comprises a plurality of printed circuit boards (PCBs) arranged substantially parallel in a direction substantially perpendicular to a longitudinal axis of the device.

13. 13. The method of claim 12, wherein the arranging step comprises sequentially arranging the power sources and the control circuits of the power source zones in a direction substantially parallel to a longitudinal axis of the device.

14. 14. The method of claim 12 or 13, comprising locating the power source in the power source zone.

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