Aerosol Delivery System

Abstract

To provide a consumable for an aerosol provision system.SOLUTION: An aerosol provision system 100 comprises: an aerosol generating medium 110; and a source 120 of energy for heating, where the source of energy for heating is configured to cause heating of the aerosol generating medium to form aerosol, where the aerosol generating medium is configured to move within the device between a first position, in which the aerosol generating medium is positioned at a first distance from the source of energy for heating and is heated by the source of energy for heating, and a second position, in which the aerosol generating medium is positioned at a second distance from the source of energy for heating, where the first distance is shorter than the second distance.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery system, a method for generating an aerosol in an aerosol delivery device, an aerosol delivery device and consumables for use in an aerosol delivery device. [Background technology]

[0002] Aerosol delivery devices are known. A typical device uses a heater to generate an aerosol from a suitable medium, which is then inhaled by a user. In many cases, the suitable medium requires a significant level of heating before it can generate an aerosol for inhalation. Similarly, current devices provide the user with a variety of media from which they can generate an inhalable aerosol.

[0003] Various approaches are described herein that aim to help address or alleviate at least some of the problems discussed above. Summary of the Invention

[0004] Aspects of the invention are defined in the appended claims.

[0005] According to some embodiments described herein, an aerosol delivery system is disclosed comprising an aerosol generating medium and a heating energy source configured to cause heating of the aerosol generating medium to generate an aerosol, wherein the aerosol generating medium is configured to move within the device between a first position, where the aerosol generating medium is disposed at a first distance from the heating energy source and is heated by the heating energy source, and a second position, where the aerosol generating medium is disposed at a second distance from the heating energy source, the first distance being less than the second distance.

[0006] According to some embodiments described herein, a consumable for an aerosol delivery system is disclosed.

[0007] According to some embodiments described herein, there is provided an aerosol supply means comprising an aerosol generating means and a heating means configured to cause heating of the aerosol generating means to generate an aerosol, wherein the aerosol generating means source is configured to move within the device between a first position where the aerosol generating means is positioned a first distance from a heating energy source and heated by the heating means, and a second position where the aerosol generating means is positioned a second distance from the heating means, the first distance being smaller than the second distance.

[0008] According to some embodiments described herein, there is provided a method of generating an aerosol in an aerosol delivery system, the method comprising the steps of providing an aerosol generating medium; providing a heating energy source; and moving the aerosol generating medium from a first position, where the aerosol generating medium is disposed a first distance from the heating energy source and is heated by the heating energy source, to a second position, where the aerosol generating medium is disposed a second distance from the heating energy source, the first distance being less than the second distance.

[0009] According to some embodiments described herein, there is provided an aerosol delivery device configured to receive an aerosol generating medium, the aerosol delivery device comprising a heating energy source configured to heat the aerosol generating medium in use to generate an aerosol, the aerosol delivery device being configured to move in use between a first position where the aerosol generating medium is disposed a first distance from the heating energy source and heated by the heating energy source, and a second position where the aerosol generating medium is disposed a second distance from the heating energy source, the second distance being less than the first distance.

[0010] The present teachings will now be described, by way of example only, with reference to the following figures, in which like parts are indicated with like reference numerals, in which: [Brief description of the drawings]

[0011] [Figure 1] 1 is a schematic cross-sectional view of a portion of an aerosol delivery system according to an example embodiment. [Diagram 2] 1 is a schematic cross-sectional view of a portion of an aerosol delivery system according to an example embodiment. [Diagram 3] 1 is a schematic cross-sectional view of a portion of an aerosol delivery system according to an example embodiment. [Figure 4] 1 is a schematic diagram of a heater and an aerosol-generating medium source, according to some examples. [Diagram 5] 1 is a schematic cross-sectional view of a portion of an aerosol delivery system according to an example embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] While the invention is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description of the specific embodiments are not intended to limit the invention to the particular forms disclosed. On the contrary, the invention covers all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

[0013] Aspects and features of specific examples and embodiments are discussed / described herein. Some aspects and features of specific examples and embodiments may be implemented in a conventional manner and, for the sake of brevity, are not discussed / described in detail. Thus, it should be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented according to any conventional technique for implementing such aspects and features.

[0014] The present disclosure relates to aerosol delivery systems, such as e-cigarettes (also referred to as aerosol delivery systems). Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may sometimes be used. However, it should be understood that these terms may be used interchangeably with aerosol delivery systems / devices and electronic aerosol delivery systems / devices. Additionally, as is common in the art, the terms "aerosol" and "vapor" and related terms such as "vaporization," "volatilization," and "aerosolization" may generally be used interchangeably.

[0015] 1 shows a schematic diagram of a portion of an aerosol delivery system 100. The system (sometimes referred to herein as device) 100 includes an aerosol-generating medium source 110 (including or consisting of an aerosol-generating medium) within the device 100. The device 100 includes a heating energy source 120 (sometimes referred to as a heater) configured to cause heating of the aerosol-generating medium to generate an aerosol. The source 110 is configured to move within the device 100 between a second position (stowing position) 130 away from the heater 120 and a first position (aerosol-generating position) 140 in which the aerosol-generating medium source 110 is in contact with the heating energy source 120 (or heater). The heater 120 may be configured to heat the aerosol-generating medium directly or indirectly.

[0016] The aerosol-generating medium source 110 may include an aerosol-generating medium in the form of a portion or dose 114 of the aerosol-generating medium. The terms portion and dose may be used interchangeably throughout this specification and are intended to mean a portion of the entire aerosol-generating medium.

[0017] The aerosol-generating medium source 110 may take any suitable form or configuration. In one embodiment, the aerosol-generating medium source may include a substrate (e.g., paper, card, foil) including a first and second side, and the aerosol-generating medium is disposed on the first side of the substrate. The substrate in this case may act as a carrier for the aerosol-generating medium. In some embodiments, the substrate may be or may include a metal element arranged to be heated by a varying magnetic field. In such an embodiment, the heating energy source 120 may include an induction coil that, when energized, causes heating in the metal element of the source 110. The degree of heating may be affected by the distance between the metal element and the induction coil. In a further alternative embodiment, the aerosol-generating medium source 110 may consist entirely (or substantially entirely) of the aerosol-generating medium (i.e., no carrier). For purposes of describing a specific example, the source 110 described herein includes a substrate having an aerosol generating medium disposed on a first side of the substrate, and the heating energy source 120 is herein a resistive heater.

[0018] As shown in FIG. 1, the source 110 can move between the stowed position 130 and the aerosol generation position 140 along the direction indicated by arrow A. The heater 120 is a constrained heater 120. The heater 120 is constrained from moving towards the stowed position 130 within the device 100. "Towards" in this context is interpreted to mean directly towards, rather than in any direction in which the distance between the heater 120 and the stowed position 130 is reduced. The heater 120 is prevented from moving on an axis aligned with the stowed position 130 and the heater 120. The axis along which the heater 120 is prevented from moving is indicated in FIG. 1 by arrow A.

[0019] During periods of non-operation of the device 100, the source 110 is maintained in the storage position 130. The storage position 130 may be located between two sections of the housing of the device 100, as shown in FIG. 1. The storage position 130 may be a groove, a protected cavity, or the like, in the device 100. The storage position 130 is a protected position in the device 100, and may protect the source 110 from damage, for example, during transportation of the device 100. Protection may be provided by elements or features of the housing of the device 100, as shown in FIG. 1. Protection may be provided by shielding or covering the source 110 in some way, for example, by covering a majority of the source 110. There may be only one path in and out of the storage (second) position 130 along the axis of movement of the source 110. In another configuration (not shown), the device 100 may have a door or cover that can be closed when the source 110 is in the storage position 130 to completely cover the source 110. When the source 110 is moved into the storage location 130 through the entrance to the storage location 130, the door can automatically close over the entrance to the storage location 130.

[0020] The aerosol generation (first) position 140, shown by the position depicted in dashed lines in FIG. 1, is a position where the heater 120 can cause heating of the source 110. The heater 120 and the source 110 can be proximate, adjacent, or abutting while at the aerosol generation position 140. The source 110 can be positioned downstream of the heater 120 in relation to the air flow through the device, such that the aerosol generated by the heater 120 from the source 110 flows away from the heater 120. This configuration reduces the possibility of aerosol condensation on the heater 120, thus increasing the cleanliness of operation of the device 100. Furthermore, this increases the life of the heater 120, thus reducing the maintenance costs of the device 100.

[0021] At the aerosol-generating location 140, the distance between the aerosol-generating medium source 110 and the heating energy source 120 may be controlled (e.g., kept the same) to provide a more consistent user experience. In one example, the aerosol-generating medium is positioned at a distance from the heating energy source 120 within a range of 0.010 mm, 0.015 mm, 0.017 mm, 0.020 mm, 0.023 mm, 0.025 mm, 0.05 mm, 0.075 mm, 0.1 mm to about 4 mm, 3.5 mm, 3 mm, 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm, 0.5 mm, or 0.3 mm. In some cases, there may be a minimum spacing between the heating energy source 120 and the aerosol-generating medium 110 of at least about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm, or 0.1 mm. These distances may include the thickness of the substrate of the source 110. In other examples, the heating energy source 120 and the aerosol-generating medium may be in direct contact, thus a distance of 0.000 mm. In embodiments in which the heating energy source 120 is in contact with the aerosol-generating medium source 110, the heating energy source 120 may actively compress at least a portion of the aerosol-generating medium source 110 (which may cause a reduction in the thickness of the aerosol-generating medium source 110 in the vicinity of the application of the compressive force, compared to the uncompressed state). This may further increase the efficiency of heat transfer.

[0022] The source 110 can be moved to the aerosol generation position 140 before or at the start of a smoking session. The movement of the source 110 can be automated or can occur at the request of the user. The automation of the movement of the source 110 can be achieved, for example, using a puff detector. Upon detection of a puff by the user (one puff being one inhale), the source 110 can be moved from the storage position 130 to the aerosol generation position 140. The device 100 can have a detector or sensor, for example, located in the mouthpiece of the device 100, so that when the user places the device 100 in his mouth, the source 110 is moved from the storage position 130 to the aerosol generation position 140. Alternatively, the mouthpiece (or other components connected to the source 110) can be movable to affect the movement of the source 110. The mouthpiece may have an element, such as a biased member, e.g., a tensioned spring, that is influenced by placement of the mouthpiece in the user's mouth to directly or indirectly move the source 110. The mouthpiece and housing of the device 100 may be slidably movable relative to one another, with movement of the mouthpiece directly moving the source 110 into abutment against the heater 120. The device 100 may alternatively or additionally have a button or the like that a user can press to indicate movement of the source 110 from the stowed position 130 to the aerosol generating position 140. Activation of the heater 120 may occur prior to, in parallel with, or with a delay from the movement of the source 110.

[0023] FIG. 2 shows a schematic diagram of a portion of the aerosol delivery device 100. Reference numbers indicating the same features as those shown in FIG. 1 are the same as those used in FIG. 1. These same features will not be discussed in detail here. FIG. 2 shows the aerosol delivery device 100 with a heater movement mechanism 150. The source 110 shown in FIG. 2 has a plurality of doses 114 of an aerosol generating medium. The doses 114 may be disposed on a surface of a substrate of the source 110 or may be disposed within the source 110. The heater movement mechanism 150 is configured to move the heater 120 at least on an axis indicated by the arrow B in the example shown in FIG. 2. The heater movement mechanism 150 includes a link 152 to the heater 120 to facilitate the movement of the heater 120. The link 152 may be an element that allows the heater 120 to move, such as a shaft connected to a motor. The link 152 may be a mechanical link 152 that may cooperate with other elements, such as a rail, biased member, or pulley system, to allow movement of the heater 120. The movement of the heater 120 is along an axis that is not parallel to the axis along which the source 110 may move between the stowed position 130 and the aerosol generation position 140. The heater 120 may be configured to move on an axis that is not aligned with the stowed position 130 and the heater 120. As shown in FIG. 2, the arrows A and B are disposed at an angle. In the particular example shown in FIG. 2, the arrows A and B are set substantially perpendicular to each other.

[0024] The heater 120 may be moved prior to or at the start of a smoking session. As described above with reference to the source 110, movement and / or activation of the heater 120 may be automated using a puff detector or sensor or the like, such that the heater 120 is in a position to provide heat to the source 110 for as long as heat is needed. Alternatively, the device 100 may have a user-actuable button to initiate a smoking sequence that includes movement of the heater 120 by the movement mechanism 150. The heater 120 may be moved mechanically, such as by a mouthpiece being placed in the user's mouth.

[0025] The heater 120 may be activated prior to movement along the axis indicated by arrow B. This may occur in response to the start of a smoking session being detected by a puff sensor or actuation of a user-actuable button, as described above. The device 100 may have a controller for controlling the movement and heating phases to maximize the user experience.

[0026] FIG. 3 shows a schematic diagram of a portion of the aerosol delivery device 100. Reference numbers indicating the same features as those shown in FIGS. 1 and 2 are the same as the reference numbers used in FIGS. 1 and 2. These same features will not be discussed in detail here. FIG. 3 shows the aerosol delivery device 100 with a source movement mechanism 160. The source movement mechanism 160 is configured to move the source 110 at least on an axis indicated by the arrow A in the example of FIG. 3. Although not explicitly shown in FIG. 3, in this embodiment, the source 110 may include a planar portion or be substantially planar, and the movement of the source 110 along the axis A may include the movement of the source along a perpendicular line to the planar section of the source 110. That is, the perpendicular line to the planar section is parallel or substantially parallel to the axis A. The source movement mechanism 160 includes a link 162 to the source 110 to enable the movement of the source 110. The link 162 may be an element that enables the movement of the source 110, such as a shaft connected to a motor. Link 162 may be a mechanical link 162 that may cooperate with other elements, such as a rail, biased member, or pulley system, to facilitate movement of source 110 .

[0027] 3 is shown disposed near both the storage location 130 and the aerosol generation location 140. In one example, the source movement mechanism 160 may be disposed within the cavity in which the storage location 130 is located. In another example, the source movement mechanism 160 may be disposed near the aerosol generation location 140. The source movement mechanism 160 may be disposed on the axis indicated by arrow A. For example, the source movement mechanism 160 may be disposed on the opposite side of the source 110 relative to the aerosol generation location 140 along the axis indicated by arrow A.

[0028] Either the heater movement mechanism 150 or the source movement mechanism 160 may be a motor or other drive system, or may be a biased member, or the like. The mechanisms 150, 160 may be structures such as cams, gears, bearings, shafts, or the like. The movement provided may be constant or variable in speed. The movement may allow for rapid movement of the source 110 towards the aerosol generation position 140 to quickly provide aerosol to the user upon actuation, or may allow for slower movement of the source 110 towards the storage position 130 so that it may be carefully stored. This may help extend the life of the system 100 by avoiding mechanical collisions.

[0029] The source 110 may include only one dose of aerosol-generating medium or several individual doses 114 of aerosol-generating medium. In embodiments including multiple doses, each dose 114 may be individually heatable to generate a predetermined amount of aerosol for each use. The doses 114 may be disposed on the substrate within or on the source 110 in separate, or may overlap or be adjacent (i.e., different doses may constitute different regions of a single region of aerosol-generating medium). Each of the multiple doses 114 may be individually heatable using a respective heater of a corresponding multiple heaters 120 or by relative translational motion between the heater 120 and the dose 114 of aerosol-generating medium to align the different doses 114 with the heater 120 at different times.

[0030] FIG. 4 shows schematic diagrams of four combinations of source 110 and heater 120. The example shown in FIG. 4(i) shows a rectangular source 110 and a rectangular heater 120. This view can be a cross-sectional view or a side view of the source 110 and heater 120. FIG. 4(i) shows a complementary combination of shapes for the source 110 and heater 120. The heater 120 can abut the source 110 such that there is no and no air gap between the source 110 and the heater 120 when the source 110 is in the aerosol generation position 140. An air gap is undesirable because air trapped in the air gap requires heating before the source 110 receives thermal energy so that it can generate an aerosol. This is inefficient for heating the source 110 and should therefore be avoided.

[0031] FIG. 4(ii) shows a curved source 110 and a complementarily curved heater 120. The source 110 is concavely curved and the heater 120 is convexly curved. The contact surface area between the source 110 and the heater 120 is larger than that in the example shown in FIG. 4(i). Therefore, the heat transfer is more efficient in the example shown in FIG. 4(ii). This reduces the time required for aerosol to be generated during heating of the source 110. Furthermore, this improves the user experience of the device 100. In other embodiments, the source 110 may not be concavely curved, but when the convex heater 120 engages with the source 110, the convex heater 120 can compress the source 110 to form a concave shape in the source 110.

[0032] The radius of curvature of the convex heater 120 can be formed about one or more axes. For example, the heater can be substantially cubic with a semi-cylindrical cross section (i.e., the radius of curvature is formed about one axis (through a longitudinal portion) of the heater 120). Alternatively, the heater can be dome- or crown-shaped (i.e., the radius of curvature is formed about multiple axes). A dome shape for the heater 120 improves heat transfer from the heater 120 to the complementary shaped source 110. Additionally, a circular or dome-shaped heater shape provides the advantage of reducing localized stress areas in the source 110 upon forcing of the heater 120 into the source 110 that may cause the source 110 to break.

[0033] FIG. 4(iii) shows a curved source 110 and a complementarily curved heater 120 with a different curvature than that shown in FIG. 4(ii). The contact surface area between the heater 120 and the source 110 is increased compared to the configuration of FIG. 4(i), similar to FIG. 4(ii). As mentioned above, this increases the heat transfer and therefore reduces the time required to generate an aerosol from the source 110. Further shapes can be envisioned, but the manufacturing complexity should be taken into account along with simply trying to maximize the contact surface area. Close but deep vibration of the heater 120 as shown in FIG. 4(iv) can result in a very high contact surface area, but this increases the manufacturing complexity and requires high accuracy of alignment between the heater 120 and the source 110.

[0034] The heater 120 can be moved to press against and apply pressure to the aerosol generating medium source 110. This further improves heat transfer, and slight compression of the source 110 further improves heat transfer and therefore the efficiency of the device 100. This can extend the battery life of the device 100 and reduce power usage. The arrangement of FIG. 4(iv) may be inappropriate for compression of the source 110, as the protrusions of both the heater 120 and the source 110 can be stress concentration areas and can be prone to bending or breaking. Furthermore, misalignment of the protrusions during movement to heat can lead to tearing of the source 110 or breakage of the heater 120. As mentioned above, the dome shape offers advantages associated with reducing localized stress areas in the source 110 so that greater compression can be used with less risk of damaging the source 110 than other types of complementary shapes. During compression, the source 110 can deform.

[0035] FIG. 5 shows a schematic diagram of a portion of an aerosol delivery device 100. Reference numbers indicating the same features as those shown in FIGS. 1, 2, and 3 are the same as those used in FIGS. 1, 2, and 3. These same features will not be discussed in detail here. FIG. 5 shows an aerosol delivery device 100 with an aerosol outlet 170 and a flow path indicated by an arrow 180. The source 110 is shown moving from a storage position 130 to an aerosol generation position 140. The storage position 130 is shown disposed within a cavity 102 formed by a housing element 105. The heater 120 is also shown moving from a non-contact position 190 to a contact position 200. The movement of both the source 110 and the heater 120 prior to generating an aerosol is shown as being substantially toward the aerosol outlet 170.

[0036] An advantage of this arrangement is that the flow paths 180 are reduced by an amount related to the distance traveled by the source 110 and heater 120. Reducing the flow paths 180 reduces the number of components (or exposed surface(s) of a given component) on which the generated aerosol can condense. This improves the functional cleanliness of the device 100 and extends the life of components that the aerosol would otherwise come into contact with and cause some damage.

[0037] In the arrangement shown in FIG. 5, the source 110 is held in a storage position 130 near the housing of the device 100. The advantage of this arrangement is that it is structurally simple to allow a user access to the cavity 102 in which the source 110 is stored. When the source 110 is depleted, the user can easily access the cavity 102 to remove the depleted source 110 and replace it with a new source 110. To realize this advantage, it is sufficient to add a door to allow user access to the cavity 102. Such a door may be prevented from opening during the heating period or during the movement of the source 110 or the heater 120 to provide a safe user experience.

[0038] Additionally, the heater 120 is positioned at the contact position 200 during the heating period. Once no more heat is required to generate the aerosol, the heater 120 can be moved to the non-contact position 190. In the example shown in FIG. 5, the non-contact position 190 is positioned further away from the exterior surface of the device 100. This placement is advantageous because the heater 120 does not provide more heat energy near the housing of the device 100 than is required to generate the aerosol from the source 110. This movement away from the housing of the device 100 ensures that the housing is less likely to become hot after aerosol generation from the source 110. This avoids a situation where the housing becomes hot, which can be very uncomfortable for the user.

[0039] The angle between the axes of movement indicated by arrows A and B for source 110 and heater 120 is seen to be substantially 90° in Figure 5. In other examples, the angle can be at least 20°, at least 25°, at least 30°, at least 35°, at least 40°, at least 45°, at least 50°, at least 55°, at least 60°, at least 65°, at least 70°, at least 75°, at least 80°, or at least 85°.

[0040] The source 110 may be moved or moved in other directions or dimensions. This movement may be affected by the source movement mechanism 160 or a different movement mechanism. In one example, the source 110 may rotate about an axis. The source 110 may rotate about an axis substantially in a direction indicated by arrow A. The source 110 may rotate through a set angle between each set of movements from the storage position 130 to the aerosol generation position 140 and back to the storage position 130. In this way, each time the source 110 is moved to the aerosol generation position 140, a different portion of the source 110, and if the source 110 includes several doses 114, a different dose 114 of the source 110 may be provided to the heater 120.

[0041] The source 110 in FIG. 2 has several (four) doses 114 of the aerosol-generating medium. The source 110 may not have any doses 114, may have a single dose 114, etc. In some examples, the doses 114 may be in the form of a block or disk, which may be continuous or discontinuous, disposed on or within the source 110. In other examples, the doses 114 may be in the form of annulus, ring, or any other shape. The source 110 may or may not have a rotationally symmetric distribution of the doses 114 on the surface of the source 110. A symmetric distribution of the doses 114 allows the evenly spaced doses 114 (within a rotationally symmetric distribution) to receive a uniform heating profile from the heater 120 when rotating about the axis A, if desired. It is clear that there is no requirement for a particular distribution of the doses 114 in or on the source 110.

[0042] The device 100 may have multiple chambers or regions that may or may not be separate from each other. The device 100 may have a power chamber (not shown) that includes a power source for powering the heating energy source 120 and / or the movement mechanisms 150, 160. The heating energy source 120 in the above example is an electrical resistance heater 120. However, in other examples, the heating energy source 120 may be a chemically activated heater 120, which may or may not operate by an exothermic reaction or the like. The heating energy source 120 may be part of an inductive heating system, where the heating energy source 120 is an inductive heating energy source and the aerosol generation medium may include a susceptor or the like. The susceptor may be, for example, a sheet of aluminum foil or the like. For purposes of providing a specific example, the heating energy source 120 is described herein as a resistive heater, but it should be understood that different heaters or heating system components are contemplated for use in the devices of the present invention.

[0043] The aerosol-generating medium source 110, or the dose 114 contained in the aerosol-generating medium source 110, may include at least one of tobacco and glycol, and may include an extract (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon, lemon juice, lemon juice, lemon juice extract ... The doses 114 may include, for example, citrus oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, pepper, ginger, anise, coriander, coffee, or mint oil from any species of the genus Mentha), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or mixtures thereof. They may be in any suitable form, such as oil, liquid, or powder. The doses 114 may be separated, adjacent, or overlapping.

[0044] The aerosol-generating layer described herein comprises an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." An amorphous solid is a solid material that can retain a fluid, such as a liquid. In some cases, the aerosol-generating layer comprises about 50 wt%, 60 wt%, or 70 wt% amorphous solid, to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. In some cases, the aerosol-generating layer consists of an amorphous solid.

[0045] In some cases, the amorphous solid may contain 1-50 wt % gelling agent, these weights being calculated on a dry weight basis.

[0046] Suitably, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 27 wt% of the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise from 5 to 40 wt%, 10 to 30 wt%, or 15 to 27 wt% of the gelling agent.

[0047] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica, or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and / or pectin and can be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid can comprise calcium cross-linked alginate and / or calcium cross-linked pectin.

[0048] Suitably, the amorphous solid may comprise from about 5 wt%, 10 wt%, 15 wt%, or 20 wt% to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of the aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise from 10 to 60 wt%, 15 to 50 wt%, or 20 to 40 wt% of the aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of, or consists of glycerol. The inventors have confirmed that if the plasticizer content is too high, the amorphous solid may absorb water and become a material that does not create a suitable consumption experience when used. The inventors have also confirmed that if the plasticizer content is too low, the amorphous solid may become brittle and easily broken. The plasticizer content specified herein provides the amorphous solid with flexibility that allows the amorphous solid sheet to be wound onto a bobbin, which is useful for the manufacture of aerosol products.

[0049] In some cases, the amorphous solid may include a flavoring. Suitably, the amorphous solid may include up to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 20 wt%, 10 wt%, or 5 wt% flavoring. In some cases, the amorphous solid may include at least about 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt%, or 30 wt% flavoring (all calculated on a dry weight basis). For example, the amorphous solid may include 10-60 wt%, 20-50 wt%, or 30-40 wt% flavoring. In some cases, the flavoring (if present) includes, consists essentially of, or consists of menthol. In some cases, the amorphous solid is free of flavoring.

[0050] In some cases, the amorphous solid further comprises tobacco material and / or nicotine. For example, the amorphous solid may further comprise powdered tobacco and / or nicotine and / or tobacco extract. In some cases, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine.

[0051] In some cases, the amorphous solid comprises tobacco extract. In some cases, the amorphous solid may comprise 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the amorphous solid may comprise about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 55 wt%, 50 wt%, 45 wt%, or 40 wt% tobacco extract (calculated on a dry weight basis). For example, the amorphous solid may comprise 5-60 wt%, 10-55 wt%, or 25-55 wt% tobacco extract. The tobacco extract may comprise nicotine in a concentration such that the amorphous solid comprises 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis). In some cases, the amorphous solid may be free of nicotine other than that which originates from the tobacco extract.

[0052] In some embodiments, the amorphous solid does not include tobacco material, but does include nicotine. In some such cases, the amorphous solid may include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 15 wt%, 10 wt%, or 5 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid may include from 1 to 20 wt%, or from 2 to 5 wt% nicotine.

[0053] In some cases, the total content of tobacco materials, nicotine, and flavorings may be at least about 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of tobacco materials, nicotine, and flavorings may be less than about 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0054] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis (WWB). In some cases, the hydrogel may contain at least about 2 wt% or at least about 5 wt% water (WWB).

[0055] The amorphous solid can be made from a gel, which may further include a solvent present at 0.1-50 wt %. However, the inventors have found that the inclusion of a solvent in which the fragrance is soluble may reduce the stability of the gel and may cause the fragrance to crystallize from the gel. Thus, in some cases, the gel does not include a solvent in which the fragrance is soluble.

[0056] The amorphous solids contain less than 20 wt%, suitably less than 10 wt%, or less than 5 wt% of filler. The fillers may include one or more inorganic fillers, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic absorbents, such as molecular sieves. The fillers may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In some cases, the amorphous solids contain less than 1 wt% of filler, and in some cases, no filler. In particular, in some cases, the amorphous solids do not contain calcium carbonate, such as chalk.

[0057] In some cases, the amorphous solid may consist essentially of, or consist essentially of, a gelling agent, an aerosol forming agent, a tobacco material and / or a nicotine source, water, and optionally flavorings.

[0058] In the above examples, the source 110 may have a base, coating, or the like that is substantially impermeable to the aerosol. This configuration may encourage the aerosol generated by heating the aerosol-generating medium source 110 to flow away from the heater 120 and along the flow path 180 towards the outlet 170. This may help reduce the likelihood of condensation of the aerosol within the device 100, thus increasing the cleanliness and lifespan of the device 100, as discussed above. The base may be formed from at least one of the following materials: a nicotine-containing material, tobacco, or a tobacco derivative.

[0059] The substrate of the source 110 may be impermeable to the aerosol, or may be porous to allow the aerosol-generating medium to enter the pores of the substrate 110. In one example, the substrate of the source 110 may have permeable and impermeable portions. The permeable portions may be located in areas where it is desired for the aerosol to pass through the substrate, allowing the aerosol to flow through the substrate of the source 110 toward the outlet of the device 100. The impermeable portions may be located in areas where it is desired to prevent the aerosol from flowing toward the heating energy source 120.

[0060] Thus, an aerosol supply device is described that includes an aerosol generating medium source and a heater configured to cause heating of the aerosol generating medium to generate an aerosol, wherein the source is configured to move within the device between a storage position away from the heater and an aerosol generating position where the aerosol generating medium source is in contact with the heater.

[0061] The aerosol delivery system can be used in tobacco industry products, for example, non-combustion aerosol delivery systems.

[0062] In one embodiment, a tobacco industry product includes one or more components of a non-combustion aerosol delivery system, such as a heater and an aerosolizable substrate.

[0063] In one embodiment, the aerosol delivery system is an e-cigarette, also known as a vaping device.

[0064] In one embodiment, an e-cigarette comprises a heater, a power source capable of powering the heater, an aerosolizable substrate such as a liquid or gel, a housing, and optionally a mouthpiece.

[0065] In one embodiment, the aerosolizable substrate is contained in or on a substrate container, hi one embodiment, the substrate container is combined with or includes a heater.

[0066] In one embodiment, the tobacco industry product is a heating product that releases one or more compounds by heating (but not burning) a substrate material. The substrate material is an aerosolizable material that may be, for example, tobacco or other non-tobacco products that may or may not contain nicotine. In one embodiment, the heating device product is a tobacco heating product.

[0067] In one embodiment, the heating product is an electronic device.

[0068] In one embodiment, the tobacco heating product includes a heater, a power source capable of powering the heater, and an aerosolizable substrate, such as a solid or gel material.

[0069] In one embodiment, the heating product is a non-electronic item.

[0070] In one embodiment, the heating product comprises an aerosolizable substrate, such as a solid or gel material, and a heat source capable of providing thermal energy to the aerosolizable substrate without electronic means, for example by burning a combustible material, such as charcoal.

[0071] In one embodiment, the heating product also includes a filter capable of filtering the aerosol generated by heating the aerosolizable substrate.

[0072] In some embodiments, the aerosolizable substrate material may include an aerosol or aerosol generating agent, or a humectant, such as glycerol, propylene glycol, triacetin, or diethylene glycol.

[0073] In one embodiment, the tobacco industry product is a hybrid system for generating an aerosol by heating (but not burning) a combination of substrate materials. The substrate materials may include, for example, solids, liquids, or gels that may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and a solid substrate. The solid substrate may be, for example, tobacco or other non-tobacco products that may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and tobacco.

[0074] To address various problems and advance the art, the entire disclosure illustrates various embodiments by way of example that may practice the claimed invention and provide an improved electronic aerosol delivery system. The advantages and features of the disclosure are merely representative examples of embodiments and are not exhaustive and / or exclusive. They are presented only to aid in the understanding and teaching of the claimed features. The advantages, embodiments, examples, features, features, structures, and / or other aspects of the disclosure should not be considered limitations on the disclosure as defined by the claims, or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and changes may be made without departing from the scope and / or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. Furthermore, the disclosure includes other inventions that are not currently claimed but may be claimed in the future.

Claims

1. an aerosol generating medium; a heating energy source configured to cause heating of the aerosol-generating medium to generate an aerosol; a first movement mechanism configured to cause movement of the aerosol generation medium; a second movement mechanism configured to effect movement of the heating energy source; An aerosol delivery system comprising: the aerosol-generating medium is configured to be moved by the first moving mechanism between a first position, where the aerosol-generating medium is disposed at a first distance from the heating energy source and is heated by the heating energy source, and a second position, where the aerosol-generating medium is disposed at a second distance from the heating energy source, the first distance being smaller than the second distance; the second moving mechanism is configured to move the heating energy source along an axis that is not parallel to a first axis, the first axis being set between the first position and the second position; the second moving mechanism is configured to move the heating energy source prior to, in parallel with, or with a delay from, the movement of the aerosol generating medium. Aerosol delivery system.

2. 2. The aerosol delivery system of claim 1, wherein the first distance is less than or equal to 4 mm.

3. 3. The aerosol delivery system of claim 1, wherein the first distance is equal to or greater than 0.010 mm.

4. The aerosol delivery system of claim 1 or 2, wherein the heating energy source is restricted from moving towards the second position within the device.

5. The aerosol delivery system of claim 1 , wherein the first movement mechanism is user-actuable.

6. 3. The aerosol delivery system of claim 1, wherein in the first position, the aerosol generating medium is compressed by the heating energy source.

7. The aerosol delivery system of any one of claims 1 to 6, wherein the aerosol-generating medium comprises a plurality of portions of aerosol-generating medium.

8. 3. The aerosol delivery system of claim 1, wherein the aerosol generating medium and the heating energy source are configured to abut in a complementary manner.

9. 9. The aerosol delivery system of claim 1, wherein the heating energy source has a substantially rounded edge directed towards the aerosol generation medium.

10. 10. The aerosol delivery system of claim 1, wherein the heating energy source has a shape that is one of a dome shape or a crown shape with a radius of curvature formed about a plurality of axes.

11. The aerosol delivery system of any one of claims 1 to 10, comprising a control unit and a replaceable consumable, the consumable comprising the aerosol generation medium.

12. 12. The aerosol delivery system of claim 1, wherein the second moving mechanism is configured to move the heating energy source at least on a second axis that is substantially perpendicular to the first axis.

13. The aerosol delivery system of any one of claims 1 to 12, wherein the second movement mechanism is user-actuable.

14. 14. The aerosol delivery system of claim 1, wherein the heating energy source provides thermal energy by converting at least one of electrical energy and chemical energy into thermal energy.

15. An aerosol generating medium; heating means configured to cause heating of the aerosol generating medium to generate an aerosol; a first movement mechanism configured to cause movement of the aerosol generation medium; a second movement mechanism configured to effect movement of the heating means; An aerosol supply means comprising: The aerosol-generating medium is configured to be moved by the first moving mechanism between a first position in the device where the aerosol-generating medium is disposed at a first distance from a heating energy source and is heated by the heating means, and a second position where the aerosol-generating medium is disposed at a second distance from the heating means, the first distance being smaller than the second distance; the second moving mechanism is configured to move the heating means along an axis that is not parallel to a first axis, the first axis being set between the first position and the second position; the second moving mechanism is configured to move the heating means prior to, in parallel with, or with a delay from, the movement of the aerosol-generating medium. Aerosol delivery means.

16. 1. A method of generating an aerosol in an aerosol delivery system, comprising: Providing an aerosol-generating medium; Providing a source of energy for heating; providing a first movement mechanism configured to effect movement of the aerosol generation medium; providing a second movement mechanism configured to effect movement of the heating energy source; moving the aerosol-generating medium by the first moving mechanism from a first position where the aerosol-generating medium is disposed at a first distance from the heating energy source and is heated by the heating energy source to a second position where the aerosol-generating medium is disposed at a second distance from the heating energy source, the first distance being smaller than the second distance; moving the heating energy source by the second moving mechanism prior to, in parallel with, or with a delay from the movement of the aerosol generating medium along an axis that is not parallel to the first axis, the first axis being set between the first position and the second position; A method comprising:

17. 17. The method of claim 16, further comprising heating the aerosol generating medium with the heating energy source at the first location to generate an aerosol.

18. 18. The method of claim 16 or 17, further comprising restricting movement of the heating energy source towards the second location within the device.

19. 19. The method of any one of claims 16 to 18, further comprising compressing the aerosol-generating medium by the heating energy source at the first location prior to generating an aerosol.

20. 20. The method of claim 16, wherein the step of moving the aerosol generation medium from the second location to the first location is performed in response to a user command.

21. 1. An aerosol delivery device configured to receive an aerosol-generating medium, comprising: a heating energy source configured in use to heat the aerosol generating medium to generate an aerosol; a first movement mechanism configured, in use, to cause movement of the aerosol generation medium; and a second movement mechanism configured to effect movement of the heating energy source; Equipped with the aerosol delivery device is configured, in use, to move, by the first moving mechanism, between a first position where the aerosol generating medium is disposed at a first distance from the heating energy source and is heated by the heating energy source, and a second position where the aerosol generating medium is disposed at a second distance from the heating energy source, the second distance being smaller than the first distance; the second moving mechanism is configured to move the heating energy source along an axis that is not parallel to a first axis, the first axis being set between the first position and the second position; the second moving mechanism is configured to move the heating energy source prior to, in parallel with, or with a delay from, the movement of the aerosol generating medium. Aerosol delivery device.

22. 22. The aerosol delivery device of claim 21, wherein the first distance is less than or equal to 4 mm.

23. 23. The aerosol delivery device of claim 21 or 22, wherein the first distance is equal to or greater than 0.010 mm.

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