Non-flammable aerosol delivery device

Abstract

A non-combustible aerosol delivery device (100) for generating an aerosol from an aerosol-generating material is disclosed, comprising a chamber (102) for receiving a consumable comprising an aerosol-generating material and for enabling the non-combustible aerosol delivery device (100) to generate an aerosol from the aerosol-generating material, the chamber (102) configured to accommodate, one at a time, a first consumable comprising an aerosol-generating material at a first axial position within the chamber (102) and a second consumable comprising an aerosol-generating material having dimensions different from the dimensions of the first consumable at a second axial position within the chamber (102).

Description

[Technical Field]

[0001] The present invention relates to a non-combustible aerosol delivery device and a non-combustible aerosol delivery system, the non-combustible aerosol delivery system comprising a non-combustible aerosol delivery device and a consumable comprising an aerosol-generating material, the non-combustible aerosol delivery device being configured to generate an aerosol from the aerosol-generating material. [Background technology]

[0002] (background) Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds without combustion. Examples of such products include heating devices that release compounds by heating, rather than burning, a material. The material can be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] (overview) According to a first aspect of the present disclosure, there is provided a non-combustible aerosol delivery device for generating an aerosol from an aerosol-generating material, the non-combustible aerosol delivery device comprising a chamber for receiving a consumable comprising the aerosol-generating material and enabling the non-combustible aerosol delivery device to generate an aerosol from the aerosol-generating material, the chamber being configured to accommodate, one at a time, a first consumable comprising the aerosol-generating material at a first axial position within the chamber and a second consumable comprising the aerosol-generating material having dimensions different from the dimensions of the first consumable at a second axial position within the chamber.

[0004] The chamber can be configured to accommodate a first consumable having a first width at a first axial position within the chamber and a second consumable having a second width at a second axial position within the chamber, the first width being less than the second width.

[0005] The chamber can include a first section and a second section, the second section having a width that is less than the width of the first section.

[0006] The first section and the second section may be tubular sections arranged end to end to form a chamber, and the device may include an opening at a proximal end of the first section configured to allow insertion of the first consumable and the second consumable into at least the first section.

[0007] The proximal end of the second section may define a stopper abutted by the distal end of the second consumable to prevent the second consumable from entering the second section, thereby positioning the second consumable at a second axial position within the chamber.

[0008] The device may comprise a first heating arrangement arranged to heat the first section to generate the aerosol, and a second heating arrangement arranged to heat the second section to generate the aerosol.

[0009] The first heating arrangement and the second heating arrangement may be controllable independently of each other to heat the first section and the second section, respectively.

[0010] The device may include a first distal stopper for positioning the distal end of the first consumable and a second distal stopper for positioning the distal end of the second consumable, the first distal stopper and the second distal stopper being located at different axial positions within the chamber.

[0011] The second distal stop may comprise a step surrounding a recess extending distally of the step, and the first distal stop may be located within the recess.

[0012] The recess may include a gripping formation biased to grip a distal end of the first consumable when the distal end of the first consumable is received within the recess.

[0013] The chamber may be defined by a heated tube configured to be heated and transfer heat to a consumable comprising an aerosol-generating material received within the chamber, thereby heating the aerosol-generating material and generating an aerosol.

[0014] The heating tube may be a susceptor element configured to be inductively heated by an inductive element of the device to thereby heat the aerosol-forming material received in the chamber. The heating tube may be configured to be resistively heated to thereby heat the aerosol-forming material received in the chamber.

[0015] The device may include one or more heat transfer elements for transferring heat from the heating tube to the consumable, the one or more heat transfer elements being configured to protrude radially inward from the inner wall of the heating tube and to engage consumables having different diameters.

[0016] The one or more heat transfer elements may be flexible elements configured to flex to engage consumables having different diameters.

[0017] The device may include a heating arrangement configured to be inserted within the consumable to heat an aerosol-forming material within the consumable, thereby generating an aerosol from the aerosol-forming material.

[0018] The device may be a tobacco heating product, and the first consumable and second consumable may each be a consumable comprising tobacco that is heated by the device to produce an aerosol.

[0019] According to a second aspect of the present disclosure, there is provided a non-combustible aerosol delivery system comprising a non-combustible aerosol delivery device according to the first aspect of the present disclosure and at least one of a first consumable containing an aerosol-generating material and a second consumable containing an aerosol-generating material, wherein the first consumable and the second consumable are configured to be received by the non-combustible aerosol delivery device one at a time and enable the device to generate an aerosol from the aerosol-generating material.

[0020] Further features and advantages of the present 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: [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 shows a simplified schematic representation of an example of a non-combustible aerosol delivery device according to the present invention. [Figure 2] FIG. 2 is a side view of another exemplary non-combustible aerosol delivery device according to the present invention. [Figure 3] FIG. 3 is a cross-sectional side view of the non-combustible aerosol delivery device of FIG. 2. [Figure 4A] 4 is a cross-sectional side view of the non-combustible aerosol delivery device of FIGS. 2 and 3 showing a first consumable and a second consumable received by the device. FIG. [Figure 4B] 4 is a cross-sectional side view of the non-combustible aerosol delivery device of FIGS. 2 and 3 showing a first consumable and a second consumable received by the device. FIG. [Figure 5A] FIG. 1 is a perspective view of an exemplary heating chamber for an exemplary non-combustible aerosol delivery device. [Figure 5B] FIG. 5B is a perspective cross-sectional view of a combination of the heating chamber and insulating tube shown in FIG. 5A. [Figure 6] FIG. 2 is a perspective cross-sectional view showing another example of a non-combustible aerosol delivery device according to the present invention. [Figure 7A] 7 is a perspective cross-sectional view showing the heating chamber of the device of FIG. 6 receiving a first consumable and a second consumable. [Figure 7B] 7 is a perspective cross-sectional view showing the heating chamber of the device of FIG. 6 receiving a first consumable and a second consumable. [Figure 7C] FIG. 7C is a schematic top view of the structure shown in FIGS. 7A and 7B. [Figure 7D] FIG. 7C is a schematic top view of the structure shown in FIGS. 7A and 7B. [Figure 8] FIG. 2 is a perspective cross-sectional view showing another example of a non-combustible aerosol delivery device according to the present invention. [Figure 9A] 9 is a cross-sectional side view showing the heating chamber of the device of FIG. 8 receiving a different consumable. [Figure 9B] 9 is a cross-sectional side view showing the heating chamber of the device of FIG. 8 receiving a different consumable. [Figure 9C] FIG. 9C is an enlarged cutaway view of a portion of the construct shown in FIGS. 9A and 9B. [Figure 9D] FIG. 9C is an enlarged cutaway view of a portion of the construct shown in FIGS. 9A and 9B. [Figure 10A] FIG. 1 is a side view of an example of a heated tube for use with a non-combustible aerosol delivery device according to the present invention. [Figure 10B] 10B is an enlarged cross-sectional side view of a portion of the heated tube of FIG. 10A when the heated tube is receiving a different consumable. [Figure 10C] 10B is an enlarged cross-sectional side view of a portion of the heated tube of FIG. 10A when the heated tube is receiving a different consumable. DETAILED DESCRIPTION OF THE INVENTION

[0022] (Detailed explanation) 1 is a simplified schematic diagram of an exemplary non-combustion aerosol delivery device 100. Non-combustion aerosol delivery device 100 includes a heating chamber 102. Heating chamber 102 is configured to receive a consumable product (not shown in FIG. 1) that includes an aerosol-generating material, which may or may not include tobacco.

[0023] An aerosol-generating material is a material capable of generating an aerosol when activated, for example, by heating, irradiation, or any other method. The aerosol-generating material can be, for example, in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material can comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid can be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material can comprise, for example, about 50%, 60%, or 70% by weight of an amorphous solid to about 90%, 95%, or 100% by weight of an amorphous solid.

[0024] The aerosol-generating material may comprise one or more active agents and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0025] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, a dietary supplement, a nootropic, or a psychoactive substance. The active substance may be naturally derived or synthetically obtained. The active substance may comprise, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0026] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0027] The one or more other functional materials may comprise one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0028] The aerosol-forming material can comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material can comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0029] A consumable is an item that includes or is composed of aerosol-generating material, some or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that generates heat during use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0030] In this example, non-combustion aerosol delivery device 100 is for heating an aerosol-generating material in a consumable product to volatilize at least one component of the aerosol-generating material. Hereinafter, non-combustion aerosol delivery device 100 will be referred to as device 100. Device 100 is configured to heat an aerosol-generating material in a consumable product (not shown in FIG. 1 ) that includes the aerosol-generating material and is received in a desired heating chamber 102. Device 100 includes a heating element 104 configured to provide energy to heat the aerosol-generating material in the consumable product received in heating chamber 102. In some examples, heating element 104 includes one or more resistive heating elements positioned in thermal contact with heating chamber 102. Heat is generated by the flow of electric current against the electrical resistance of the one or more resistive heating elements. This process is referred to as Joule heating, ohmic heating, or resistive heating.

[0031] The susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field into the conductive material results in induction heating of the heating material. The heating material may be a magnetic material, such that the penetration of the varying magnetic field into the magnetic material results in magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field may also be referred to herein as a magnetic field generator.

[0032] In some examples, the heating component 104 is an induction heating component and is configured to generate a varying magnetic field to inductively heat the susceptor. As described in more detail below, in some examples, the susceptor is configured to define the heating chamber 102 for receiving the consumable. The induction heating component can include one or more inductors through which an alternating current is passed to generate the varying magnetic field. In some examples using induction heating, the heating component 104 includes one or more susceptors. In other examples using induction heating, the heating component 104 may not include a susceptor; instead, one or more susceptors may be provided as part of / with a consumable intended for use with the device 100.

[0033] The device 100 includes a power source 106. The power source 106 provides power to various components of the device 100. In some examples, the power source 106 is a battery. In some examples, the power source 106 includes a battery and a DC-DC converter, where power is provided from the battery through the DC-DC converter. The DC-DC converter can enable the power source 106 to provide power at a voltage different from that of the battery. In some examples, the device 100 can include a DC / AC converter to convert DC current, for example from a battery, to AC current, for example to provide power to one or more inductors of the heating element 104 (where the heating element 104 is an induction heating element). In the following examples, the power source 106 will be referred to simply as the battery 106.

[0034] 1, the device 100 includes a processor 108 in data communication with a computer-readable memory 110. The processor 108 is configured to control various aspects of the operation of the device 100. The processor 108 controls the various aspects by executing instructions stored on the computer-readable memory 110. For example, the processor 108 may control the operation of the heating element 104. For example, the processor may control the delivery of power from the battery 106 to the heating element 104 by controlling various electrical components such as switches and the like (not shown in FIG. 1).

[0035] Device 100 includes a housing 101 that forms the outer cover of device 100 and encloses and houses the various components of device 100. Chamber 102 in this example is configured to receive a consumable (not shown in FIG. 1 ) comprising an aerosol-generating material, and device 100 is configured to generate an aerosol from the aerosol-generating material. Device 100 can generate an aerosol from the consumable by heating the aerosol-generating material, for example, in a manner as described above. In other examples, the aerosol can be generated from the aerosol-generating material by applying energy to the aerosol-generating material in other ways, for example, by using ultrasonic energy.

[0036] Device 100 has an opening 105 at one end, which allows a consumable to be inserted into chamber 102. As shown in some examples below, in some instances, a portion of the consumable may be received within chamber 102 of device 100, while a portion of the consumable may protrude from opening 105 of device 100. In examples, the portion of the consumable received in chamber 102 comprises an aerosol-generating material, and device 100 is configured to generate an aerosol from the aerosol-generating material. The portion of the consumable protruding from opening 105 may comprise, for example, a filter, and a user can inhale the generated aerosol stream from the portion of the consumable that protrudes from opening 105 by inserting the portion of the consumable that protrudes from opening 105 into their mouth.

[0037] Device 100 may include a user-actuable control element 112, such as a button or switch, that, when pressed, operates device 100. For example, a user may turn device 100 on by operating switch 112.

[0038] The device 100 may also include electrical components, such as a socket / port (not shown), that can accept a cable for charging the battery 106. For example, the socket may be a charging port, such as a USB charging port. In some examples, the socket may also or alternatively be used to transfer data between the device 100 and another device, such as a computing device. The socket may also be electrically coupled to the battery 106 via an electrical track.

[0039] The end of device 100 closest to opening 105 may be known as the proximal end (mouth end) of device 100 because it is closest to the user's mouth during use. During use, a user inserts a consumable into opening 105, operates user control 112 to begin heating the aerosol-generating material, and can inhale at the proximal end of device 100. The aerosol then flows through device 100 along the flow path toward the proximal end of device 100. In an example, a portion of the consumable may protrude from opening 105, and the user may inhale at the proximal end of the consumable, causing the aerosol to flow to the proximal end of device 100 and be inhaled. In another example, device 100 may include a mouthpiece through which the user inhales to inhale the aerosol stream.

[0040] The end of device 100 opposite the proximal end and furthest from opening 105 is sometimes known as the distal end of device 100, as it is the end furthest from a user's mouth during use. When a user inhales aerosol generated within device 100, the aerosol flows away from the distal end of device 100.

[0041] Device 100 may, in some examples, include a lid / cap (not shown) disposed toward the distal end of device 100. Opening the lid / cap may provide access to heating chamber 102. A user may open the second lid, for example, to clean the components within heating chamber 102, e.g., to remove debris from a previous use session.

[0042] The chamber 102 is configured to accommodate, one at a time, a first consumable item and a second consumable item (not shown in FIG. 1 ), such that when the first consumable item is received within the chamber 102, it is accommodated in a first position, while when the second consumable item is received within the chamber 102, it is accommodated in a second position that is different from the first position.

[0043] The first and second consumables have different dimensions from each other. For example, the first and second consumables can have different lengths and / or different diameters. In some examples, the first and second consumables are elongated consumables that may be, for example, substantially cylindrical. The first and second consumables both comprise an aerosol-generating material. The first and second consumables can, for example, comprise a distal portion containing the aerosol-generating material. The first and second consumables can also comprise a proximal portion that may comprise, for example, a filter and / or other components. Examples of first and second consumables are described in more detail below with reference to the drawings below. Note that, herein, references to differently sized or differently dimensioned consumables refer to consumables that are intended to be different sizes from each other, and not, for example, consumables that are intended to be the same size but differ in size by some small amount, for example, due to manufacturing tolerances. The consumables may, for example, be different types from each other, and each of the different types of consumables is intended to have different dimensions.

[0044] Chamber 102 is configured to accommodate either a first consumable or a second consumable, such that device 100 can be used with either the first consumable or the second consumable, depending on the user. Because the first consumable can be accommodated in a first position within chamber 102, while the second consumable can be accommodated in a second position within chamber 102, chamber 102 may not need to be reconfigured to accommodate either consumable.

[0045] In some examples, the heating chamber 102 may be defined by a heating tube (not shown in FIG. 1 ). The heating tube may surround the heating chamber 102 such that a hollow bore of the heating tube defines the heating chamber 102. The heating tube may be configured to be heated, thereby heating a consumable received within the heating chamber 102. For example, the heating component 104 may include one or more induction elements, and the heating tube may comprise a susceptor material and be configured to be inductively heated by one or more induction elements. In other examples, the heating tube may be configured to be heated by one or more resistance elements. For example, the heating tube may be formed from or configured to be in contact with a resistance heater, such as a thin-film heater. Examples of such components are discussed in more detail below. In other examples, the heating tube itself may not be configured to heat the consumable, but may contain the consumable while it is being heated. For example, the consumable may comprise a susceptor material that is heated by one or more induction elements of the heating component 104, thereby generating an aerosol stream.

[0046] The heating tube may have a circular cross-section or may have a cross-section of another shape. The adjustment mechanism may allow the dimensions of the heating chamber 102 to be adjusted by adjusting the dimensions of the heating tube. For example, the diameter of the heating tube may be adjustable to adjust the diameter of the heating chamber 102. Additionally or alternatively, the length of the heating tube may be adjustable to adjust the length of the heating chamber.

[0047] In certain examples, the chamber 102 of the device 100 may be configured to accommodate other consumables having dimensions different from either the first consumable or the second consumable. For example, the chamber 102 may be configured to accommodate each of a plurality of consumables at a different respective location within the chamber 102.

[0048] It will be understood that device 100 may include other components not shown in Figure 1, such as ventilation inlets / outlets, control interfaces, etc. It should be noted that Figure 1 is merely a schematic diagram illustrating several components that may be included in device 100. Figure 1 is not intended to communicate the specific locations of the various components.

[0049] Figure 2 shows a side view of a second device 200 according to an example of the present invention. Figure 3 shows a schematic side view of the second device 200, with the outer cover removed so that details of the chamber 202 and other internal components of the second device 200 can be seen. The second device 200 can include any of the features of the device 100 described above with reference to Figure 1, and a discussion of these features will not be repeated here. Similar drawing reference numerals are used to refer to features already described with reference to Figure 1.

[0050] 2, a first consumable item 120a is shown received in the heating chamber 102 of the device 200 to be heated. A portion of the first consumable item 120a protrudes through the opening 105.

[0051] The device 200 includes a heating tube 210, as shown in Figure 3. The interior of the heating tube 210 defines a heating chamber 202. The heating tube 210, in this example, is a conductive heating tube configured to be resistively heated by a plurality of heating coils 232, 234, 236.

[0052] In this example, the heated tube 210 comprises a first section 210a and a second section 210b. The first section 210a is located toward the proximal end of the device 200. The second section 210b is located toward the distal end of the device 200. The first section 210a and the second section 210b are located axially end-to-end. The distal end of the first section 210a communicates with the proximal end of the second section 210b. The first section 210a has a first diameter, and the second section 210b has a second diameter that is less than the first diameter. The opening 105 allows a consumable, such as the first consumable 120a, to be inserted into the first section 210. Because the diameter of the second section 210b is less than the diameter of the first section 210a, only consumables having a diameter equal to or less than the diameter of the second section 210b can be inserted into the second section 210b. Consumables having a diameter that is too large to allow them to be inserted into the second section 210b will abut against a step 210c in the heating tube 210.

[0053] Thus, the difference in diameter between the first section 210a and the second section 210b allows the heated tube 210 to accommodate consumables having different sizes at different points within the heated tube 210. An example is shown in Figures 4A and 4B.

[0054] In this example, the first consumable 120a has a diameter less than the diameter of the second consumable 120b shown in FIG. 4B. In one example, the first consumable 120a has a diameter of approximately 5.40 mm, while the second consumable 120b has a diameter of approximately 6.68 mm. In some examples, the first consumable 120a and the second consumable 120b have different lengths. In one example, the first consumable 120a has a length of approximately 83 mm, while the second consumable 120b has a length of approximately 75 mm.

[0055] 4A, the first consumable 120a is shown housed within the heating tube 210. The first consumable 120a has a diameter that allows for insertion into the second section 210b of the heating tube 210. The first consumable 120a has a length such that it can be inserted up to the distal end of the heating tube 210, where a distal stopper 240 is located. The distal stopper 240 is configured to be abutted by the distal end of the first consumable 120a to position the first consumable 120a within the heating tube 210.

[0056] 4A, it can be seen that because the first consumable 120a has a diameter smaller than the first section 210a, a gap exists between the first consumable 120a and the inner surface of the first section 210a. For example, an annular gap may exist around the first consumable 120a in the first section 210a. In some examples, the gap may allow the first section 210a to act as an expansion chamber for the aerosol flow generated from the heated first consumable 120a in the second section 210b.

[0057] 4B, the second consumable 120b is shown housed within the heated tube 210. The second consumable 120b has a larger diameter than the second section 210b of the heated tube 210. Thus, the second consumable 120b can be inserted into the first section 210a through the opening 105, but cannot be inserted into the second section 210b. Thus, the distal end of the second consumable 120b abuts against the step 210c between the first section 210a and the second section 210b.

[0058] In this example, the heating tube 210 is a conductive heating tube that may be formed from a metal such as steel. The heating tube 210 is configured to be heated and to conduct heat to the first consumable 120a and the second consumable 120b, whichever is received within the heating tube 210. In an example, the device 200 may be configured to independently heat different sections of the heating tube 210, for example, by using separate heating elements for the different sections of the heating tube 210. In such an example, the heating elements may be controllable independently of one another. In this example, the heating tube 210 is arranged to be heated by multiple coils 232, 234, 236. The first heating coil 232 is arranged to heat the first section 210a of the heating tube 210. In this example, the first heating coil 232 is wrapped around the first section 210a. The second heating element 234 and the third heating element 236 are positioned to heat the proximal and distal zones of the second section 210b, respectively, and thus, in this example, the second section 210b is divided into two separate heating zones.

[0059] The first, second, and third coils 232, 234, 236 may be independently operated to heat desired portions of the heated tube 210. For example, as shown in FIG. 4B, when a second consumable 120b is received in the heated tube 210, the first coil 232 may be operated to heat the first section 210a of the heated tube 210 to heat the second consumable 120b. However, as shown in FIG. 4A, when the first consumable 120a is received in the heated tube 210, the second coil 234 and the third coil 236 may be operated to heat respective heating zones in the second section 210b of the heated tube 210, as desired. In an example, the first coil 232 may remain inoperable while the first consumable 120a is received in the heated tube 210.

[0060] The insulating tube 250 surrounds the heating tube 210 and insulates it from other components of the device 200. The insulating tube 250 may be generally tubular and may at least partially surround the susceptor tube 210. The insulating tube 250 may be constructed from an insulating material, such as plastic. In this particular example, the insulating tube 250 is constructed from polyetheretherketone (PEEK). The insulating tube 250 can help insulate the various components of the device 200 from heat generated by the coils 232, 234, and 236. The insulating tube 250 may also be configured to prevent material from flowing from the chamber 202 to portions of the device 200 outside the insulating tube 250.

[0061] Figure 5A shows a perspective view of heater tube 210 and coils 232, 234, 236. As can be seen in Figure 5A, first section 210a of heater tube 210 in this example comprises a portion that tapers from a larger diameter at the proximal end of heater tube 210 to a first diameter. Figure 5B shows heater tube 210, coils 232, 234, 236, and insulating tube 250 in a perspective cross-sectional view.

[0062] In this example, device 200 is a device that uses resistance heating to heat heating tube 210 and thereby heat consumables 120a, 120b, but in another example, device 200 may use induction heating. When induction heating is used, the induction element may be located outside of insulating tube 250. In one example using induction heating, multiple coils, for example, three coils corresponding to respective sections of heating tube 210, with coils 232, 234, and 236, may be placed outside of insulating tube 250, for example, wrapped around the outside of insulating tube 250. Heating tube 210 may be formed from a metal such as stainless steel or aluminum.

[0063] The diameters of the first and second sections 210a and 210b of the heated tube can be such that when the first consumable 120a is received by the heated tube 210, the first section 210a is in close contact with the first consumable 120a. Similarly, when the second consumable 120b is received by the heated tube 210, the second section 210b is in close contact with the second consumable 120b. In some examples, the heated tube 210 may be referred to as a stepped heated tube. This allows either the consumable 120a or 120b inserted into the heating chamber 210 to be effectively heated by the respective portions of the heated tube. A user can operate the device according to whether the consumable 120a or 120b is being used. For example, a user can interact with the operating switch 112 to select a usage mode appropriate for the inserted consumable. Alternatively, or in addition, the device 200 may detect which of the consumables 120a, 120b is inserted into the heated tube 210 and may operate in the appropriate mode accordingly.

[0064] FIG. 6 illustrates an example third device 300 according to the present invention. The third device 300 may include any of the features described for the first device 100, and the description of these features will not be repeated. FIGS. 7A and 7B illustrate, in perspective and cross-section, a portion of the third device 300 including a heated tube 310 for receiving consumables of different sizes. FIG. 7A illustrates a first consumable 320a received in the heated chamber 310, while FIG. 7B illustrates a second consumable 320b received in the heated chamber 310. For clarity, other components of the device 300 have been omitted from FIGS. 7A and 7B. FIGS. 7C and 7D illustrate schematic top views of the configurations shown in FIGS. 7A and 7B, respectively.

[0065] The heating tube of the third device 300 is a stepped heating tube 310 similar to the heating tube 210 of the second device 200. The heating tube 310 comprises a first section 310a at its proximal end and a second section 310b at its distal end. Like the heating tube 210 of the second device 200, the second section 310b has a diameter less than the diameter of the first section 310a. Thus, a step 310c is formed between the first section 310a and the second section 310b.

[0066] The heating tube 310 of the third device 300 is configured to receive a first consumable 320a and a second consumable 320b. Similar to the configuration described for the second device 200, the first consumable 320a has a smaller diameter than the second consumable 320b and a length that allows it to be inserted into the second section 310b of the heating tube 310. In some examples, the first consumable 320a may abut the distal component 340 in the second section. The second consumable 320b has a larger diameter than the first consumable 320a, preventing it from being inserted into the second section 310b. Therefore, the distal end of the second consumable 320b is configured to abut the step 310c.

[0067] In this example, the second section 310b of the heating tube 310 is much shorter in length than the first section 310a. In some instances, the second section 310b can function as a stepped structure for the consumables 320a, 320b but may not provide heating to the consumables. For example, the first section 310a of the heating tube may heat the consumables 320a, 320b, while the second section 320b does not. The first and second consumables 320a, 320b have different lengths. In some instances, the difference in length between the first and second consumables 320a, 320b may be substantially equal to the length of the second section 310b, thereby allowing the proximal ends of the first and second consumables 320a, 320b to protrude substantially equal amounts from the opening 305 into the heating tube 302. For example, in some instances, the filter portions and various other components of consumables 320a, 320b may be positioned the same distance from the proximal ends of each of consumables 320a, 320b, thereby allowing the consumables to protrude from opening 305 by a substantially equal amount, thereby allowing ventilation holes and the like to be positioned at the same axial location relative to opening 305.

[0068] The third device 300 is configured to heat the heated tube 310 through the use of a heating foil 352 disposed externally to the heated tube 310. The heating foil 352 is a resistive heater. Additionally, a heating element 354 is disposed within the heated chamber 302. The heating element 354 protrudes from the distal component 340 into the heated chamber 302. The heating element 354 is configured to enter the first consumable 320a or the second consumable 320b, whichever is received within the heated tube 310. The heating element 354 is a resistive heating element and may be operated to heat the aerosol-generating material from within the respective consumable. The heating element 354 may be controllable independently of the heating foil 352.

[0069] In this example, the second consumable 320b has a diameter such that, when inserted into the chamber 302, it fits closely against the inner wall of the first section 310a of the heated tube 310, thereby allowing the second consumable 320b to be effectively heated by the heated tube 310. However, because the first consumable 320a has a diameter smaller than that of the second consumable 320b, a gap is formed between the first consumable 320a and the inner wall of the first section 310a. Therefore, heat transfer from the heated tube 310 may not be as effective for the first consumable 320a as for the second consumable 310b. In some examples, the heating element 354 may allow more uniform heating of the first consumable 320a and the second consumable 320b than would be possible if heating were performed by the heated tube 310 alone. For example, when the first consumable 320a is received in the chamber 302, but the second consumable 320b is not received in the chamber 302, the heating element 354 may be operated to heat the aerosol-generating material.

[0070] Figure 7C shows a gap 302a formed between the first consumable 320a and the inner wall of the first section 310a when the first consumable 320a is received within the heated tube 310. Figure 7D shows a second consumable 320b received within the heated tube 310 and in intimate contact with the inner wall of the first section 310a.

[0071] 8 illustrates a fourth device 400 according to one example of the present invention. The fourth device 400 shares certain features described with reference to the exemplary devices described above, and the description of these features will not be repeated. Certain components of the fourth device 400 have been omitted from FIG. 8 for clarity.

[0072] The fourth device 400 is an induction heating device that includes a heater tube 410. A first coil 432 and a second coil 434 surround the heater tube 410 and are configured to heat a proximal portion and a distal portion of the heater tube 410, respectively. The heater tube 410 includes a set of flexible members 456 configured to engage a first consumable 120a or a second consumable 120b, whichever is received within the heater tube 410. In this example, there are four rows of flexible members, but it will be understood that in other examples, there may be any other number of flexible members 456. The flexible members 456 are conductive and configured to conduct heat from the heater tube 410, whichever is received within the heater tube 410. The flexible members 456 protrude radially inward and are configured to bend when either the first consumable 120a or the second consumable 120b is inserted into the heater tube 410. This can provide effective heat transfer from the inductively heated heater tube 410, i.e., susceptor tube, and the received consumables. Because the flexible member 456 is configured to engage the larger diameter second consumable 120b and the smaller diameter first consumable 120a, the first and second consumables 120a, 120b can be heated more uniformly than if relying on conduction from the heater tube 410 alone. That is, as described in the previous example, the second consumable 120b can be in closer contact with the inner wall of the heater tube 410 than the first consumable 120a. Thus, the flexible member 456 can provide more uniform heating of both consumables 120a, 120b.

[0073] Figure 9A shows a first consumable item 120a received within the heated tube 410, while Figure 9C shows an enlarged cutaway view of the flexible member 456 engaging the first consumable item 120a. Similarly, Figure 9B shows a second consumable item 120b received within the heated tube 410, while Figure 9D shows an enlarged cutaway view of the flexible member 456 engaging the first consumable item 120a. It can be seen from Figures 9A-9D that the flexible member 456 protrudes radially inward further to engage the first consumable item 120a than it would to engage the second consumable item 120b.

[0074] 10A-10C illustrate a heated tube 510 according to another example of the present invention. A second section 560 of the heated tube 510 is configured to grip the distal end of the first or second consumable 120a, 120b, regardless of whether the consumable is received within the heated tube 510. The second section 560 is flexible and configured to be biased to grip the distal end of an inserted consumable. The second section 560 includes a proximal section 562 for receiving and gripping the distal end of the second consumable 120b and a distal section 564 for receiving and gripping the distal end of the first consumable 120a. Step 563 separates the distal section 564 from the proximal section 562, allowing the first consumable 120a to be inserted into the distal section 564 while preventing the second consumable 120b from being inserted into the distal section 564. The second section 560 includes a plurality of slits and is slightly tapered and configured to conform to the diameter of the inserted consumable and to flex to grip the distal end of the consumable. The heating tube 510 may be a susceptor tube or may act as a heating tube for a device that uses resistive heating.

[0075] The above-described embodiments are understood as illustrative examples of the present invention. Further embodiments of the present invention are envisioned. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other described features, and may also be used in combination with one or more features of any other embodiment or any combination of any other embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the present invention, which is defined in the appended claims.

Claims

1. 1. A non-combustion aerosol delivery device for generating an aerosol from an aerosol-forming material, the non-combustion aerosol delivery device comprising: a chamber for receiving a consumable comprising an aerosol-generating material and for enabling the non-combustible aerosol delivery device to generate an aerosol from the aerosol-generating material; the chamber is configured to accommodate, one at a time, a first consumable comprising an aerosol-generating material at a first axial position within the chamber and a second consumable comprising an aerosol-generating material at a second axial position within the chamber having dimensions different than the dimensions of the first consumable; the chamber is configured to accommodate the first consumable having a first width at the first axial location in the chamber and the second consumable having a second width at the second axial location in the chamber, the first width being less than the second width; the chamber comprises a first section and a second section, the second section having a width less than a width of the first section; the device comprises a first heating arrangement arranged to heat the first section to generate the aerosol, and a second heating arrangement arranged to heat the second section to generate the aerosol. A non-flammable aerosol delivery device.

2. 2. The non-combustible aerosol delivery device of claim 1, wherein the first section and the second section are tubular sections arranged end-to-end to form the chamber, and the device comprises an opening at a proximal end of the first section configured to allow insertion of the first consumable and the second consumable into at least the first section.

3. 3. The non-combustible aerosol delivery device of claim 2, wherein the proximal end of the second section defines a stopper abutted by a distal end of the second consumable to prevent the second consumable from entering the second section, thereby positioning the second consumable at the second axial position within the chamber.

4. 2. The non-combustible aerosol delivery device of claim 1, wherein the first heating element and the second heating element are controllable independently of each other to heat the first section and the second section, respectively.

5. 2. The non-combustible aerosol delivery device of claim 1, comprising a first distal stopper for positioning a distal end of the first consumable and a second distal stopper for positioning a distal end of the second consumable, the first distal stopper and the second distal stopper being located at different axial positions within the chamber.

6. 6. The non-combustible aerosol delivery device of claim 5, wherein the second distal stopper comprises a step surrounding a recess extending distally of the step, and the first distal stopper is disposed within the recess.

7. A non-combustible aerosol delivery device for generating an aerosol from an aerosol-generating material, the non-combustible aerosol delivery device comprising: a chamber for receiving a consumable comprising an aerosol-generating material and for enabling the non-combustible aerosol delivery device to generate an aerosol from the aerosol-generating material; the chamber is configured to accommodate, one at a time, a first consumable having a first width at a first axial location within the chamber and comprising an aerosol-generating material, and a second consumable having a second width at a second axial location within the chamber having a dimension different from a dimension of the first consumable and comprising an aerosol-generating material; the first width is less than the second width; the non-combustible aerosol delivery device comprises a first distal stopper for positioning a distal end of the first consumable and a second distal stopper for positioning a distal end of the second consumable, the first distal stopper and the second distal stopper being located at different axial positions within the chamber; the second distal stop comprises a step surrounding a recess extending distally of the step, the first distal stop being located within the recess; A non-combustible aerosol delivery device, wherein the recess comprises a gripping structure biased to grip the distal end of the first consumable when the distal end of the first consumable is contained within the recess.

8. 8. The non-combustible aerosol delivery device of claim 7, wherein the chamber is defined by a heating tube configured to be heated and to transfer heat to a consumable comprising an aerosol-generating material received in the chamber, thereby heating the aerosol-generating material and generating the aerosol.

9. 9. The non-combustible aerosol delivery device of claim 8, wherein the heating tube is a susceptor element configured to be inductively heated by an induction element of the device, thereby heating the aerosol-generating material received in the chamber, or the heating tube is configured to be resistively heated, thereby heating the aerosol-generating material received in the chamber.

10. A non-combustible aerosol delivery device for generating an aerosol from an aerosol-generating material, the non-combustible aerosol delivery device comprising: a chamber for receiving a consumable comprising an aerosol-generating material and for enabling the non-combustible aerosol delivery device to generate an aerosol from the aerosol-generating material; the chamber is configured to accommodate, one at a time, a first consumable comprising an aerosol-generating material at a first axial position within the chamber and a second consumable comprising an aerosol-generating material at a second axial position within the chamber having dimensions different than the dimensions of the first consumable; the chamber is defined by a heating tube configured to be heated and to transfer heat to a consumable comprising an aerosol-forming material received within the chamber, thereby heating the aerosol-forming material to generate the aerosol; A non-combustible aerosol delivery device, wherein the device comprises one or more heat transfer elements for transferring heat from the heating tube to the consumable, the one or more heat transfer elements being configured to protrude radially inward from an inner wall of the heating tube and engage consumables having different diameters.

11. The non-combustible aerosol delivery device of claim 10 , wherein the one or more heat transfer elements are flexible elements configured to flex to engage consumables having different diameters.

12. The non-combustible aerosol delivery device of any one of claims 1 to 7, 10 and 11, wherein the device comprises a heating arrangement configured to be inserted into the consumable to heat the aerosol generating material in the consumable, thereby generating the aerosol from the aerosol generating material.

13. A non-combustible aerosol delivery device as described in any one of claims 1 to 7, 10 and 11, wherein the device is a tobacco heating product, and the first consumable and the second consumable are each consumables comprising tobacco that is heated by the device to produce the aerosol.

14. A non-combustible aerosol delivery system comprising the non-combustible aerosol delivery device of any one of claims 1 to 7, 10 and 11, and at least one of the first consumable containing an aerosol generating material and the second consumable containing an aerosol generating material, wherein the first consumable and the second consumable are configured to be received by the non-combustible aerosol delivery device one at a time to enable the device to generate an aerosol from the aerosol generating material.

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