Heating elements suitable for aerosolizable materials

Abstract

To provide an improved heating element for use in heating an aerosolizable material to volatilize at least one component of the aerosolizable material.SOLUTION: A heating element comprises a heat resistant support 3a and a coating 3b on a support. The heating coating comprises cobalt. Further, the heating element comprises a protective coating 3c. Further, an article for use with apparatus for heating aerosolisable material in thermal contact with the heating element is disclosed. A system for heating aerosolisable material using the heating element is further disclosed. The apparatus comprises a magnetic field generator for generating a varying magnetic field for penetrating the heating element of claim 1.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to heating elements for use in heating an aerosolizable material to volatilize at least one component of the aerosolizable material, articles for use with devices for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and devices for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these items by creating products that release compounds without combustion. Examples of such products are the so-called "heat-not-burn" products or tobacco heating devices or products, which release compounds by heating a material without burning it. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] A first aspect of the present invention provides a heating element for use in heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the heating element comprising a heat resistant support and a coating on the support, the coating comprising cobalt.

[0004] In one exemplary embodiment, the heating element is planar or substantially planar.

[0005] In one exemplary embodiment, the heating element is tubular or substantially tubular.

[0006] In one exemplary embodiment, the coating is positioned radially outward of the support.

[0007] In one exemplary embodiment, the coating is 50 microns or less in thickness. In one exemplary embodiment, the coating is 20 microns or less in thickness.

[0008] In an exemplary embodiment, the support comprises one or more materials selected from the group consisting of a metal, a metal alloy, a ceramic material, and a plastic material, hi an exemplary embodiment, the support comprises stainless steel.

[0009] In one exemplary embodiment, the heating element includes a thermally resistant protective coating, and the cobalt-containing coating is positioned between the support and the thermally resistant protective coating.

[0010] In one exemplary embodiment, the cobalt coating is encapsulated. In one exemplary embodiment, the thermal protective coating and the support integrally encapsulate the cobalt coating. In one exemplary embodiment, the thermal protective coating encapsulates the cobalt coating and the support.

[0011] In one exemplary embodiment, the thermally resistant protective coating comprises one or more materials selected from the group consisting of ceramic materials, metal nitrides, titanium nitride, and diamond.

[0012] In one exemplary embodiment, the thermal protective coating is 50 microns or less in thickness. In one exemplary embodiment, the thermal protective coating is 20 microns or less in thickness.

[0013] A second aspect of the invention provides an article for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the article comprising a heating element of the first aspect of the invention and an aerosolizable material in thermal contact with the heating element.

[0014] In one exemplary embodiment, the aerosolizable material is in surface contact with the heating element.

[0015] In an exemplary embodiment, the aerosolizable material is regenerated, cellulosic, or gelfoam.

[0016] In one exemplary embodiment, the aerosolizable material includes tobacco and / or one or more humectants.

[0017] In one exemplary embodiment, the article is substantially cylindrical.

[0018] A third aspect of the present invention provides a system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising an article of the second aspect of the present invention and an apparatus for heating the aerosolizable material of the article to volatilize at least one component of the aerosolizable material of the article, the apparatus comprising a heating zone that receives the article and a device that heats a heating element of the article when the article is in the heating zone.

[0019] In one exemplary embodiment, the device includes a magnetic field generator that generates a varying magnetic field that penetrates a heating element of the article when the article is in the heating zone.

[0020] A fourth aspect of the present invention provides an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the apparatus comprising a heating zone for receiving an article comprising the aerosolizable material, a heating element according to the first aspect of the present invention for heating the heating zone, and a device for heating the heating element.

[0021] In one exemplary embodiment, the device comprises a magnetic field generator which generates a varying magnetic field that, during use, penetrates the heating element.

[0022] In one exemplary embodiment, the heating element protrudes into the heating zone.

[0023] A fifth aspect of the present invention provides a system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising an apparatus of the fourth aspect of the present invention and an article present in a heating zone of the apparatus.

[0024] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0025] [Figure 1] FIG. 2 is a schematic cross-sectional side view of an example of a heating element used to heat an aerosolizable material to volatilize at least one component of the aerosolizable material. [Diagram 2] FIG. 2 is a schematic cross-sectional side view of another example heating element used to heat an aerosolizable material to volatilize at least one component of the aerosolizable material. [Diagram 3] FIG. 2 is a schematic cross-sectional side view of another example heating element used to heat an aerosolizable material to volatilize at least one component of the aerosolizable material. [Figure 4] FIG. 2 is a schematic cross-sectional side view of yet another example heating element for use in heating an aerosolizable material to volatilize at least one component of the aerosolizable material. [Diagram 5] FIG. 4 is a schematic cross-sectional side view of an example of an article for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the article including the heating element of FIG. [Figure 6] FIG. 5 is a schematic cross-sectional side view of another example article for use with a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the article including the heating element of FIG. 4. [Figure 7] FIG. 6 is a schematic cross-sectional side view of an example of a system that includes the article of FIG. 5 and an apparatus for heating an aerosolizable material of the article to volatilize at least one component of the aerosolizable material. [Figure 8]FIG. 7 is a schematic cross-sectional side view of an example of a system that includes the article of FIG. 6 and an apparatus for heating an aerosolizable material of the article to volatilize at least one component of the aerosolizable material. [Figure 9] FIG. 4 is a schematic cross-sectional side view of an example of a system including an article containing an aerosolizable material and a device including the heating element of FIG. [Figure 10] 5 is a schematic cross-sectional side view of an example of a system including an article containing an aerosolizable material and a device including the heating element of FIG. 4. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] As used herein, the term "aerosolizable material" includes materials that provide volatilization upon heating, usually in the form of a vapor or aerosol. "Aerosolizable material" may be a non-tobacco-containing material or a tobacco-containing material. "Aerosolizable material" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extracts, homogenized tobacco, and tobacco substitutes. Aerosolizable material may be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, gelled sheet, powder, or mass, etc. "Aerosolizable material" may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. "Aerosolizable material" may include one or more humectants, such as glycerol or propylene glycol.

[0027] In this specification, the term "heating material" or "heater material" refers to a material that can be heated by the penetration of a varying magnetic field.

[0028] Induction heating is a process in which a conductive object is heated by the penetration of a varying magnetic field into the object. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably positioned relative to one another such that the resulting varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, they flow against the electrical resistance of the object, causing the object to heat up. This process is called Joule heating, Ohmic heating, or resistive heating. An object that can be inductively heated is known as a susceptor.

[0029] It has been found that when the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet during use is enhanced, resulting in increased or enhanced Joule heating.

[0030] Magnetic hysteresis heating is the process by which an object composed of a magnetic material is heated by the penetration of a fluctuating magnetic field into the object. A magnetic material can be thought of as containing many atomic-scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles become aligned with the magnetic field. Thus, when a fluctuating magnetic field, such as an alternating magnetic field produced by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the application of the fluctuating magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0031] If an object is both conductive and magnetic, the penetration of a varying magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can result in stronger magnetic fields, which can increase Joule heating and magnetic hysteresis heating.

[0032] In each of the above processes, because heat is generated within the object itself, rather than by conduction from an external heat source, rapid heating and more even heat distribution within the object may be achieved, particularly by selection of suitable object materials and shapes and suitable varying magnetic field magnitudes and orientations relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the varying magnetic field source and the object, allowing greater freedom and control in the design of the heating profile and potentially lower costs.

[0033] During induction heating, energy from a fluctuating magnetic field is transferred to the susceptor to induce one or more fluctuating currents in the susceptor, thereby increasing the temperature of the susceptor. To heat the susceptor as efficiently as possible, the energy transfer to the susceptor is as lossy as possible so that the energy of the current is rapidly converted to heat. Reducing the thermal mass of the susceptor increases the temperature change for a given energy input. Reducing the overall magnitude of the induced currents can also help reduce or avoid energy reflection back to the magnetic field generator.

[0034] In producing a practical system for a consumer product, many aspects must be considered, such as cost, availability of materials, ease of construction in manufacturing, and longevity (including corrosion resistance). Mild steel offers some of these benefits, but its vulnerability to corrosion makes it unsuitable for long term use. Also, for reasons possibly related to its vulnerability to corrosion, mild steel in very thin sheet form has limited potential applications.

[0035] Conversely, stainless steel is more widely available and much more robust in use than mild steel. Unfortunately, its use is limited in induction heating systems due to its lack of ferromagnetic properties. From an ohmic heating perspective, stainless steel can be around 6-7 times more resistive than mild steel, but its magnetization ability is very small, due to its relative permeability (μr) value of around 1. By comparison, the corresponding value for mild steel can be around 100. There are stainless steel alloys with higher relative permeability (μr) values, such as SUS430 stainless steel, but these tend to be only available to specialists in the market and are not widely available, especially in thin sections.

[0036] The present invention is based on the inventors' findings as to how an acceptable compromise between cost and performance can be achieved for the production of practical induction heating susceptors.

[0037] For any conductive (and magnetizable) medium, there is a characteristic depth ("skin depth") that the electromagnetic field can penetrate. In mild steel, the penetration of the electromagnetic field has an exponential dependence on the distance from the surface. Thus, the electromagnetic field strength (and, by implication, the energy it contains) is mostly absorbed in about 25 microns of material. Calculations for stainless steel give a characteristic absorption depth of about 280 microns, but show that a much thicker susceptor would be needed to extract the same amount of energy from a given magnetic field.

[0038] The inventors have found that if the surface of the heating element, such as the surface facing the magnetic field generator, is coated with a thin (such as a few microns) coating of pure nickel, the coating only needs to be about 15 microns thick to achieve the same absorption as a thicker mild steel plate. The nickel can also be applied, for example, by chemical plating, electrochemical plating, or by vacuum deposition. Furthermore, if cobalt is used instead of nickel, the thickness of the coating or layer can be reduced to about 10 microns. The thickness of one or more skin depths should help guide most of the available energy to the susceptor. In some embodiments, a thickness of around two skin depths is believed to be optimal. The cobalt can also be applied by plating.

[0039] Furthermore, cobalt has a higher Curie point temperature than nickel (1,120-1,127°C versus 353-354°C). The Curie point temperature, or Curie temperature, is the temperature at which the magnetic properties of a particular magnetic material undergo a rapid change. It is understood that the Curie point temperature is the temperature below which spontaneous magnetization exists without the application of an external magnetic field and above which the material becomes paramagnetic. For example, the Curie point temperature is the magnetic transformation temperature between the ferromagnetic and paramagnetic phases of a ferromagnetic material. When such a magnetic material reaches its Curie point temperature, its magnetic permeability decreases or becomes zero, and the ability of the material to be heated by the penetration of a fluctuating magnetic field also decreases or becomes zero. That is, it is believed that it is not possible to heat the material above its Curie point temperature by magnetic hysteresis heating. Cobalt has a Curie point temperature well above the normal operating temperature of the heating elements of embodiments of the present invention, so that in normal operation the effect of the Curie point temperature is much less noticeable (or in some embodiments is indiscernible) than if nickel were substituted.

[0040] The support on which the cobalt coating or layer is provided does not need to interact with an applied fluctuating magnetic field to generate heat therein. That is, the support does not need to be heatable by itself due to the penetration of a fluctuating magnetic field. The support only needs to be capable of supporting the cobalt coating while withstanding the heat generated therein. Thus, the support can be constructed of any suitable heat-resistant material. Exemplary materials are aluminum, steel, copper, and high temperature polymers such as polyetheretherketone (PEEK) or Kapton.

[0041] Thus, the heating elements of the exemplary embodiments of the present invention allow efficient transfer of energy from a varying magnetic field to the heating element while retaining the benefits of relatively low cost, ready availability of materials, and ease of construction during manufacturing.

[0042] At higher temperatures, the cobalt coating may become more susceptible to oxidation. This may increase the relative emissivity (εr) of the unoxidized metal surface, which may increase the rate at which energy is lost by radiation, thereby increasing heat loss by radiation. Such radiation may reduce the energy efficiency of the system if the radiated energy is ultimately lost to the environment. Oxidation may also reduce the resistance of the cobalt coating to chemical attack, which may shorten the useful life of the heating element. Thus, in some embodiments, the cobalt coating is covered by a thermally resistant protective coating, such as titanium nitride. Titanium nitride can be applied, for example, using physical vapor deposition techniques. Other exemplary thermally resistant protective coatings are ceramic materials, metal nitrides, and diamond. In some embodiments, the thermally resistant protective coating may be applied in different ways, such as by chemically treating the cobalt coating to promote the growth of a protective film on the cobalt coating, or by forming a protective oxide layer using a process such as anodization. In addition to protecting the underlying cobalt coating from oxidation, the thermal protective coating may also serve to physically protect the cobalt coating from mechanical wear. In some embodiments, the cobalt coating is encapsulated. In some embodiments, the thermal protective coating and the support may integrally encapsulate the cobalt coating. In some embodiments, the thermal protective coating may encapsulate the cobalt coating and the support.

[0043] In some embodiments, the thermal protective coating may be poorly conductive or non-conductive such that it does not induce (or does not significantly induce) electrical current in the thermal protective coating, as opposed to the cobalt coating.

[0044] Several exemplary embodiments will now be described with reference to the drawings.

[0045] 1 is a schematic cross-sectional side view of an example heating element according to one embodiment of the present invention. Heating element 1 is used to heat an aerosolizable material to volatilize at least one component of the aerosolizable material. Heating element 1 can be used in a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material and / or in an article that is used with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material. Heating element 1 is planar or substantially planar. However, in other embodiments, heating element 1 can be non-planar.

[0046] The heating element 1 comprises a heat-resistant support 1a. In this embodiment, the heat-resistant support 1a comprises steel, more specifically stainless steel. However, in other embodiments, the heat-resistant support 1a may comprise one or more materials selected from the group consisting of, for example, metals, alloys, ceramic materials, and plastic materials. For example, in some embodiments, the heat-resistant support 1a may comprise steel, mild steel, aluminum, copper, or a high-temperature polymer such as polyetheretherketone (PEEK) or Kapton.

[0047] The heating element 1 comprises a layer, film or coating 1b on a support 1a. The coating 1b comprises cobalt. In this embodiment, the cobalt coating 1b is approximately 10 microns thick. However, in other embodiments, the cobalt coating 1b may have a different thickness, such as a thickness of 50 microns or less, or 20 microns or less. The coating may be a plating.

[0048] Figure 2 is a schematic cross-sectional side view of another example heating element according to an embodiment of the present invention. The heating element 2 of Figure 2 comprises a heat-resistant support 2a and a coating 2b comprising cobalt on the support 2a. The heating element 2 can be used in a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material and / or in an article for use with a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material.

[0049] The heating element 2 is planar or substantially planar. However, in other embodiments, the heating element 2 may be non-planar. The heating element 2 of FIG. 2 is the same as the heating element 1 of FIG. 1, except that it also includes a heat-resistant protective coating 2c. The heat-resistant protective coating 2c is provided on the cobalt coating 2b. More specifically, the cobalt coating 2b is located between the support 2a and the heat-resistant protective coating 2c. In this embodiment, the heat-resistant protective coating 2c includes titanium nitride. However, in other embodiments, the heat-resistant protective coating 2c may include one or more materials selected from the group consisting of, for example, ceramic materials, metal nitrides, titanium nitride, and diamond. In this embodiment, the heat-resistant protective coating 2c has a thickness of approximately 10 microns. However, in other embodiments, the heat-resistant protective coating 2c may have a different thickness, such as a thickness of 50 microns or less, or 20 microns or less. Any of the possible variations described herein for the embodiment of FIG. 1 may be made to the embodiment of FIG. 2 to form another embodiment.

[0050] 3 is a schematic cross-sectional side view of another example of a heating element according to an embodiment of the present invention. The heating element 3 of FIG. 3 includes a heat-resistant support 3a, a coating 3b containing cobalt positioned on the support 3a, and a heat-resistant protective coating 3c arranged such that the cobalt coating 3b is positioned between the support 3a. The heating element 3 can be used in a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material and / or in an article used with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material.

[0051] The heating element 3 is planar or substantially planar. However, in other embodiments, the heating element 3 may be non-planar. The heating element 3 of FIG. 3 is the same as the heating element 2 of FIG. 2, except that in the embodiment of FIG. 2, the cobalt coating 2b and the heat-resistant protective coating 2c are located only on one side of the heat-resistant support 2a, while in the embodiment of FIG. 3, the cobalt coating 3b and the heat-resistant protective coating 3c are located on each of the two main sides of the heat-resistant support 3a. That is, in the embodiment of FIG. 3, the support 3a is located between two masses of the cobalt coating 3b, and the combination of the support 3a and the mass of the cobalt coating 3b is located between two masses of the heat-resistant protective coating 3c. In another embodiment, the heat-resistant protective coating 3c may be omitted or may be provided only on one side of the combination of the masses of the support 3a and the cobalt coating 3b. Any of the possible variations described herein for the embodiments of Figures 1 and 2 may be made to the embodiment of Figure 3 to form alternative embodiments.

[0052] Figure 4 is a schematic cross-sectional side view of an example of a heating element according to another embodiment of the present invention. Again, the heating element 4 of Figure 4 comprises a heat-resistant support 4a, a coating 4b containing cobalt positioned on the support 4a, and a heat-resistant protective coating 4c arranged such that the cobalt coating 4b is positioned between the support 4a. The heating element 4 can be used in a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material and / or in an article used with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material.

[0053] In this embodiment, the heating element 4 is substantially cylindrical with a substantially circular cross section, but in other embodiments, the heating element 4 may have an oval or elliptical cross section, or may be other than cylindrical. In some embodiments, the heating element 4 may have a cross section that is, for example, polygonal, rectangular, square, triangular, star-shaped, or irregular. In this embodiment, the heating element 4 is tubular with a hollow inner region 4d. In other embodiments, the heating element 4 may have an axially extending gap around its circumference, but still be substantially tubular. In some embodiments, the heating element 4 may be a rod. In some embodiments, a material, such as an aerosolizable material, may be located in or fill the inner region 4d.

[0054] In this embodiment, the heating element 4 is elongated and has a longitudinal axis AA. In other embodiments, the heating element 4 may not be elongated. In some such other embodiments, the heating element 4 still has an axial direction AA perpendicular to the cross section of the heating element 4.

[0055] In this embodiment, the cobalt coating 4b is located radially outward of the heat-resistant support 4a. That is, the cobalt coating 4b is on the outside of the heat-resistant support 4a. Furthermore, in this embodiment, the radially inward facing surface of the heat-resistant support 4a is devoid of the cobalt coating 4b. In other embodiments, the cobalt coating 4b may be provided radially inward of the heat-resistant support 4a in addition to or instead of the radially outward of the heat-resistant support 4a. However, if the cobalt coating 4b is provided radially inward in addition to the radially outward, the thermal mass of the heating element 4 may be increased, which may reduce the rate at which the heating element 4 can be heated by a given fluctuating magnetic field during use.

[0056] In this embodiment, the heat-resistant protective coating 4c is positioned radially outward of the heat-resistant supporting part 4a and the cobalt coating 4b. That is, the heat-resistant protective coating 4c is on the outside of the cobalt coating 4b. Furthermore, in this embodiment, the heat-resistant protective coating 4c is not present on the radially inward facing surface of the heat-resistant supporting part 4a. However, in other embodiments, the heat-resistant protective coating 4c may be provided radially inward of the heat-resistant supporting part 4a in addition to or instead of the radially outward of the heat-resistant supporting part 4a. However, even in this case, if the heat-resistant protective coating 4c is provided radially inward as an addition to the radially outward, the thermal mass of the heating element 4 may increase.

[0057] In some embodiments, each of which is a variation of the illustrated embodiment, the cobalt coating 2b, 3b, 4b is encapsulated. In some embodiments, each of which is a variation of the illustrated embodiment, the heat-resistant protective coating 2c, 3c, 4c and the supporting portion 2a, 3a, 4a integrally encapsulate the cobalt coating 2b, 3b, 4b. In other embodiments, each of which is a variation of the illustrated embodiment, the heat-resistant protective coating 2c, 3c, 4c encapsulates the cobalt coating 2b, 3b, 4b and the supporting portion 2a, 3a, 4a.

[0058] 5 is a schematic cross-sectional side view of an exemplary article 10 in accordance with one embodiment of the present invention, the article being used in conjunction with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material.

[0059] Article 10 comprises heating element 3 of Figure 3 and aerosolizable material 11. Aerosolizable material 11 may be any of the aerosolizable materials discussed herein, such as regenerated aerosolizable material (e.g., regenerated tobacco) or gelfoam. Article 10 may comprise a substrate, such as paper, impregnated or coated with aerosolizable material 11, such as a gel. Aerosolizable material 11 may be a cellulosic aerosolizable material.

[0060] Article 10 is substantially cylindrical with a substantially circular cross-section, although in other embodiments, article 10 may have an oval or elliptical cross-section or may be other than cylindrical. In some embodiments, article 10 may have a polygonal, quadrangular, rectangular, square, triangular, star-shaped, or irregular cross-section, for example. In this embodiment, article 100 is a rod.

[0061] In this embodiment, the article 10 is elongated and has a longitudinal axis BB. The longitudinal axis BB of the article 10 coincides with the longitudinal axis AA of the heating element 3. In other embodiments, the article 10 may not be elongated. In such other embodiments, the article 10 still has an axial direction BB perpendicular to the cross-section of the article 10.

[0062] The aerosolizable material 11 is in thermal contact with the heating element 3. Thus, in use, heat generated in the heating element 3 can be used to heat the aerosolizable material 11 to volatilize at least one component of the aerosolizable material 11. In some embodiments, the aerosolizable material 11 is in surface contact with the heating element 3. This can allow direct heat transfer from the heating element to the aerosolizable material 11. This can help to further improve the efficiency of heating the aerosolizable material 11. In other embodiments, the heating element 3 can be kept out of surface contact with the aerosolizable material 11. For example, in some embodiments, a heat transfer barrier free of heating material and aerosolizable material can separate the heating element 3 from the aerosolizable material 11. In some embodiments, the heat transfer barrier can be a coating on the aerosolizable material 11 or the heating element 3. Providing such a barrier is advantageous as it can help to mitigate hot spots in the heating element 3 by dissipating heat.

[0063] Article 10 also includes a wrapper 12 wrapped around aerosolizable material 11. Wrapper 12 surrounds aerosolizable material 11 and may help protect aerosolizable material 11 from damage during shipping and use. Wrapper 12 may also help direct air flow through and over aerosolizable material 11 during use, as well as help direct a stream of vapor or aerosol through aerosolizable material 11 for emission.

[0064] In this embodiment, the wrapper 12 is wrapped around the aerosolizable material 11 such that the free ends overlap each other. The wrapper 12 may comprise all or a majority of the circumferential exterior surface of the article 10. The wrapper 12 may be comprised of any suitable material, such as paper, cardboard, recycled aerosolizable material (e.g., reconstituted tobacco), or heating material (e.g., metal or alloy foil such as aluminum foil). The wrapper 12 may also include an adhesive (not shown) that bonds the overlapped free ends of the wrapper 12 together. The adhesive may include, for example, one or more of gum arabic, natural or synthetic resins, starch, and varnish. The adhesive helps prevent separation of the overlapped free ends of the wrapper 12. In other embodiments, the adhesive may be omitted or the wrapper 12 may be in a different form than described above. Any one of these types of wrappers may be applied to other articles described or illustrated herein to form alternative embodiments. In some embodiments, the wrapper 12 may be omitted.

[0065] In some embodiments, the article 10 may include one or more other components. For example, the article 10 may include a filter that filters aerosol or vapor released from the aerosolizable material 11 of the article 10 during use. The filter may be of any type used in the tobacco industry. For example, the filter may be made of cellulose acetate. The filter may be substantially cylindrical with a substantially circular cross-section and longitudinal axis. In other embodiments, the filter may have a different cross-section, such as any of the cross-sections discussed herein with respect to the article, may be other than cylindrical, and / or may not be elongated. In some embodiments, the filter is adjacent to the longitudinal end of the aerosolizable material 11 and is axially aligned with the heating element 3. In other embodiments, the filter may be separated from the aerosolizable material 11, such as by a gap and / or one or more other components of the article 10. An exemplary other component(s) is an additive or flavor source (additive or flavor-containing capsule or thread), which may be retained, for example, by the body of the filter material or between two bodies of the filter material.

[0066] In some embodiments, the article 10 includes a wrap around the aerosolizable material 11 and the filter (if provided) to hold the filter against the aerosolizable material 11. The wrap may surround the aerosolizable material 11 and the filter. The wrap may also help direct airflow through the aerosolizable material 11 during use, and may also help direct vapor or aerosol flow through the aerosolizable material 11 for release. The wrap may be wrapped around the aerosolizable material 11 and the filter such that the free ends overlap each other. The wrap may comprise all or a majority of the circumferential outer surface of the article 10. The wrap may be comprised of any suitable material, such as paper, cardboard, or recycled aerosolizable material (e.g., reconstituted tobacco). The wrap may also include an adhesive (not shown) that bonds the overlapped free ends of the wrap together, such as one of the adhesives discussed elsewhere herein. The adhesive helps prevent separation of the overlapped free ends of the wrap. In other embodiments, the adhesive may be omitted or the wrap may be in a different form than described above. In other embodiments, the filter may be held to the aerosolizable material 11 by a connector other than a wrap, such as an adhesive.

[0067] FIG. 6 is a schematic cross-sectional side view of another example of an article according to an embodiment of the present invention. The article 20 is used with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. The article 20 of FIG. 6 is the same as FIG. 5, except that the article 20 of FIG. 6 has the heating element 4 of FIG. 4 instead of the heating element 3 of FIG. 3. The article 20 is tubular with a hollow interior region defined by the hollow interior region 4d of the heating element 4, and a wrapper 22 is wrapped around the aerosolizable material 21 and the heating element 4. Any of the possible variations of the article 10 of FIG. 5 discussed herein may be made to the article 20 of FIG. 6 to form another embodiment. Additionally, in some embodiments, a material such as an aerosolizable material may be positioned in or fill the interior region 4d of the heating element 4.

[0068] In some embodiments, the article 10, 20 may be provided with a device that heats the aerosolizable material 11, 21 of the article 10, 20 to volatilize at least one component of the aerosolizable material 11, 21. The article 10, 20 and the device may be provided together in a system.

[0069] For example, Figure 7 is a schematic cross-sectional side view of an example of a system according to one embodiment of the present invention. The system 1000 includes the article 10 of Figure 5 and an apparatus 100 for heating an aerosolizable material 11 of the article 10 to volatilize at least one component of the aerosolizable material 11. In other embodiments, the article 10 can be replaced with any of the other articles described herein. In this embodiment, the apparatus 100 is a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device).

[0070] Generally, the apparatus 100 comprises a heating zone 111 for receiving the article 10 and a device 112 for causing the heating element 3 of the article 10 to heat when the article 10 is in the heating zone 111 .

[0071] More specifically, the device 100 of this embodiment comprises a body 110 and a mouthpiece 120. The mouthpiece 120 may be constructed of any suitable material, such as a plastic material, cardboard, cellulose acetate, paper, metal, glass, ceramic, or rubber. The mouthpiece 120 defines a channel 122 therethrough. The mouthpiece 120 is positionable relative to the body 110 to cover an opening to the heating zone 111. When the mouthpiece 120 is so positioned relative to the body 110, the channel 122 of the mouthpiece 120 is in fluid communication with the heating zone 111. During use, the channel 122 acts as a passageway that allows volatilized material to pass from an aerosolizable material of an article inserted into the heating zone 111 to the exterior of the device 100. In this embodiment, the mouthpiece 120 is releasably engageable with the body 110 so as to be connected to the body 110. In other embodiments, the mouthpiece 120 and the body 110 may be permanently connected, such as by a hinge or a flexible member. In some embodiments, such as those in which the article itself includes a mouthpiece, the mouthpiece 120 of the device 100 may be omitted.

[0072] The device 100 may define an air inlet (not shown) fluidly connecting the heating zone 111 with the exterior of the device 100. Such an air inlet may be defined by the body 110 and / or the mouthpiece 120. A user may be able to inhale the volatile component(s) of the aerosolizable material by drawing the volatile component(s) through the channel 122 of the mouthpiece 120. Once the volatile component(s) have been removed from the article 10, air may be drawn into the heating zone 111 via the air inlet of the device 100.

[0073] In this embodiment, the body 110 includes a heating zone 111. In this embodiment, the heating zone 111 includes a recess 111 that receives at least a portion of the article 10. In other embodiments, the heating zone 111 may be other than a recess, such as a shelf, surface, or protrusion, and may require mechanical engagement with the article to cooperate with or receive the article. In this embodiment, the heating zone 111 is elongated and sized and shaped to receive the entire article 10. In other embodiments, the heating zone 111 may be other than elongated and / or sized to receive only a portion of the article 10.

[0074] In this embodiment, the device 112 comprises a magnetic field generator 112 that generates a varying magnetic field that penetrates the heating element 3 of the article 10 when the article 10 is in the heating zone 111. However, other forms of the device 112 can be used in other embodiments.

[0075] In this embodiment, the magnetic field generator 112 comprises a power source 113, a coil 114, a device 116 for passing a varying current, such as an alternating current, through the coil 114, a controller 117, and a user interface 118 for user operation of the controller 117.

[0076] In this embodiment, power source 113 is a rechargeable battery. In other embodiments, power source 113 may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power source.

[0077] The coil 114 may be of any suitable form. In this embodiment, the coil 114 is a helical coil of a conductive material such as copper. In some embodiments, the magnetic field generator 112 may include a magnetically permeable core around which the coil 114 is wound. Such a magnetically permeable core concentrates the magnetic flux generated by the coil 114 during use to create a stronger magnetic field. The magnetically permeable core may be constructed of, for example, iron. In some embodiments, the magnetically permeable core may extend only partially along the length of the coil 114 to concentrate the magnetic flux in a particular area. In some embodiments, the coil may be a flat coil. That is, the coil may be a two-dimensional helix. In this embodiment, the coil 114 surrounds the heating zone 111. The coil 114 extends along a longitudinal axis that is substantially aligned with the longitudinal axis of the heating zone 111. The aligned axes are coincident. In variations of this embodiment, the axes may be parallel, oblique, or perpendicular to one another.

[0078] In this embodiment, the device 116 for passing a varying current through the coil 114 is electrically connected between the power source 113 and the coil 114. Also in this embodiment, the controller 117 is electrically connected to the power source 113 and communicatively connected to the device 116 to control the device 116. More specifically, in this embodiment, the controller 117 controls the device 116 to control the supply of power from the power source 113 to the coil 114. In this embodiment, the controller 117 comprises an IC, such as an integrated circuit (IC) on a printed circuit board (PCB). In other embodiments, the controller 117 may be in a different form. In some embodiments, the device may have only one electrical or electronic component, including the device 116 and the controller 117. In this embodiment, the controller 117 is operated by user manipulation of the user interface 118. In this embodiment, the user interface 118 is located on the outside of the body 110. The user interface 518 may comprise a push button, a toggle switch, a dial, a touch screen, or the like. In other embodiments, the user interface 118 may be remotely and wirelessly connected, such as via Bluetooth, to other pieces of equipment.

[0079] In this embodiment, a user's manipulation of a user interface 118 causes a controller 117 to cause the device 116 to pass an alternating current through the coil 114, which generates an alternating magnetic field. The coil 114 and the heating zone 111 of the apparatus 100 are suitably positioned relative to one another such that when the article 10 is positioned in the heating zone 111, the varying magnetic field generated by the coil 114 penetrates the heating element 3 of the article 10. This penetration generates one or more eddy currents in the cobalt coating 3b of the heating element 3, since the cobalt in the cobalt coating 3b of the heating element 3 is an electrically conductive material. The flow of eddy currents relative to the electrical resistance of the cobalt causes the cobalt coating 3b to heat by Joule heating. Since cobalt is ferromagnetic, the orientation of the magnetic dipoles in the cobalt can change with the applied varying magnetic field, which generates heat in the cobalt coating 3b of the heating element 3. The thermal energy generated in the cobalt coating 3 b is transferred to the aerosolizable material of the article 30 .

[0080] The apparatus 100 of this embodiment includes a temperature sensor 119 that senses the temperature of the heating zone 111. The temperature sensor 119 is communicatively connected to the controller 117 so that the controller 117 can monitor the temperature of the heating zone 111. Based on one or more signals received from the temperature sensor 119, the controller 117 may cause the device 116 to adjust the characteristics of the fluctuating or alternating current passing through the coil 114 as necessary to maintain the temperature of the heating zone 111 within a predetermined temperature range. The characteristics may be, for example, amplitude, frequency, or duty cycle. When in use within the predetermined temperature range, sufficient heating of the aerosolizable material in an article positioned in the heating zone 111 volatilizes at least one component of the aerosolizable material without combustion of the aerosolizable material. Thus, the controller 117 (and the apparatus 100 as a whole) is configured to heat the aerosolizable material to volatilize at least one component of the aerosolizable material without combustion of the aerosolizable material. In some embodiments, the temperature range is from about 50° C. to about 300° C., such as from about 50° C. to about 250° C., from about 50° C. to about 150° C., from about 50° C. to about 120° C., from about 50° C. to about 100° C., from about 50° C. to about 80° C., or from about 60° C. to about 70° C. In some embodiments, the temperature range is from about 170° C. to about 220° C. In other embodiments, the temperature range may be outside of this range. In some embodiments, the upper limit of the temperature range may be greater than 300° C. In some embodiments, the temperature sensor 119 may be omitted. In some embodiments, the coating 3 b of the heating element 3 may include a cobalt alloy having a Curie point temperature selected based on the maximum temperature to which it is desired to heat the coating 3 b, and further heating beyond that temperature by induction heating of the coating 3 b is inhibited or prevented.

[0081] Figure 8 is a schematic cross-sectional side view of an example of another system according to an embodiment of the present invention. System 2000 includes article 20 of Figure 6 and device 200 for heating aerosolizable material 21 of article 20 to volatilize at least one component of aerosolizable material 21. In other embodiments, article 20 can be replaced with any of the other articles described herein. Any of the possible variations described herein for the device of Figure 7 can be made to the device of Figure 8 to form alternative embodiments of the device and / or system.

[0082] 7 (and therefore like features are indicated with like reference numerals), except that in this embodiment, the apparatus 200 of Figure 8 includes a support 130 which is positioned in the hollow interior region 4d of the article 20 to position the article 20 in a predetermined location in the heating zone 111 during use. This may aid in correctly positioning the heating element 4 of the article 20 relative to the coil 114 of the apparatus 200. Otherwise, the operation of the apparatus 200 and its effect on the article 20 is substantially as described above and therefore will not be described again for the sake of brevity.

[0083] 9 is a schematic cross-sectional side view of an example of another system according to an embodiment of the present invention. The system 3000 includes an article 30 including an aerosolizable material. The system 3000 also includes an apparatus 300 for heating the aerosolizable material of the article 30 to volatilize at least one component of the aerosolizable material. In other embodiments, the article 30 can be replaced with any of the other articles described herein. Any of the possible variations described herein for the apparatus of FIG. 7 or FIG. 8 can be made to the apparatus of FIG. 9 to form alternative embodiments of the apparatus and / or alternative embodiments of the system.

[0084] In this embodiment, the device 300 is the same as the device 100 shown in FIG. 7 (and therefore the same features are indicated by the same reference numbers), except that the device 300 of FIG. 9 itself includes a heating element 140 for heating the heating zone 111. The heating element 140 protrudes into the heating zone 111. The heating element 140 is the same as the heating element 3 of FIG. 3, and therefore includes a heat-resistant support 3a, a coating 3b containing cobalt located on the support 3a, and a heat-resistant protective coating 3c arranged such that the cobalt coating 3b is located between the support 3a. Any of the possible modifications described herein for the heating element 3 of FIG. 3 may be made to the heating element 140 of the device of FIG. 9 to form other embodiments of the device and / or other embodiments of the system. For example, in some embodiments, the heat-resistant protective coating 3c may be omitted from the heating element 140 of the device 300. In some embodiments, the heating element of the apparatus 300 surrounds at least a portion of the heating zone 111 in addition to or as an alternative to protruding into the heating zone 111 .

[0085] Figure 10 is a schematic cross-sectional side view of an example of another system according to an embodiment of the present invention. The system 4000 includes an article 40 that includes an aerosolizable material. The system 4000 also includes an apparatus 400 that heats the aerosolizable material of the article 40 to volatilize at least one component of the aerosolizable material. In other embodiments, the article 40 can be replaced with any of the other articles described herein. Any of the possible variations described herein for the apparatus of Figures 7, 8, or 9 may be made to the apparatus of Figure 10 to form alternative embodiments of the apparatus and / or alternative embodiments of the system.

[0086] In this embodiment, the apparatus 400 is the same as the apparatus 300 shown in FIG. 9 (and therefore the same features are indicated with the same reference numbers), except that the heating element of the apparatus 400 of FIG. 10 is the same as the heating element 4 of FIG. 4. Thus, the heating element 150 comprises a heat-resistant support 4a, a coating 4b containing cobalt positioned radially outward on the support 4a, and a heat-resistant protective coating 4c arranged such that the cobalt coating 4b is positioned between the support 4a. Any of the possible variations described herein for the heating element 4 of FIG. 4 may be made to the heating element 150 of the apparatus of FIG. 10 to form alternative embodiments of the apparatus and / or alternative embodiments of the system. For example, in some embodiments, the heat-resistant protective coating 4c may be omitted from the heating element 150 of the apparatus 400.

[0087] In the systems 3000, 4000 of Figures 9 and 10, respectively, the coil 114 and the heating elements 140, 150 are suitably positioned relative to one another such that the varying magnetic field generated by the coil 114 penetrates the heating elements 140, 150 of the devices 300, 400 during use. This penetration generates one or more eddy currents in the cobalt coatings 3b, 4b of the heating elements 140, 150, as the cobalt in the cobalt coatings 3b, 4b of the heating elements 140, 150 is an electrically conductive material. The flow of eddy currents against the electrical resistance of the cobalt causes the heating elements 140, 150 to heat by Joule heating. As cobalt is ferromagnetic, the orientation of the magnetic dipoles in the cobalt can change with the applied varying magnetic field, which generates heat in the cobalt coatings 3b, 4b of the heating elements 140, 150.

[0088] 9 and 10, respectively, when the article 30, 40 is inserted into the heating zone 111, the heating elements 140, 150 can be positioned within the article 30, 40 (such as within an existing hollow region of the article 30, 40 or by replacing a portion of the aerosolizable material of the article 30, 40) such that heat generated by the heating elements 140, 150 is efficiently transferred by conduction (and / or, in some cases, convection) to the aerosolizable material of the article 30, 40 when the article 30, 40 is positioned in the heating zone 111. Otherwise, the operation of the apparatus 300, 400 and its effect on the article 30, 40 is substantially as described above and therefore will not be described again for the sake of brevity.

[0089] In some embodiments, one of the articles 30, 40 of the system 3000, 4000 may include a heating element that is heatable by penetration of the varying magnetic field generated by the coil 114. Thus, the aerosolizable material of the article 30, 40 may be heated by one or both of the heating element of the article 30, 40 and the heating element 140, 150 of the device 300, 400.

[0090] In some embodiments, the cobalt-containing coating consists solely of cobalt. However, in other embodiments, the coating may include cobalt and one or more materials selected from the group consisting of conductive materials, magnetic materials, and magnetic conductive materials. In some embodiments, the coating may include a cobalt alloy. In some embodiments, the cobalt-containing coating may include one or more materials selected from the group consisting of aluminum, gold, iron, nickel, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, copper, and bronze. In other embodiments, other heating material(s) may be used in addition to cobalt.

[0091] In some embodiments, the heating element is free of holes or slits. In some embodiments, the heating element comprises a foil. However, in some embodiments, the heating element may have holes or slits. For example, in some embodiments, the heating element may comprise a mesh, a perforated sheet, or a perforated foil.

[0092] In some embodiments, the heating element comprises or consists of a stainless steel heat resistant support, a cobalt coating on the support, and a heat resistant protective coating comprising titanium nitride, the cobalt coating being positioned between the support and the heat resistant protective coating.

[0093] The cobalt coating may have a skin depth, which is the outer zone where most of the induced currents and / or induced reorientation of magnetic dipoles occurs. Given that the thickness of the cobalt coating is relatively small, a greater percentage of the cobalt coating may be heatable by a given varying magnetic field, as compared to heating materials having a relatively greater depth or thickness than other dimensions. This results in more efficient use of materials and also reduces costs.

[0094] In some embodiments, the aerosolizable material includes tobacco, although in other embodiments, the aerosolizable material may consist of tobacco, consist substantially entirely of tobacco, include tobacco and aerosolizable materials other than tobacco, or may be tobacco-free. In some embodiments, the aerosolizable material may include a vapor or aerosol-forming agent or a humectant such as glycerol, propylene glycol, triacetin, or diethylene glycol. In some embodiments, the aerosolizable material is a non-liquid aerosolizable material and the device is for heating the non-liquid aerosolizable material to volatilize at least one component of the aerosolizable material.

[0095] In some embodiments, the article 10, 20, 30 is a consumable item. When all or substantially all of the volatilizable component(s) of the aerosolizable material in the article 10, 20, 30 are depleted, the user may remove the article 10, 20, 30 from the heating zone 111 of the device 100, 200, 300, 400 and discard it. The user may then reuse the device 100, 200, 300, 400 with another article 10, 20, 30. However, in other embodiments, the article may be a non-consumable item, and the device and article may be discarded together when the volatilizable component(s) of the aerosolizable material are depleted.

[0096] In some embodiments, articles 10, 20, 30 are sold, supplied, or provided separately from an apparatus 100, 200, 300, 400 that can be used with the articles 10, 20, 30. However, in some embodiments, the apparatus 100, 200, 300, 400 and one or more articles 10, 20, 30 may be provided together as a system, such as a kit or assembly, possibly with additional components, such as cleaning implements.

[0097] To address various problems and advance the art, the present disclosure generally provides, by way of illustrative examples, various embodiments that enable the claimed invention to be practiced and include novel heating elements for use in heating an aerosolizable material to volatilize at least one component of the aerosolizable material, articles for use with devices for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, devices for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and systems including such articles and / or devices. The advantages and features of the present disclosure are merely a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. They are presented solely for the purpose of aiding in the understanding and teaching of the claimed or disclosed features. The advantages, embodiments, examples, features, characteristics, structures, and / or other aspects of the present disclosure should not be considered limitations on the present 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 improved upon without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably include, consist of, or essentially consist of various combinations of the disclosed elements, components, features, parts, steps, means, etc. The present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A heating element for use in heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the heating element comprising a heat resistant support and a coating on the support, the coating comprising cobalt, the heat resistant support being positioned between two masses of the coating.

2. The heating element of claim 1 which is planar or substantially planar.

3. The heating element of claim 1 , which is tubular or substantially tubular.

4. The heating element of claim 3 , wherein the coating is positioned radially outward of the support.

5. A heating element according to any one of the preceding claims, wherein the coating has a thickness of up to 50 microns.

6. The heating element of claim 5 , wherein the coating is no greater than 20 microns in thickness.

7. The heating element of any one of claims 1 to 6, wherein the support comprises one or more materials selected from the group consisting of metals, alloys, ceramic materials, and plastic materials.

8. A heating element according to any one of the preceding claims, comprising a heat resistant protective coating, said coating comprising cobalt being positioned between said support and said heat resistant protective coating.

9. The heating element of claim 8 , wherein the heat resistant protective coating comprises one or more materials selected from the group consisting of ceramic materials, metal nitrides, titanium nitride, and diamond.

10. 10. A heating element according to claim 8 or 9, wherein the heat resistant protective coating has a thickness of 50 microns or less.

11. 11. The heating element of claim 10, wherein the heat resistant protective coating is 20 microns or less in thickness.

12. 12. An article for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the article comprising a heating element according to any one of claims 1 to 11 and an aerosolizable material in thermal contact with the heating element.

13. The article of claim 12 , wherein the aerosolizable material is in surface contact with the heating element.

14. 14. The article of claim 12 or 13, wherein the aerosolizable material is regenerated, cellulosic, or gel foam.

15. The article of any one of claims 12 to 14, wherein the aerosolizable material comprises tobacco and / or one or more humectants.

16. The article of any one of claims 12 to 15, which is substantially cylindrical.

17. 1. A system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: An article according to any one of claims 12 to 16, an apparatus for heating the aerosolizable material of the article to volatilize at least one component of the aerosolizable material of the article, the apparatus comprising: a heating zone that receives the article; and a device that heats the heating element of the article when the article is in the heating zone; A system equipped with

18. 20. The system of claim 17, wherein the device comprises a magnetic field generator that generates a varying magnetic field that penetrates the heating element of the article when the article is in the heating zone.

19. 1. An apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a heating zone for receiving an article including an aerosolizable material; A heating element according to any one of claims 1 to 11 for heating the heating zone; a device for heating the heating element; An apparatus comprising:

20. 20. The apparatus of claim 19, wherein the device comprises a magnetic field generator that generates a varying magnetic field that, in use, penetrates the heating element.

21. 21. Apparatus according to claim 19 or 20, wherein the heating element protrudes into the heating zone.

22. 1. A system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: An apparatus according to any one of claims 19 to 21, an article present in the heating zone of the apparatus; A system equipped with

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