Device for heating an aerosolizable material and method for arranging and configuring the device

Abstract

To provide a method of arranging an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material.SOLUTION: An apparatus 1 comprises: a heating arrangement 23 comprising an elongate heating zone 29 for receiving and heating aerosolizable material; a power zone for installing a power source 27 for providing heating power to heat the heating zone 29; and control circuitry 25 for controlling the heating power. The power zone and the control circuitry 25 are arranged in sequence in a direction substantially parallel with a longitudinal axis of the apparatus 1. The elongate heating zone 29 is arranged adjacently to and substantially in parallel with the power zone and the control circuitry 25.SELECTED DRAWING: Figure 6

Description

Technical Field

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

Background Art

[0002] Smoking articles such as cigarettes and cigars generate tobacco smoke by burning the tobacco during use. Attempts have been made to provide alternatives to these articles by creating products that release compounds without burning. Examples of such products include so-called "non-combustion heating" products, or tobacco heating devices or tobacco heating products, which release compounds by heating rather than burning the material. 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 an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user. The apparatus comprises a heating configuration having an elongated heating zone for receiving and heating the aerosolizable material, a power supply zone for installing a power supply for supplying heating power to heat the heating zone, and a control circuit for controlling the heating power, wherein the power supply zone and the control circuit are arranged in sequence in a direction substantially parallel to the longitudinal axis of the apparatus, and the elongated heating zone is arranged substantially parallel adjacent to the power supply zone and the control circuit.

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

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

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

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

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

[0009] In an exemplary embodiment, one end of the control circuit is such that one end of the elongated heating zone is at the

[0010] In an exemplary embodiment, the device comprises an opening for receiving an aerosolizable material, and the power supply zone is arranged closer to the opening than the control circuit is to the opening.

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

[0012] In an exemplary embodiment, the power zone is arranged alongside the heating zone and only along a part of the entire length of the heating zone.

[0013] In an exemplary embodiment, the control circuit is arranged alongside the heating zone and only along a part of the entire length of the heating zone.

[0014] In an exemplary embodiment, the power zone is arranged along a first portion of the entire length of the heating zone, the control circuit is arranged along a second portion of the entire length of the heating zone, and the size of the first portion is larger than the size of the second portion.

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

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

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

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

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

[0020] In an exemplary embodiment, the apparatus comprises a first chassis for independently supporting the power zone and a second chassis for independently supporting the heating assembly and the control circuit.

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

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

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

[0024] A second aspect of the present invention provides a method for arranging and configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user. The method includes providing a heating configuration including an elongated heating zone for receiving and heating the aerosolizable material, and arranging the power zone and the control circuit in sequence in a direction substantially parallel to the longitudinal axis of the apparatus. The power zone is for installing a power source for supplying heating power for heating the heating zone, and the elongated heating zone is arranged substantially parallel adjacent to the power zone and the control circuit.

[0025] In an exemplary embodiment, the arranging step includes arranging the power source of the power zone and the control circuit in sequence in a direction substantially parallel to the longitudinal axis of the apparatus.

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

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

[0028] Further features and advantages of the present invention will become apparent from the following description of the preferred embodiments of the present invention, which is merely provided as an example with reference to the accompanying drawings.

[0029] Hereinafter, embodiments of the present invention will be described merely as examples with reference to the accompanying drawings.

Brief Description of the Drawings

[0030]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

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

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

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

[0034] As used herein, the term "heating material" or "heater material" in some examples refers to a material that can be heated by penetration by a varying magnetic field, for example when an aerosolizable material is heated by an induction heating configuration.

[0035] Other forms of heating the heating material include resistive heating involving an electrical resistance heating element, which heats up when an electric current is applied to the electrical resistance heating element and thereby transfers heat by conduction to the heating material.

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

[0037] The apparatus 1 includes a first end 3 and a second end 5 opposite the first end 3. The first end 3 may be referred to herein as the mouth-side end or proximal end of the apparatus 1. The second end 5 may be referred to herein as the distal end of the apparatus 1. The apparatus 1 has an on / off button 7 to enable the apparatus 1 to be switched on and off as a whole when desired by a user of the apparatus 1.

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

[0039] In the example, steam is generated, and then this steam at least partially condenses to form an aerosol before exiting the device 1 so as to be aspirated by the user.

[0040] In this regard, first of all, generally speaking, steam is a gaseous substance at a temperature lower than its critical temperature, which means, for example, that the steam can be condensed into a liquid by increasing its pressure without lowering the temperature. On the other hand, generally speaking, an aerosol is a colloid of fine solid particles or droplets in air or another gas. A "colloid" is a substance in which microscopically dispersed insoluble particles are suspended throughout another substance.

[0041] For reasons of simplicity, when used in this specification, the term "aerosol" should be taken to mean an aerosol, steam, or a combination of an aerosol and steam.

[0042] The device 1 comprises a casing 9 for arranging and protecting the various internal components of the device 1. Thus, the casing 9 is an outer housing for accommodating the internal components. In the illustrated embodiment, the casing 9 comprises a sleeve 11 covered by an upper panel 17 at a first end 3 that surrounds the device 1 and generally defines the "top" of the device 1, and a bottom panel 19 at a second end 5 (see FIGS. 2 - 5) that generally defines the "bottom" of the device 1.

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

[0044] In this embodiment, the first sleeve 11a and the second sleeve 11b are detachably engaged with each other. In this embodiment, the first sleeve 11a is engaged with the second sleeve 11b by a snap-fit arrangement including a groove and a recess.

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

[0046] The upper panel 17 of the device 1 has an opening 20 at the mouth-side end 3 of the device 1, through which, during use, a consumable 21 containing an aerosolizable material is inserted into and removed from the device 1 by the user. In this embodiment, the consumable 21 functions as a mouthpiece for the user to place between the user's lips. In other embodiments, an external mouthpiece can be provided, and at least one volatile component of the aerosolizable material is inhaled through this mouthpiece. When an external mouthpiece is used, the aerosolizable material is not installed within the external mouthpiece.

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

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

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

[0050] FIGS. 3 and 4 show the right side and the left side of the device 1 respectively. Here, the consumable 21 is shown to be in a central position in the lateral direction. This is because the opening 20 into which the consumable 21 is inserted is arranged at the midpoint of the device along the Z-axis direction and is offset from the center.

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

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

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

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

[0055] The advantage of arranging the power source 27 adjacent to the heater configuration 23 laterally is that a physically large power source 27 can be used without the device 1 becoming overly long as a whole. As will be appreciated, a physically large power source 27 has a higher capacity (i.e., the total electrical energy that can be supplied, often measured in ampere hours or the like), and thus the battery life of the device 1 can be longer.

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

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

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

[0059] The heater assembly 23 is sized such that when the consumable 21 is inserted into the device 1, substantially the entire aerosolizable material is heated during use.

[0060] In some embodiments, the heating element or each heating element may be arranged such that a selected zone of the aerosolizable material is heated independently, for example in sequence (over time) or together (simultaneously) as desired.

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

[0062] The casing 9, also referred to as a housing, may further include an internal support structure 37 (shown explicitly in FIG. 6) for supporting all internal components and the heater assembly 23.

[0063] The apparatus 1 further includes a collar 33 that extends around the opening 20 and protrudes from the opening 20 into the interior of the housing 9, and an expansion element 35 located between the collar 33 and one end of the vacuum region 31. The expansion element 35 is bell-shaped and forms an expansion chamber 40 at the mouth-side end 3 of the apparatus 1. The collar 33 is a holder for holding the consumable 21 (shown explicitly in FIG. 5). In this embodiment, the holder can be removably removed from the apparatus 1 in a recoverable manner.

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

[0065] As shown explicitly in FIG. 6, the collar 33, the expansion element 35, and the vacuum region 31 / heater assembly 23 are coaxially arranged such that when the consumable 21 is inserted into the apparatus 1, as shown explicitly in FIG. 5, the consumable extends through the collar 33 and the expansion element 35 into the heating chamber 29.

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

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

[0068] As shown explicitly in FIG. 6, in this embodiment, the expansion element 35 is disposed within the housing 9 between the collar 33 and the vacuum region 31 / heater assembly 23. More specifically, at the second opening end of the expansion element 35, the expansion element 35 is disposed between the end portion of the support tube 75 of the heater assembly 23 and the inside of the vacuum region 31 such that the second opening end engages with the inside of the support tube 75 and the vacuum region 31. At the first opening end, the expansion element 35 receives the collar 33 such that the leg portion 59 of the collar 33 projects into the expansion chamber 40. Thus, the inner diameter of the first section of the expansion element 35 is larger than the outer diameter of the leg portion when the consumable 21 is received within the apparatus 1 (see FIG. 5) and when the consumable 21 is not present.

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

[0070] As shown explicitly in FIG. 6, color 33 includes a plurality of legs 59. In this embodiment, there are four legs 59, and only three can be seen from the perspective of FIG. 6. However, in other embodiments, the number of legs 59 may be more or less than four. The legs 59 are equally circumferentially spaced on the inner surface of color 33 and are disposed within the expansion chamber 40 when the device 1 is assembled. In this embodiment, when installed in the device 1, the legs 59 are equally circumferentially spaced on the periphery of the opening 20. In one embodiment, there are four legs 59, and in other embodiments, the number of legs 59 may be more or less than four. Each of the legs 59 extends in the Y-axis direction, extends parallel to the longitudinal axis of the expansion chamber 40, and protrudes into the opening 20. The legs 59 also extend radially in a direction towards the expansion element 35 at the tip 59a of the legs 59, such that as a result, the tips 59a are angled away from each other. The tip 59a of each leg 59 facilitates the passage of the consumable 21 to avoid damage to the consumable 21 when the consumable 21 is inserted and / or removed from the device 1. The legs 59 collectively provide a gripping section for gripping the consumable 21 to correctly position and hold the consumable 21 within the expansion chamber 40 when the consumable 21 is within the device 1. Therein, the legs 59 lightly compress or clamp the consumable 21 in the area of the consumable that is contacted by the legs 59.

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

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

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

[0074] The device 1 further comprises a lid 61 at the distal end 5 of the device 1, and this lid 61 opens and closes an opening in the bottom panel 19 to enable access to the heating chamber 29 so that the heating chamber 29 can be cleaned. The lid 61 pivots about a hinge 63. Such access through the lid 61 enables the user to clean, in particular, the heater assembly 23 and the interior of the heating chamber 29 at the distal end 5. When the lid 61 is open, a straight through-hole is provided through the entire device 1 between the opening 20 at the mouth-side end 3 and the opening at one end of the cleaning chamber at the distal end 5 of the device 1. Thus, the user can easily clean substantially the entire interior of the hollow heating chamber 29. For this purpose, the user can access the heating chamber 29 through either end of the device 1 as desired. The user can use one or more various cleaning devices for this purpose, including, for example, an old-fashioned pipe cleaner or brush or the like.

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

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

[0077] As best understood from FIGS. 5 and 6, the open space defined by adjacent pairs of the legs 59 of the consumable 21 and the color 33 forms a ventilation passage 20a around the outside of the consumable 21. Such a ventilation passage 20a allows the hot vapor leaking from the consumable 21 to flow out of the device 1 and also allows the cooling air to flow into the device 1 around the consumable 21. In this embodiment, four ventilation passages are located around the periphery of the consumable 21, which provides ventilation for the device 1. In other embodiments, more or fewer such ventilation passages 20a may be provided.

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

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

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

[0081] It is undesirable for the volatile components flowing from the consumable 21 into the expansion chamber 40 to be aspirated by the user, as these components have not passed through the filter / cooling element 21c and are thus neither filtered nor cooled.

[0082] It is advantageous for the volume of air surrounding the consumable 21 within the expansion chamber 40 to cool at least a portion of the volatile components leaking from the consumable 21 through its outer layer and condense them on the inner wall of the expansion chamber 40, preventing these volatile components from being aspirated by the user.

[0083] This cooling effect can be facilitated by cooling air that can enter through the ventilation passage 20a, which enables fluid to flow into and out of the device, into the space 36 surrounding the consumable 21 within the expansion chamber 40 from outside the device 1. The first ventilation passage is defined between a pair of adjacent legs 59 of the collar 33 so as to provide ventilation around the outside of the consumable 21 at the insertion point. The second ventilation passage is provided between a second pair of adjacent legs 59 such that at least one heated volatile component flows from the consumable 21 at a second location. Thus, ventilation is provided around the outside of the consumable 21 at the insertion point by the first and second ventilation passages. Furthermore, the heated volatile components leaking from the consumable 21 through its outer covering can flow safely out of the device 1 through the ventilation passage 20a without condensing on the inner wall of the expansion chamber 40 and without being aspirated by the user. Both the expansion chamber 40 and the ventilation help reduce the temperature and content of the water vapor composition released from the heated volatile components of the aerosolizable material.

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

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

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

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

[0088] As shown in FIG. 6, the heating assembly 23 of the device 1 is disposed in the first space of the device 1. The heating zone 29 is located in the first space. In the illustrated embodiment, the heating zone 29 is elongated to receive an elongated article containing aerosolizable material through the opening 20. Thus, the elongated heating zone 29 is for receiving and heating aerosolizable material.

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

[0090] The power supply zone is a second space for installing the power supply 27. That is, the power supply 27 occupies the second space. Therefore, the power supply 27 can be installed within the compartment of the device, and the compartment defines the second space.

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

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

[0093] Both the control circuit 25 and the heating assembly 23 are attached to a separate chassis shown as the bottom panel 19. The bottom panel defines a space for housing the control circuit 25. The bottom panel 19 supports the heating device 23 and the control circuit 25 independently.

[0094] As shown in FIG. 6, the elongated heating zone 29 of the heating device 23 is arranged transversely to both the power supply zone and the control circuit 25. In the longitudinal direction (Y-axis direction), the elongated heating zone 29 overlaps a part of the power supply zone and a part of the control circuit 25. FIG. 6 shows the elongated heating zone 29 with the longitudinal axis B-B extending in the Y-axis direction. Therefore, the power supply zone and the control circuit 25 are arranged in sequence in a direction substantially parallel to the longitudinal axis B-B of the elongated heating zone 29. That is, the power supply zone and the control circuit 25 are arranged continuously (in sequence) in the Y-axis direction, the power supply zone is above the control circuit 25 and closer to the proximal end 3 of the device 1 than the control circuit 25.

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

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

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

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

[0099] Referring to FIG. 7, a flowchart is shown. This flowchart shows an example of a method 100 of arranging and configuring an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. This method is suitable for the apparatus 1 shown in FIGS. 1 - 6.

[0100] This method 100 includes a step of providing a heating device 101 having an elongated heating zone for receiving and heating an aerosolizable material, and a step 102 of arranging a power supply zone and a control circuit in sequence in a direction substantially parallel to the longitudinal axis of the device. The power supply zone is for installing a power supply for supplying heating power to heat the heating zone. The elongated heating zone is arranged substantially parallel and adjacent to the power supply zone and the control circuit. That is, the power supply zone and the control circuit are stacked on top of each other. When arranged, the elongated heating zone is lateral to the power supply zone and the control circuit.

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

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

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

[0104] When all or substantially all of one or more volatile components of the aerosolizable material within the consumable 21 are consumed, the user may remove the article 21 from the device 1 and discard the article 21. The user may then reuse the device 1 with another article 21. However, in other embodiments, the article may be non-consumable, and when one or more volatile components of the aerosolizable material are consumed, the device and the article may be discarded together.

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

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

[0107] To address various problems and develop the technology, the entire disclosure illustrates and shows, by way of illustration and example, various embodiments that provide an excellent heating element for use with an apparatus for heating an aerosolizable material, a method of forming a heating element for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and a system comprising the apparatus and a heating element that can be heated by such an apparatus. The advantages and features of the disclosure are only those of representative samples of the embodiments and are not thorough and / or exclusive. They are presented only to assist in understanding and to teach the claimed and separately disclosed features. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the disclosure should not be considered as limitations to the disclosure as defined by the claims or equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of the disclosure. Various embodiments may suitably include, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. The disclosure may include other inventions that may be claimed in the future and are not currently claimed.

Claims

1. An apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, comprising a heating configuration having an elongated heating zone for receiving and heating the aerosolizable material, a power supply zone for installing a power supply for supplying heating power for heating the heating zone, a control circuit for controlling the heating power, and the elongated heating zone is arranged together with the power supply zone and the control circuit, the power supply zone and the control circuit are arranged in sequence in a direction substantially parallel to the longitudinal axis of the apparatus, the control circuit is arranged in a direction substantially parallel to the longitudinal axis of the elongated heating zone, and the control circuit is arranged adjacent to the elongated heating zone laterally.

2. comprising an opening for receiving the aerosolizable material, and the power supply zone is arranged closer to the opening than the control circuit is arranged at the opening, the apparatus according to claim 1.

3. The apparatus according to claim 1 or 2, wherein the power supply zone is arranged alongside the heating zone and only along a part of the entire length of the heating zone.

4. The apparatus according to any one of claims 1 to 3, wherein the control circuit is arranged alongside the heating zone and only along a part of the entire length of the heating zone.

5. The apparatus according to any one of claims 1 to 4, wherein the power supply zone is arranged along a first part of the entire length of the heating zone, the control circuit is arranged along a second part of the entire length of the heating zone, and the size of the first part is larger than the size of the second part.

6. The apparatus according to any one of claims 1 to 5, comprising a first chassis for independently supporting the power supply zone and a second chassis for independently supporting the heating configuration and the control circuit.

7. A method for arranging a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material to form an aerosol for inhalation by a user, comprising: providing a heating configuration comprising an elongate heating zone for receiving and heating the aerosolizable material; arranging the elongate heating zone together with a power supply zone and a control circuit; arranging the power supply zone and the control circuit in sequence in a direction substantially parallel to the longitudinal axis of the device; arranging the control circuit in a direction substantially parallel to the longitudinal axis of the elongate heating zone; arranging the control circuit laterally adjacent to the elongate heating zone; including wherein the power supply zone is for installing a power supply for supplying heating power for heating the heating zone.

8. The method according to claim 7, wherein the elongate heating zone is arranged substantially parallel and adjacent to the power supply zone and the control circuit.

9. The method according to claim 7 or 8, wherein the arranging step includes arranging the power supply and the control circuit of the power supply zone in sequence in a direction substantially parallel to the longitudinal axis of the device.

10. The method according to any one of claims 7 to 9, including the step of installing the power supply in the power supply zone.

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