Non-flammable aerosol supply device

Abstract

A non-combustible aerosol delivery device (100) for generating an aerosol from an aerosol-generating material is disclosed that includes a housing, a chamber (102) within the housing for receiving a consumable including an aerosol-generating material, and a resilient material (114) that surrounds at least a portion of the consumable when the consumable is received within the chamber (102), the resilient material (114) having a thickness that is adaptable according to a thickness of the consumable including the aerosol-generating material such that consumables of different thicknesses can be selectively and snugly received within the chamber (102).

Description

Technical Field

[0001] The present invention relates to a non-flammable aerosol supply device.

Background Art

[0002] Smoking articles such as cigarettes and cigars produce tobacco smoke by burning tobacco during use. Attempts have been made to provide alternatives to such articles that burn tobacco by creating products that release compounds without burning. An example of such a product is a heating device that releases compounds by heating a material without burning it. The material may be, for example, a tobacco product or other non-tobacco product, and these products may or may not contain nicotine.

Summary of the Invention

[0003] According to a first aspect of some embodiments described herein, a non-flammable aerosol supply device for generating an aerosol from an aerosol-generating material is provided, the non-flammable aerosol supply device comprising a housing, a chamber within the housing for receiving a consumable containing the aerosol-generating material, and an elastic material surrounding at least a portion of the consumable when the consumable is received within the chamber, the elastic material having a thickness adaptable according to the thickness of the consumable, whereby consumables of different thicknesses can be selectively and snugly received within the chamber.

[0004] The housing may be configured to facilitate insertion of a consumable containing the aerosol-generating material into the chamber or removal of a consumable containing the aerosol-generating material from the chamber.

[0005] The housing may be configured to open along the length of the chamber to facilitate insertion of a consumable containing the aerosol-generating material into the chamber or removal of a consumable containing the aerosol-generating material from the chamber.

[0006] The housing may further include an opening into the chamber that allows a consumable containing the aerosol-generating material to protrude from the housing when the consumable containing the aerosol-generating material is received into the chamber.

[0007] The elastic material may be a thermally conductive material.

[0008] The elastic material may include metallic wool.

[0009] The non-combustible aerosol supply device may further include an aerosol generator system for generating an aerosol from a consumable containing the aerosol-generating material when the consumable containing the aerosol-generating material is received into the chamber during use.

[0010] The aerosol generator system may include at least one heater for heating the aerosol-generating material in the consumable containing the aerosol-generating material to generate an aerosol when the consumable containing the aerosol-generating material is received into the chamber.

[0011] The at least one heater may include a layer of flexible heating foil.

[0012] The flexible heating foil may be made of metal.

[0013] The chamber may include a tube disposed between the at least one heater and the elastic material.

[0014] The chamber may further include an annular stepped bottom having a first section with a first width and a second section with a second width smaller than the first width, in which case the first portion defines the distal end point of the chamber for a first type of consumable containing the aerosol-generating material, the second portion defines the distal end point of the chamber for a second type of consumable containing the aerosol-generating material, and the first type of consumable containing the aerosol-generating material is thicker than the second type of consumable containing the aerosol-generating material.

[0015] The non-combustible aerosol supply device may further comprise a thin film layer on the surface of the elastic material. In this case, during use, when the consumable containing the aerosol generating material is received in the chamber, the thin film layer contacts the consumable containing the aerosol generating material.

[0016] According to a second aspect of some embodiments described herein, there is provided a non-combustible aerosol supply system comprising a non-combustible aerosol supply device according to the first aspect and at least one consumable containing an aerosol generating material for being received in the chamber.

[0017] 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 made with reference to the accompanying drawings and provided by way of example only.

Brief Description of the Drawings

[0018]

Figure 1

Figure 2

Figure 3

Figure 4a

Figure 4b

Figure 4c

Figure 4d

DETAILED DESCRIPTION OF THE INVENTION

[0019] FIG. 1 is a simplified schematic view of a non-flammable aerosol supply device 100. The non-flammable aerosol supply device 100 includes a chamber 102 configured to receive a consumable (not shown in FIG. 1) containing an aerosol generating material.

[0020] The aerosol generating material is a material capable of generating an aerosol when heated, illuminated with light, or activated by any other method. The aerosol generating material may or may not contain an active substance and / or a flavoring substance, and may be in the form of, for example, a solid, a liquid, or a gel. In some embodiments, the aerosol generating material may include an "amorphous solid", which may alternatively be referred to as an "integral structure solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material capable of holding any fluid, such as a liquid, therein. In some embodiments, the aerosol generating material may include, for example, from about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0021] The aerosol generating material may include one or more active substances and / or flavoring substances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0022] An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive agents. The active substance may occur naturally or be artificially obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids or their constituent substances, derivatives or combinations. The active substance may include one or more constituent substances, derivatives or extracts of tobacco, cannabis or another plant.

[0023] In some examples, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin or vitamin B12.

[0024] The aerosol-forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid and propylene carbonate.

[0025] One or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer and / or an antioxidant.

[0026] The non-combustible aerosol supply device 100 will hereinafter be referred to as device 100 in this specification. The device 100 includes an aerosol generator 104 for generating an aerosol from the aerosol-generating material in the consumable received in the chamber 102.

[0027] An aerosol generator is a device configured to generate an aerosol from an aerosol - generating material. In some embodiments, the aerosol generator or each aerosol generator is a heater configured to apply thermal energy to the aerosol - generating material to release one or more volatile substances from the aerosol - generating material to form an aerosol. In some embodiments, the aerosol generator or each aerosol generator is configured to generate an aerosol from the aerosol - generating material without heating. For example, the aerosol generator may be configured to apply to the aerosol - generating material one or more of vibration, increased pressure, or electrostatic energy.

[0028] Accordingly, in some examples, the aerosol generator comprises a heating assembly configured to provide energy to heat the aerosol - generating material of a first consumable received in chamber 102. In some examples, the heating assembly comprises one or more resistive heating elements disposed within chamber 102 or in thermal contact with chamber 102. The flow of an electric current opposing the electrical resistance of the one or more resistive heating elements generates heat. This process is called Joule heating, ohmic heating, or resistive heating.

[0029] In some examples, the aerosol generator 104 is an induction - heating assembly and is configured to generate a varying magnetic field to inductively heat a susceptor. The induction - heating assembly may comprise one or more inductors through which an alternating current passes to generate the varying magnetic field. In some examples, the aerosol generator 104 comprises one or more susceptors. In other examples, the aerosol generator 104 does not comprise a susceptor, and one or more susceptors may instead be provided as part of a consumable or with such a consumable intended to be used with device 100.

[0030] The susceptor is a material that can be heated by the intrusion of a varying magnetic field such as an alternating magnetic field. The susceptor may be a conductive material, and thus its intrusion by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, and thus its intrusion by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and thus the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0031] Device 100 includes a power source 106. The power source 106 supplies power to various components of the device 100. In some examples, the power source 106 is a battery. In some examples, the power source 106 includes a battery and a DC-DC converter, and power is supplied from the battery through the DC-DC converter. The DC-DC converter may enable the power source 106 to supply power to the battery voltage at a different voltage. In some examples, the device 100 may include a DC-to-AC converter for converting, for example, a DC current from a battery to an AC current to supply power to one or more inductors of the heating assembly 104, in which case the heating assembly 104 is an induction heating assembly. In the following examples, the power source 106 is simply referred to as the battery 106.

[0032] In the example of FIG. 1, the device 100 includes a control circuitry 108 configured to control various aspects of the operation of the device 100 including the aerosol generator 104. In this example, the control circuitry 108 is a control processor 108 that communicates data with a computer-readable memory 110. The control circuitry 108 controls various operations of the device, for example, by executing instructions stored in the computer-readable memory 110. For example, the control circuitry 108 controls the delivery of power from the battery 106 to the first aerosol generator 104 by controlling various electrical components such as switches (not shown in FIG. 1).

[0033] Device 100 includes a housing 101 that forms an outer cover of the device 100 and surrounds and houses various components of the device 100.

[0034] Device 100 further includes a user input device 112 electrically connected to a control circuitry 108, and the user can operate the device 100 using the user input device. Examples of suitable user input devices 112 include one or more buttons, a trackpad, and a touch screen, although any suitable device may be used.

[0035] The housing 101 is openable to allow access to the interior of the housing 101, so that consumables can be placed in the chamber 102 in preparation for use and then removed from the chamber 102 after use. In some examples, the housing 101 may be two hinged parts that together allow the housing 101 to be opened and closed.

[0036] In this example, device 100 also includes an opening 105 at one end of the housing 101 that allows a consumable received in the chamber 102 to protrude from the device 100. A portion of the consumable received in the chamber 102 contains an aerosol-generating material configured such that the device 100 generates an aerosol therefrom. A portion of the consumable protruding from the opening 105 may be provided with, for example, a filter, and the user can inhale the aerosol by sucking on a portion of the consumable protruding from the opening 105.

[0037] In an alternative example, the consumable is fully received within the chamber 102, and the device 100 is provided with a mouthpiece (not shown) connected to the housing 101 and in fluid communication with the chamber 102 for the user to suck on to inhale the aerosol.

[0038] In this example, chamber 102 includes a layer 114 of elastic material that surrounds at least a portion of a consumable (not shown) when the consumable is received within chamber 102. The layer 114 of elastic material is configured to conform to the thickness of the consumable, thereby enabling the selective and snug reception of consumables of different thicknesses within chamber 102.

[0039] It should be understood that device 100 may include other components not shown in FIG. 1, such as, for example, a ventilation inlet / outlet, a charging port, etc. Note that FIG. 1 is merely a schematic sketch showing some of the components that may be included in device 100. FIG. 1 is not intended to convey the specific positions of the various components.

[0040] Next, referring to FIGS. 2 through 4b, a simplified diagram of a second example of a non-combustible aerosol supply device 200 is shown, which will hereinafter be referred to as the second device 200. The second device 200 may include any of the features of device 100 described above with reference to FIG. 1, and the consideration of these features will not be repeated here. Like reference numerals are used to represent such features already described with reference to FIG. 1.

[0041] The second device 200 includes a first end 220, referred to as the mouth or proximal end 220, and a second end 222, referred to as the distal end 222. Although not shown in FIGS. 2 through 4b, the second device 200 includes a user input that enables a user to control the second device 200.

[0042] The second device 200 includes a housing 101 configured to protect the internal components of the second device 200. In this example, the housing 101 is divided into two compartments, namely a first compartment 216 and a second compartment 218. The first compartment 216 is connected to the second compartment 218 by a hinge mechanism 224 that extends longitudinally between a mouth end 220 and a distal end 222. Thus, the housing 101 is configured to allow access to the chamber 102 by opening along a length extending between the mouth end 220 and the distal end 222.

[0043] In this example, the first section 216 of the housing 101 contains therein a power source (not shown), a processor (not shown), and a memory (not shown) as described above with respect to the device 100 of FIG. 1.

[0044] The housing 101 includes a plurality of panels including a first panel 226 and a second panel 228. In this example, one or more of the plurality of panels are removable from the housing 101 as a whole to allow access to the internal components for repair or replacement. The one or more panels include any suitable material, for example, a plastic material including glass-filled nylon or metal. The plastic panel may be formed by injection molding. Different ones of the plurality of panels may be made of different materials.

[0045] The first panel 226 of the second device includes an opening 230 at the mouth end 220, and in this example, when a consumable (not shown) is received within the second device 200, the consumable protrudes through this opening. This enables the user to place the mouth end of the consumable in their mouth in order to inhale the aerosol released from the consumable while the second device is in use.

[0046] As optimally shown in FIG. 2, in this example, the chamber 102 comprises a first chamber section 102a defined in a first compartment 216 of the housing 101 and a second chamber section 102b defined in a second compartment 218 of the housing 101. Each of the first chamber section 102a and the second chamber section 102b is in the form of an elongated channel having a semi-circular cross-section.

[0047] When the second device 200 is closed along the hinge 224, the first chamber section 102a and the second chamber section 102b overlap each other along their lengths, so that the entire chamber 102 is in the form of a hollow cylindrical tube.

[0048] The chamber 102 includes an aerosol generator, which in this example is a heating configuration 204 extending substantially along the axial length of the chamber 102. As optimally illustrated in FIG. 3, when the second device 200 is closed, the heating configuration 204 comprises a plurality of cylindrical coaxial layers arranged radially within the chamber 102. Each of the coaxial layers comprises a first semi-cylindrical layer disposed in the first chamber section 102a and a second semi-cylindrical layer disposed in the second chamber section 102b. As can be optimally seen in FIG. 2, when the second device 200 is opened along the hinge 224, the first semi-cylindrical layer is separated from the second semi-cylindrical layer, which enables the user to insert a consumable into the chamber 102.

[0049] In order from the radially "outermost" layer to the radially "innermost" layer, the plurality of layers comprise an outer sealing layer 246, a vacuum insulation tube 248, an inner sealing layer 250, a heating element 244, a support tube layer 252, a layer 114 of elastic material and a protective inner foil layer 256.

[0050] The vacuum insulation tube 248 is located between the outer sealing layer 246 and the inner sealing layer 250 and provides a heat insulating layer to prevent heat from flowing from the chamber 102 to the housing 101 or to other internal components of the second device 200. In this example, the vacuum insulation tube 248 comprises, for example, a metal tube of steel (although non-metallic materials are also possible), and is provided with a radially outer wall and a radially inner wall that are connected to define a sealed predetermined volume of space with at least a portion of the air exhausted to prevent heat from moving through the vacuum insulation tube 248.

[0051] The outer sealing layer 246 and the inner sealing layer 250 each include a layer of rubber or other suitable sealant material that acts to seal the chamber 102 to prevent aerosol from leaking from the chamber 102 when the second device 200 is in use.

[0052] In this example, the heating element 244 comprises a layer of flexible heating foil, such as a metal foil, supported on the support tube layer 252. The heating element 244 is electrically connected to a power source and enables a processor of the second device 200 to control the power supplied to the heating element 244 when the second device 200 is in use. Thus, in this example, the heating element 244 heats using resistive heating.

[0053] The support tube layer 252 includes a heat conductive material. For example, the tube is a metal tube, such as a steel tube, so that the heat generated by the heating element 244 easily passes through the support tube layer 252.

[0054] As described above with reference to the device 100 illustrated in FIG. 1, the layer 114 of elastic material surrounds at least a portion of the consumable when the consumable is received within the chamber 102 and is configured to conform to the thickness of the consumable.

[0055] In this example, the layer 114 of elastic material comprises a pad of single fibers of highly pure metal, for example steel. The layer 114 of elastic material may include, for example, a material commonly known as wire wool or wire sponge.

[0056] The layer 114 of elastic material is in thermal contact with the inner protective foil layer 256, which may be an aluminum foil. The inner protective foil layer 256 has a smooth inner surface that contacts the consumable when the consumable is placed within the chamber 102. The inner protective foil layer 256 protects the consumable from being damaged by the layer 114 of elastic material and is easily cleanable.

[0057] The user first opens the second device 200 by means of the hinge mechanism 224, firmly places the consumable in the first chamber section 102a defined in the first compartment 216 of the housing 101, and then closes the second device 200 by means of the hinge mechanism 224 and presses the second compartment 218 of the housing 101 against the consumable to insert the consumable into the second device 200.

[0058] When the second device 200 is closed, the layer 114 of elastic material is compressed and thus conforms in shape to surround the consumable. This conforming action of the layer 114 of elastic material surrounding the aerosol-generating article ensures that the aerosol-generating article is held firmly in place and provides an optimal heat path between the heating element 244 and the consumable. When the second device 200 is subsequently opened and the consumable is removed, the tension in the layer 114 of elastic material relaxes to the uncompressed thickness it assumes when no consumable is inserted into the second device 200.

[0059] The layer 114 of elastic material enables the second device 200 to be adaptable for use with different types of consumables, in particular different types of consumables having different thicknesses, which thicknesses can be selected by the user for insertion into the second device 200.

[0060] This is illustrated in FIGS. 4a through 4d, where FIGS. 4a and 4c illustrate a first type of consumable 262 inserted into the second device 200, and FIGS. 4b and 4d illustrate a second type of consumable 260 inserted into the second device 200. The first type of consumable 262 and the second type of consumable 260 are of different sizes. More specifically, in this example, the first type of consumable 262 is thinner (i.e., the first type of consumable 262 has a smaller width or a smaller diameter than the second type of consumable). In this example, the first type of consumable is also longer than the second type of consumable.

[0061] As can be seen by comparing FIGS. 4c and 4d, the layer 114 of elastic material is compressed radially to a greater extent when the relatively thick second type of consumable 260 is inserted into the second device 200 (FIG. 4d) than when the relatively thin first type of consumable 262 is inserted into the second device 200 (FIG. 4c).

[0062] In this example, the chamber 102 further includes an annular step 236 toward its distal end that includes a hole 238. The annular step 236 is defined, for example, by the outer seal layer 246.

[0063] As best illustrated in FIG. 4b, the width of the hole 238 is smaller than the width of the second type of consumable 260. When the second type of consumable 260 is inserted into the second device 200, the distal end of the second type of consumable 260 abuts against the annular edge above the annular step 236.

[0064] As best illustrated in FIG. 4a, the width of the hole 238 is slightly larger than the width of the first type of consumable 262. When the first type of consumable 262 is inserted into the second device 200, the distal end of the first consumable extends through the hole 238 and abuts against the inner surface of the panel of the housing 101.

[0065] The diameter of the annular step 236 is selected such that the range 264 in which the mouth end or proximal end of each respective type of consumable extends outward from the second device 200 is substantially the same, notwithstanding the difference in the overall length of the first type of consumable 262 and the second type of consumable 260.

[0066] The above embodiments should be understood as illustrative examples of the present invention. Further embodiments of the present invention are contemplated. It should be understood that any feature described in connection with any one embodiment may be used alone, in combination with any other feature described, or in combination with one or more features of any other of the embodiments, or in any combination of any other of the embodiments. Further, equivalents and modifications not described above may also be utilized without departing from the scope of the present invention as defined in the appended claims.

Claims

1. A non-combustible aerosol supply device for generating an aerosol from an aerosol-generating material, comprising: a housing; a chamber within the housing for receiving a consumable containing the aerosol-generating material; an elastic material that surrounds at least a portion of the consumable when the consumable is received within the chamber, the elastic material having an adaptable thickness according to the thickness of the consumable containing the aerosol-generating material, so that consumables of different thicknesses can be selectively and snugly received within the chamber.

2. The housing is configured to facilitate insertion of the consumable containing the aerosol-generating material into the chamber or removal of the consumable containing the aerosol-generating material from the chamber. The non-combustible aerosol supply device according to claim 1, wherein the housing is configured to open along the length of the chamber to facilitate insertion of the consumable containing the aerosol-generating material into the chamber or removal of the consumable containing the aerosol-generating material from the chamber.

3. The non-combustible aerosol supply device according to claim 1 or 2, further comprising an opening into the chamber that allows the consumable to protrude from the housing when the consumable containing the aerosol-generating material is received within the chamber.

4. The non-combustible aerosol supply device according to any one of claims 1 to 3, wherein the elastic material is a heat-conductive material.

5. The non-combustible aerosol supply device according to claim 4, wherein the elastic material includes metallic wool.

6. The non-combustible aerosol supply device according to any one of claims 1 to 5, further comprising an aerosol generator system for generating an aerosol from the consumable containing the aerosol-generating material when the consumable containing the aerosol-generating material is received within the chamber during use.

7. The non-combustible aerosol supply device according to claim 6, wherein the aerosol generator system includes at least one heater for heating the aerosol-generating material within the consumable containing the aerosol-generating material to generate the aerosol when the consumable containing the aerosol-generating material is received within the chamber.

8. The non-combustible aerosol supply device according to claim 7, wherein the at least one heater comprises a layer of a flexible heating foil.

9. The non-combustible aerosol supply device according to claim 8, wherein the flexible heating foil is made of metal.

10. The non-combustible aerosol supply device according to any one of claims 7 to 9, wherein the chamber further comprises a tube disposed between the at least one heater and the elastic material.

11. The non-combustible aerosol supply device according to any one of claims 1 to 10, wherein the chamber further comprises a bottom with an annular step having a first portion with a first width and a second portion with a second width smaller than the first width, the first portion defining a distal end point of the chamber for a first type of consumable containing the aerosol-generating material, the second portion defining a distal end point of the chamber for a second type of consumable containing the aerosol-generating material, and the first type of consumable containing the aerosol-generating material being thicker than the second type of consumable containing the aerosol-generating material.

12. The non-combustible aerosol supply device according to any one of claims 1 to 11, further comprising a thin film layer on a surface of the elastic material, wherein during use, when a consumable containing the aerosol-generating material is received in the chamber, the thin film layer contacts the consumable containing the aerosol-generating material.

13. A non-combustible aerosol supply device according to any one of claims 1 to 12, and at least one consumable containing the aerosol-generating material for being received in the chamber, comprising a non-combustible aerosol supply system.

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