Heating elements

Abstract

To provide a heating element for a non-combustible aerosol provision device.SOLUTION: A heating element 1 has a rod 10. The rod 10 has a longitudinal axis, a distal end portion 13, and a first tapered portion 11 and a second tapered portion 12 at respective longitudinal positions along the longitudinal axis. The second tapered portion 12 extends from the distal end portion 13 towards the first tapered portion 11, and a cross-sectional area of the rod 10 increases with distance from the distal end portion 13 in each of the first tapered portion 11 and second tapered portion 12. A first angle between the longitudinal axis and an outer tapered surface 11s of the first tapered portion 11 is smaller than a second angle between the longitudinal axis and an outer tapered surface 12s of the second tapered portion 12.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a heating element for a non-combustion aerosol delivery device, a non-combustion aerosol delivery device, and a non-combustion aerosol delivery system. The non-combustion aerosol delivery device can be a tobacco heating product.

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to such smoking articles by creating products that release compounds without combustion. Examples of such products are so-called "heat-and-burn" products or tobacco heating devices or products, which release compounds by heating a material rather than 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 a non-combustion type aerosol delivery device, the heating element comprising a rod having a longitudinal axis, a distal end portion, and a first tapered portion and a second tapered portion at respective longitudinal positions along the longitudinal axis, the second tapered portion extending from the distal end portion toward the first tapered portion, a cross-sectional area of ​​the rod increasing with distance from the distal end portion at each of the first tapered portion and the second tapered portion, and a first angle between the longitudinal axis and an outer tapered surface of the first tapered portion being smaller than a second angle between the longitudinal axis and the outer tapered surface of the second tapered portion.

[0004] In an exemplary embodiment, the first angle is between 0.5° and 25°.

[0005] In an exemplary embodiment, the first angle is between 5° and 20°.

[0006] In an exemplary embodiment, the first angle is between 10° and 15°.

[0007] In an exemplary embodiment, the first angle is selected to facilitate removal of the rod from a tobacco industry product in use.

[0008] In an exemplary embodiment, the first tapered section extends over the majority of the length of the rod.

[0009] In an exemplary embodiment, the second tapered portion is conical.

[0010] In an exemplary embodiment, the second tapered section is non-conical.

[0011] In an exemplary embodiment, the rod is a flat strip.

[0012] A second aspect of the present invention provides a heating element for a non-combustion aerosol delivery device, the heating element comprising a rod, the rod having a longitudinal axis and an outer tapered surface, and over at least a majority of the length of the rod, the angle between the longitudinal axis and the outer tapered surface is between 0.5° and 25°.

[0013] In an exemplary embodiment, the angle is between 5° and 20°.

[0014] In an exemplary embodiment, the angle is between 10° and 15°.

[0015] In an exemplary embodiment, the angle is selected to facilitate removal of the rod from a tobacco industry product in use.

[0016] In an exemplary embodiment, the rod comprises a distal end portion and a first tapered portion and a second tapered portion at respective longitudinal positions along the longitudinal axis, the second tapered portion extending from the distal end portion toward the first tapered portion, a cross-sectional area of ​​the rod increasing with distance from the distal end portion at each of the first tapered portion and the second tapered portion, an angle being a first angle between the longitudinal axis and an outer tapered surface of the first tapered portion, the first angle being less than a second angle between the longitudinal axis and the outer tapered surface of the second tapered portion.

[0017] In an exemplary embodiment, the second angle is less than or equal to 45 degrees.

[0018] In an exemplary embodiment, the second angle is between 10° and 40°.

[0019] In an exemplary embodiment, the second angle is between 15° and 35°.

[0020] In an exemplary embodiment, the second angle is selected to facilitate insertion of the rod into a tobacco industry product during use.

[0021] In an exemplary embodiment, the second tapered portion extends from the distal end portion toward the first tapered portion.

[0022] In an exemplary embodiment, the first tapered portion is longer in the direction of the longitudinal axis than the second tapered portion.

[0023] In an exemplary embodiment, the rod comprises a heating material that is heatable by the penetration of a varying magnetic field.

[0024] In an exemplary embodiment, the rod consists of or consists essentially of a heating material that is heatable by the penetration of a varying magnetic field.

[0025] In an exemplary embodiment, the heating material includes one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material.

[0026] In an exemplary embodiment, the heating material comprises a metal or metal alloy.

[0027] In an exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

[0028] In an exemplary embodiment, the rods are electrically conductive.

[0029] In an exemplary embodiment, perpendicular to the longitudinal axis, the rod has a cross-sectional shape selected from the group consisting of: circular, oval, rectangular, square, and triangular.

[0030] In an exemplary embodiment, the rod is substantially incompressible in use.

[0031] A third aspect of the present invention provides a non-combustion aerosol delivery device comprising: a heating chamber for receiving at least a portion of a tobacco industry product containing an aerosolizable material; a heating element having a rod protruding into the heating chamber and aligned with or parallel to the axis of the heating chamber; and a heating device for heating the rod, thereby heating the aerosolizable material when the tobacco industry product is in the heating chamber, wherein the rod has a distal end portion and first and second tapered portions at respective axial positions along the axis, the second tapered portion extending from the distal end portion toward the first tapered portion, the cross-sectional area of ​​the rod increasing with distance from the distal end portion at each of the first and second tapered portions, and a first angle between the axis and an outer tapered surface of the first tapered portion being smaller than a second angle between the axis and the outer tapered surface of the second tapered portion.

[0032] In the exemplary embodiment, the axis is a central axis of the heating chamber.

[0033] In an exemplary embodiment, the heating chamber is elongated and the axis is the longitudinal axis of the heating chamber.

[0034] In an exemplary embodiment, the first angle is between 0.5° and 25°.

[0035] In an exemplary embodiment, the first angle is between 5° and 20°.

[0036] In an exemplary embodiment, the first angle is between 10° and 15°.

[0037] In an exemplary embodiment, the first angle is selected to facilitate removal of the rod from a tobacco industry product in use.

[0038] In an exemplary embodiment, the second angle is less than or equal to 45 degrees.

[0039] In an exemplary embodiment, the second angle is between 10° and 40°.

[0040] In an exemplary embodiment, the second angle is between 15° and 35°.

[0041] In an exemplary embodiment, the second angle is selected to facilitate insertion of the rod into a tobacco industry product during use.

[0042] In an exemplary embodiment, the second tapered portion extends from the distal end portion toward the first tapered portion.

[0043] In an exemplary embodiment, the first tapered portion is longer in the axial direction than the second tapered portion.

[0044] In an exemplary embodiment, the rod comprises a heating material that is heatable by the penetration of a varying magnetic field.

[0045] In an exemplary embodiment, the rod consists of or consists essentially of a heating material that is heatable by the penetration of a varying magnetic field.

[0046] In an exemplary embodiment, the heating device comprises a magnetic field generator for generating a varying magnetic field that penetrates the rod.

[0047] In an exemplary embodiment, the heating material includes one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material.

[0048] In an exemplary embodiment, the heating material comprises a metal or metal alloy.

[0049] In an exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

[0050] In an exemplary embodiment, the rods are electrically conductive.

[0051] In an exemplary embodiment, perpendicular to the axis, the rod has a cross-sectional shape selected from the group consisting of: circular, oval, rectangular, square, and triangular.

[0052] In an exemplary embodiment, the rod is substantially incompressible in use.

[0053] In exemplary embodiments, the heating element comprises a heating element according to the first or second aspect of the present invention.

[0054] A fourth aspect of the present invention provides a non-combustion aerosol delivery system comprising a non-combustion aerosol delivery device according to the third aspect of the present invention and a tobacco industry product comprising an aerosolizable material, the tobacco industry product being insertable into the heating chamber of the non-combustion aerosol delivery device such that the second tapered portion and at least a portion of the first tapered portion penetrate into the tobacco industry product.

[0055] In an exemplary embodiment, the tobacco industry product is insertable into the heating chamber of the non-combustion aerosol delivery device so that the second tapered portion and at least a portion of the first tapered portion penetrate the aerosolizable material.

[0056] In an exemplary embodiment of a non-combustion aerosol delivery device or system, the aerosolizable material is a non-liquid material.

[0057] In an exemplary embodiment of the non-combustion aerosol delivery device or system, the aerosolizable material includes tobacco.

[0058] In an exemplary embodiment of the non-combustion aerosol delivery device or system, the aerosolizable material comprises a reconstituted aerosolizable material, such as reconstituted tobacco.

[0059] A fifth aspect of the present invention provides a heating element for a non-combustion aerosol delivery device, the heating element being for use in penetrating and heating aerosolizable material of a tobacco industry product, the heating element having an outer surface configured to contact the aerosolizable material in use, the outer surface having a surface roughness selected to reduce frictional forces exerted by the heating element on the aerosolizable material when the heating element is removed from the aerosolizable material, thereby reducing the extent to which the aerosolizable material is pulled by the heating element while the heating element is being removed from the aerosolizable material.

[0060] In an exemplary embodiment, the exterior surface is polished, for example, electropolished.

[0061] In an exemplary embodiment, the exterior surface is coated with a low friction material. Exemplary low friction materials will be known to those skilled in the art.

[0062] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0063] [Figure 1] 1 shows a schematic side view of one embodiment of a heating element for a non-combustion aerosol delivery device. [Figure 2] FIG. 2 is a schematic top view of the heating element of FIG. 1. [Figure 3] 10 shows a schematic top view of another embodiment of a heating element for a non-combustion aerosol delivery device. [Figure 4] 10 shows a schematic top view of a further example of a heating element for a non-combustion aerosol delivery device. [Figure 5] 1 shows a schematic cross-sectional side view of one embodiment of a non-combustion aerosol delivery system including a non-combustion aerosol delivery device and a tobacco industry product containing an aerosolizable material. Detailed Description

[0064] As used herein, the term "aerosolizable material" includes materials that, upon heating, produce volatilized components, typically in the form of a vapor or aerosol. "Aerosolizable materials" may be non-tobacco-containing or tobacco-containing. "Aerosolizable materials" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. Aerosolizable materials may be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, solid, amorphous solid, gelled sheet, powder, or mass. "Aerosolizable materials" further include other non-tobacco products, which may or may not contain nicotine, depending on the product. "Aerosolizable materials" may also include one or more humectants, such as glycerol or propylene glycol.

[0065] In some examples, the aerosolizable material is in the form of an "amorphous solid." Any material referred to herein as an "amorphous solid" may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous), or a "dry gel." In some cases, it may be referred to as a "thick film." In some examples, the amorphous solid may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, a tobacco material and / or a nicotine source, water, and optionally, a flavoring agent.

[0066] In some embodiments, the gel or amorphous solid is in the form of a foam, such as an open-cell foam.

[0067] As used herein, the term "heating material" or "heater material" means a material that can be heated by the penetration of a varying magnetic field.

[0068] Induction heating is a process in which a conductive object is heated by the penetration of a changing magnetic field into the object. This process is explained by Faraday's law of induction and Ohm's law. An induction heater can include an electromagnet and a device that passes a changing current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another so that the resulting changing magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are induced in the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are induced in the object, the object heats up due to the eddy currents flowing against the object's electrical resistance. This process is called Joule heating, Ohmic heating, or resistive heating. An object that can be inductively heated is known as a susceptor.

[0069] It has been found that when the susceptor is in the form of a closed electrical circuit, the magnetic coupling between the susceptor and the electromagnet in use is enhanced, resulting in greater or improved Joule heating.

[0070] Magnetic hysteresis heating is a process by which an object made of a magnetic material is heated by the penetration of a changing magnetic field into the object. Magnetic materials can be thought of as containing a multitude of atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align with the field. Therefore, when a changing magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the applied changing magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0071] If an object is both conductive and magnetic, then both Joule heating and magnetic hysteresis heating can occur in the object when a varying magnetic field penetrates the object. Furthermore, the use of magnetic materials can increase the magnetic field, which can enhance Joule heating and magnetic hysteresis heating.

[0072] Because each of the above processes generates heat within the object itself rather than from an external heat source via thermal conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selecting the appropriate object material and geometry, and the appropriate magnitude and orientation of the varying magnetic field relative to the object. Furthermore, because induction heating and magnetic hysteresis heating do not require a physical connection between the varying magnetic field source and the object, greater design freedom and control of the heating profile may be possible, and costs may be lower.

[0073] 1, a schematic side view of an embodiment of a heating element is shown, in accordance with one embodiment. Heating element 1 is for a non-combustion aerosol delivery device, such as device 100, described below with reference to FIG.

[0074] The heating element 1 comprises a rod 10. The rod 10 may be in the form of, for example, a pin, a rod, or a flat strip. The rod 10 has a longitudinal axis AA. Orthogonal to the longitudinal axis AA, the rod 10 may have a cross-sectional shape selected from the group consisting of: circular, oval, rectangular, square, and triangular. In other embodiments, other cross-sectional shapes may be used, such as, for example, star-shaped or hexagonal. In this embodiment, the rod 10 is substantially incompressible during use.

[0075] Rod 10 has a first tapered portion 11, a second tapered portion 12, and a distal end portion 13. Distal end portion 13 constitutes the free end of rod 10. In use, the free end is the end of rod 10 that first enters a tobacco industry product containing aerosolizable material for subsequent heating of the aerosolizable material, as described below. Distal end portion 13 is distal from proximal end portion 14 of rod 10. Proximal end portion 14 may be the end portion of rod 10 at which rod 10 is attachable or mountable to (or attached or mounted to) the remainder of a non-combustion aerosol delivery device. In this example, proximal end portion 14 is one end of first tapered portion 11. In other examples, rod 10 can include one or more additional portions (not shown), such as non-tapered portions, between first tapered portion 11 and proximal end portion 14.

[0076] The first tapered portion 11 and the second tapered portion 12 are at respective longitudinal positions along the longitudinal axis AA. The second tapered portion 12 is disposed between the first tapered portion 11 and the distal end portion 13. The second tapered portion 12 extends from the distal end portion 13 toward the first tapered portion 11. In this embodiment, the second tapered portion 12 extends from the distal end portion 13 toward the first tapered portion 11 such that the second tapered portion 12 connects the distal end portion 13 and the first tapered portion 11. In other embodiments, the rod 10 can include one or more additional portions (not shown) between the distal end portion 13 and the first tapered portion 11. The first tapered portion 11 and the second tapered portion 12 are configured and arranged so that the cross-sectional area of ​​the rod 10 increases with distance from the distal end portion 13 in each of the first tapered portion 11 and the second tapered portion 12.

[0077] Rod 10 has a length L along longitudinal axis AA. In some embodiments, length L is between 5 mm and 100 mm, e.g., between 7 mm and 70 mm, or between 10 mm and 50 mm, or between 11 mm and 40 mm. In other embodiments, length L of rod 10 may be outside one of these ranges. Preferably, length L of rod 10 is greater than a dimension or any dimension of rod 10 measured in a direction perpendicular to length L of rod 10.

[0078] The first tapered portion 11 has a length L1 along the longitudinal axis AA. The second tapered portion 12 has a length L2 along the longitudinal axis AA. In this embodiment, the length L of the rod 10 is the sum of the length L1 of the first tapered portion 11 and the length L2 of the second tapered portion 12. In embodiments in which the rod 10 includes one or more additional portions (not shown) between the first tapered portion 11 and the proximal end portion 14, the length L of the rod 10 is greater than the sum of the length L1 of the first tapered portion 11 and the length L2 of the second tapered portion 12.

[0079] In some embodiments, the first tapered portion 11 and the second tapered portion 12 have lengths equal to or substantially equal to the length along the longitudinal axis AA. In some embodiments, the length L1 of the first tapered portion 11 is less than the length L2 of the second tapered portion 12. However, in this embodiment, the length L1 of the first tapered portion 11 is greater than the length L2 of the second tapered portion 12. Furthermore, in this embodiment, the first tapered portion 11 extends over the majority of the length L of the rod 10.

[0080] The first tapered section 11 has an outer tapered surface 11s, and a first angle α1 is defined between the longitudinal axis AA and the outer tapered surface 11s of the first tapered section 11. Similarly, the second tapered section 12 has an outer tapered surface 12s, and a second angle α2 is defined between the longitudinal axis AA and the outer tapered surface 12s of the second tapered section 12.

[0081] The second angle α2 is selected to facilitate insertion of the rod 10 into a tobacco industry product containing an aerosolizable material during use. The distal end portion 13 and the second tapered portion 12 can effectively pierce a tobacco industry product, such as an aerosolizable material. For example, the distal end portion 13 and the second tapered portion 12 may have to displace or split portions of the aerosolizable material during such insertion. The second angle α2 may be selected to provide an acceptable compromise between allowing the distal end portion 13 and the second tapered portion 12 to be sufficiently “sharp” to facilitate such insertion into a tobacco industry product and ensuring that the second tapered portion 12 has sufficient robustness to withstand forces applied during use and sufficient thermal mass to be a useful heating element.

[0082] In this embodiment, the second angle α2 is approximately 15°. However, in other embodiments, the second angle α2 may be any angle equal to or less than 45°, such as from about 10° to about 40°, or from about 15° to about 35°. The second angle α2 may be constant along the entire length L2 of the second tapered portion 12, or may vary along the length L2 of the second tapered portion 12. However, in embodiments in which the second angle α2 varies along the length L2 of the second tapered portion 12, preferably, no portion of the outer tapered surface 12s of the second tapered portion 12 subtends an angle with respect to the longitudinal axis AA that is greater than 45°.

[0083] It has been found that in some known non-combustion aerosol delivery devices, pieces of heated aerosolizable material can get stuck or otherwise adhere to the surface of the heating element in the heating chamber of the device. As the aerosolizable material is removed from the device, pieces of consumed aerosolizable material can break off and then deposit in the heating chamber. This is undesirable from a hygiene standpoint, as the heating chamber requires periodic cleaning, and also undesirable from an organoleptic standpoint, as used aerosolizable material can add an off-taste to the aerosol generated by fresh aerosolizable material.

[0084] Thus, the first angle α1 is selected to facilitate the release of the rod 10 from the tobacco industry product. More specifically, the first angle α1 is selected to reduce the extent to which the aerosolizable material is pulled along the heating element while the heating element is being removed. The first angle α1 may be selected to provide an acceptable compromise between facilitating the withdrawal of the rod 10 from the tobacco industry product and ensuring that the first tapered portion 11 is robust enough to withstand the forces applied during use and has sufficient thermal mass to enable it to be a useful heating element.

[0085] In this embodiment, the first angle α1 is approximately 10°. However, in other embodiments, the first angle α1 may be any angle between approximately 0.5° and approximately 25°, such as between approximately 5° and approximately 20°, or between approximately 10° and approximately 15°. The first angle α1 may be constant along the entire length L1 of the first tapered portion 11, or may vary along the length L1 of the first tapered portion 11. However, in embodiments in which the first angle α1 varies along the length L1 of the first tapered portion 11, preferably no portion of the outer tapered surface 11s of the first tapered portion 11 subtends an angle with respect to the longitudinal axis AA outside the range of between approximately 0.5° and approximately 25°.

[0086] In this embodiment, the first angle α1 between the longitudinal axis AA and the outer tapered surface 11s of the first tapered section 11 is smaller than the second angle α2 between the longitudinal axis AA and the outer tapered surface 12s of the second tapered section 12. Furthermore, in this embodiment, there is a point change or a step change between the first angle α1 and the second angle α2 of the first tapered section 11 and the second tapered section 12. In other embodiments, the first tapered section 11 may smoothly transition into the second tapered section 12 without a distinct point change or step change. In some embodiments, the first angle α1 and the second angle α2 may be equal or substantially equal. In embodiments in which the first angle α1 and the second angle α2 are equal or substantially equal, the first angle α1 and the second angle α2 may be any angle between about 0.5° and about 25°, such as between about 5° and about 20°, or between about 10° and about 15°.

[0087] The dimensions of the heating element 1, including the first angle α1 and the second angle α2 and the length L1 of the first tapered section 11 and the length L2 of the second tapered section 12, are selected so that the heating element 1 is compatible with the tobacco industry product 200 into which it is inserted during use. If the angles α1, α2 and the lengths L1, L2 are too small, the heating element 1 may not be able to effectively heat the aerosolizable material 201 of the tobacco industry product 200. On the other hand, if the angles α1, α2 and the lengths L1, L2 are too large, the heating element 1 may not fit within the aerosolizable material 201, may displace the aerosolizable material 201 too much during insertion, or may be so close to a wrapper (if present) wrapped around the aerosolizable material 201 that the heating element 1 may burn or otherwise damage the wrapper during use. By way of example only, the proximal end portion 14 of the rod 10 may have a width perpendicular to the longitudinal axis AA of less than 8 mm, or less than 7 mm, or less than 6 mm.

[0088] FIG. 1 shows a schematic side view of heating element 1. A schematic top view of heating element 1 is shown in FIG. 2. The view in FIG. 2 is therefore orthogonal to the view in FIG. 1. As can be seen in FIG. 2, rod 10 has the same cross-sectional shape in both directions orthogonal to longitudinal axis AA. Rod 10 therefore has rotational symmetry about longitudinal axis AA. Indeed, in this embodiment, second tapered section 12 is conical, and first tapered section 11 is frustoconical. Thus, rod 10 has infinite rotational symmetry or rotational symmetry of an infinite order. In other embodiments, rod 10 may have rotational symmetry of a non-infinite order, such as second, third, fourth, sixth, or eighth order.

[0089] In a variation of the embodiment shown in Figures 1 and 2, as shown in Figure 3, rod 10, when viewed from above, tapers at a constant or nearly constant angle α3 over the combined lengths L1, L2 of first tapered section 11 and second tapered section 12. When viewed from the side, heating element 1 in Figure 3 has the same dimensions as that shown in Figure 1. Angle α3 can be any angle between about 0.5° and about 25°, such as between about 5° and about 20°, or between about 10° and about 15°.

[0090] In another variation of the embodiment shown in Figures 1 and 2, as shown in Figure 4, the rod 10, when viewed from above, is not tapered at the first tapered portion 11 and the second tapered portion 12. That is, the cross-sectional area of ​​the rod 10 is constant or nearly constant over the combined lengths L1, L2 of the first tapered portion 11 and the second tapered portion 12. When viewed from the side, the heating element 1 in Figure 4 has the same dimensions as that shown in Figure 1.

[0091] In other embodiments, rod 10 may have a different shape when viewed from above. For example, rod 10 may be tapered over length L2 of second tapered section 12 and not tapered over length L1 of first tapered section 10 when viewed from above. When viewed from the side, the rod still has the same dimensions as shown in FIG. 1.

[0092] The rod 10 of any one of the embodiments described herein can include a heating material that can be heated by the penetration of a fluctuating magnetic field. For example, the rod 10 can consist of, or consist essentially of, a heating material that can be heated by the penetration of a fluctuating magnetic field. The rod 10 can include, consist of, or consist essentially of two or more different heating materials, each of which can be heated by the penetration of a fluctuating magnetic field. In some embodiments, the rod 10 can include a support and a heating material on or within the support. The support can be free of, or substantially free of, a heating material that can be heated by the penetration of a fluctuating magnetic field. For example, the support can include a ceramic material, glass, or a polymer such as polyetheretherketone (PEEK). The heating material can be provided in the support in the form of one or more channels, each of which can follow a serpentine and / or spiral path. Thus, the rod 10, or at least a portion thereof, can be electrically conductive.

[0093] In some embodiments, the heating material of rod 10 is aluminum. However, in other embodiments, the heating material can include one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material. In some embodiments, the heating material can include a metal or metal alloy. In some embodiments, the heating material can 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, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze. Other heating material(s) may be used in other applications.

[0094] In some embodiments, such as those in which the heating element may comprise iron, such as steel (e.g., mild steel or stainless steel), or aluminum, the heating material may be coated to help prevent corrosion or oxidation of the heating element during use. Such coatings may include, for example, nickel plating, gold plating, or a ceramic or inert polymer coating.

[0095] In some embodiments, rod 10 can alternatively or additionally be resistively heated by connecting a source of electrical energy to rod 10 so that an electrical current can be passed through rod 10 .

[0096] Referring to FIG. 5, a schematic cross-sectional side view of one embodiment of a non-combustion aerosol delivery system is shown.

[0097] System 1000 includes a non-combustion aerosol delivery device 100 and a tobacco industry product 200 that includes an aerosolizable material 210. In this example, aerosol delivery device 100 is a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device).

[0098] The aerosol delivery device 100 comprises a heating chamber 110 that receives the tobacco industry product 200 and a heating device 112 that causes the aerosolizable material 210 to heat when the tobacco industry product 200 is in the heating chamber 110 .

[0099] Aerosol delivery device 100 can define at least one air flow inlet (not shown) fluidly connecting heating chamber 110 with the exterior of aerosol delivery device 100. A user can make the volatilized component(s) of the aerosolizable material inhalable by drawing the volatilized component(s) from heating chamber 110 through tobacco industry product 200. Once the volatilized component(s) have been removed from heating chamber 110 and tobacco industry product 200, air may be drawn into heating chamber 110 through air flow inlet(s) of aerosol delivery device 100.

[0100] In this embodiment, the heating chamber 110 extends along an axis HH and is sized and shaped to accommodate only a portion of the tobacco industry product 200. In this embodiment, the axis HH is the central axis of the heating chamber 110. Furthermore, in this embodiment, the heating chamber 110 is elongated, and therefore the axis HH is the longitudinal axis HH of the heating chamber 110. In other embodiments, the heating chamber 110 may or may not be elongated and may be sized to accommodate the entire tobacco industry product 200.

[0101] Aerosol delivery device 100 has a heating element 1 with a rod 10. Rod 10 protrudes into heating chamber 110 and is aligned with an axis HH of heating chamber 110. In other embodiments, rod 10 can be parallel to axis HH of heating chamber 110 rather than aligned with axis HH of heating chamber 110.

[0102] The heating device 112 heats the rod 10, thereby heating the aerosolizable material 210 when the tobacco industry product 200 is in the heating chamber 110. In this embodiment, the heating element 1 is the heating element 1 shown in FIGS. 1 and 2 and described above. However, in other embodiments, the heating element 1 of the aerosol delivery device 100 may be any of the variations of the heating element 1 shown in FIGS. 1 and 2 described herein. Thus, in this embodiment, and referring again to FIG. 1 , the rod 10 of the heating element 1 has a distal end portion 13 and first and second tapered portions 11 and 12 at respective axial positions along the axis HH. The second tapered portion 12 extends from the distal end portion 13 toward the first tapered portion 11, and the cross-sectional area of ​​the rod 10 increases with distance from the distal end portion 13 in each of the first tapered portion 11 and the second tapered portion 12. A first angle α1 between the axis HH and the outer tapered surface 11s of the first tapered portion 11 is smaller than a second angle α2 between the axis HH and the outer tapered surface 11s of the second tapered portion 12.

[0103] 5, the heating device 112 comprises a magnetic field generator for generating a varying magnetic field that penetrates the rod 10. In this embodiment, the magnetic field generator 112 comprises a power supply 113, a coil 114, a device 116 for applying a varying current, such as an alternating current, to the coil 114, a controller 117, and a user interface 118 for user operation of the controller 117.

[0104] In this embodiment, power supply 113 is a rechargeable battery. In other embodiments, power supply 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 supply.

[0105] The coil 114 can take any suitable form. In some embodiments, the coil 114 is a helical coil of conductive material, such as copper. In some embodiments, the coil 114 surrounds at least a portion of the heating element 1. In some embodiments, the coil 114 surrounds at least a portion of the heating chamber 110. In some embodiments, the coil 114 extends along a longitudinal axis substantially aligned with the longitudinal axis of the heating chamber 110. The aligned axes may be coincident. Alternatively, the aligned axes may be parallel or oblique to one another. In some embodiments, the coil 114 is a planar coil. That is, the coil 114 may comprise a spiral of conductive material, such as copper, lying in a plane. The plane may be a flat plane or a curved plane. In some embodiments where the plane is a curved plane, the plane may be curved about the axis AA of the rod 10 and / or the axis HH of the heating chamber 110.

[0106] In this embodiment, device 116 for passing a varying current through coil 114 is electrically connected between power source 113 and coil 114. In this embodiment, controller 117 is also electrically connected to power source 113 and communicatively connected to device 116 to control device 116. More specifically, in this embodiment, controller 117 is for controlling device 116 to control the supply of power from power source 113 to coil 114. In this embodiment, controller 117 comprises an integrated circuit (IC), e.g., an IC on a printed circuit board (PCB). In other embodiments, controller 117 may take different forms. In some embodiments, aerosol delivery device 100 can have a single electrical or electronic component comprising device 116 and controller 117. Controller 117, in this embodiment, is operated by user manipulation of user interface 118. User interface 118 can comprise a push button, a toggle switch, a dial, a touch screen, or the like. In other embodiments, user interface 118 may be remote and wirelessly connected to the rest of aerosol delivery device 100, such as via Bluetooth®.

[0107] In this embodiment, user interaction with user interface 118 causes controller 117 to cause device 116 to pass an alternating current through coil 114, which in turn generates an alternating magnetic field. Coil 114 and rod 10 are preferably positioned relative to one another such that the varying magnetic field generated by coil 114 penetrates rod 10. If the heating material of rod 10 is conductive, this penetration generates one or more eddy currents in the heating material. The flow of eddy currents in the heating material against the heating material's electrical resistance heats the heating material via Joule heating. If the heating element of rod 10 is magnetic, the orientation of the magnetic dipoles of the heating element changes with the applied magnetic field, generating heat in the heating element.

[0108] The aerosol delivery device 100 of this example includes a temperature sensor 119 that senses the temperature of the heating chamber 110. The temperature sensor 119 is communicatively connected to the controller 117 so that the controller 117 can monitor the temperature of the heating chamber 110. Based on one or more signals received from the temperature sensor 119, the controller 117 can cause the device 112 to adjust the characteristics of the fluctuating or alternating current passing through the coil 114 as necessary to ensure that the temperature of the heating chamber 110 remains within a predetermined temperature range. This characteristic may be, for example, amplitude, frequency, or duty cycle. Within the predetermined temperature range, in use, the aerosolizable material 210 within a tobacco industry product placed in the heating chamber 110 is heated sufficiently to volatilize at least one component of the aerosolizable material 210 without burning the aerosolizable material 210. Thus, the controller and aerosol delivery device 100, collectively, are configured to heat the aerosolizable material 210 to volatilize at least one component of the aerosolizable material 210 without burning the aerosolizable material 210. The temperature range may be from about 50°C to about 350°C, e.g., from about 100°C to about 300°C, or from about 150°C to about 280°C. In other embodiments, the temperature range may be outside of one of these ranges. In some embodiments, the upper limit of the temperature range may be greater than 350°C. In some embodiments, the temperature sensor 119 may be omitted.

[0109] In some embodiments, the heating element 1 is instead a resistive heater that is heated by passing electricity through the resistive heater, and the controller 117 is configured to control the passage of electricity to the resistive heater. In such embodiments, the coil 114 and the device 116 for passing a varying current through the coil 114 may be omitted.

[0110] The tobacco industry product 200 is insertable into the heating chamber 110 of the non-combustion aerosol delivery device 100 such that the second tapered portion 12 and at least a portion of the first tapered portion 11 penetrate the tobacco industry product 200. More specifically, in this embodiment, the tobacco industry product 200 is insertable into the heating chamber 110 such that the second tapered portion 12 and at least a portion of the first tapered portion 11 penetrate the aerosolizable material 210 of the tobacco industry product 200. As mentioned above, the second angle α2 defined between the longitudinal axis AA of the rod 10 and the outer tapered surface 12s of the second tapered portion 12 facilitates such penetration of the tobacco industry product 200 by the rod 10.

[0111] In some embodiments, aerosolizable material 210 is a non-liquid material. In some embodiments, aerosolizable material 210 is a gel. In some embodiments, aerosolizable material 210 includes tobacco. However, in other embodiments, aerosolizable material 210 may consist of tobacco, consist substantially entirely of tobacco, include tobacco and aerosolizable materials other than tobacco, include aerosolizable materials other than tobacco, or be tobacco-free. In some embodiments, aerosolizable material 210 may include a vapor or aerosol-forming agent, or a humectant, such as glycerol, propylene glycol, triacetin, or diethylene glycol. In some embodiments, aerosolizable material 210 includes a reconstituted aerosolizable material, such as reconstituted tobacco.

[0112] In some embodiments, aerosolizable material 210 is generally cylindrical with a generally circular cross-section and a longitudinal axis, while in other embodiments, aerosolizable material 210 may have a different cross-section or may not be elongated.

[0113] The aerosolizable material 210 of the tobacco industry product 200 may have an axial length of, for example, between 8 mm and 120 mm. For example, the axial length of the aerosolizable material 210 may be greater than 9 mm, or 10 mm, or 15 mm, or 20 mm. For example, the axial length of the aerosolizable material 210 may be less than 100 mm, or less than 75 mm, or less than 50 mm, or less than 40 mm.

[0114] In some embodiments, such as shown in FIG. 5 , tobacco industry product 200 includes a filter arrangement 220 that filters aerosol or vapor emitted from aerosolizable material 210 during use. Alternatively, or additionally, filter arrangement 220 may be for controlling the pressure drop across the length of tobacco industry product 200. Filter arrangement 220 may include one or more filters. Filter arrangement 220 may be of any type used in the tobacco industry. For example, the filter may be made of cellulose acetate. In some embodiments, filter arrangement 220 is generally cylindrical with a generally circular cross-section and a longitudinal axis. In other embodiments, filter arrangement 220 may have a different cross-section or may not be elongated.

[0115] In some embodiments, filter arrangement 220 abuts a longitudinal end of aerosolizable material 210. In other embodiments, filter arrangement 220 may be spaced apart from aerosolizable material 210, for example, by a gap and / or one or more additional components of tobacco industry product 200. In some embodiments, filter arrangement 220 may include an additive or flavor source (e.g., an additive or flavor-containing capsule or thread), which may be held, for example, by the body of filtering material or between two bodies of filtering material.

[0116] The tobacco industry product 200 may further include a wrapper (not shown) wrapped around the aerosolizable material 210 and the filter configuration 220 to hold the filter configuration 220 against the aerosolizable material 210. The wrapper may be wrapped around the aerosolizable material 210 and the filter configuration 220 such that the free ends of the wrapper overlap. The wrapper may form part or all of the circumferential outer surface of the tobacco industry product 200. The wrapper may be made of any suitable material, such as paper, card, or reconstituted aerosolizable material (e.g., reconstituted tobacco). The paper may be tipping paper, as known in the art. The wrapper may further include an adhesive (not shown) that adheres the overlapping free ends of the wrapper to one another to help prevent separation of the overlapping free ends. In other embodiments, the adhesive may be omitted, or the wrapper may take a different form than that described. In other embodiments, the filter configuration 220 may be held against the aerosolizable material 210 by a connector other than the wrapper, such as an adhesive. In some embodiments, the filter arrangement 220 may be omitted.

[0117] Once all, substantially all, or many of the volatilizable components of the aerosolizable material 210 in the tobacco industry product 200 have been consumed, the user can remove the tobacco industry product 200 from the heating chamber 110 of the device 100 and discard the tobacco industry product 200.

[0118] As noted above, the first angle α1 defined between the longitudinal axis AA of the rod 10 and the outer tapered surface 11s of the first tapered section 11 facilitates such removal of the rod 10 from the tobacco industry product 200. More specifically, the first angle α1 is selected to reduce the extent to which the aerosolizable material 210 is pulled along the rod 10 while it is being removed. This helps to avoid or reduce the extent to which pieces of the consumed aerosolizable material 210 break off and subsequently deposit in the heating chamber 110. The user can then reuse the device 100 with another such tobacco industry product 200.

[0119] Alternatively, or in addition to providing the heating element with tapered portion(s), the heating element can have an outer surface configured to contact the aerosolizable material during use, the outer surface providing a heating element with a surface roughness selected to reduce the frictional force exerted by the heating element on the aerosolizable material when the heating element is removed from the aerosolizable material, thereby reducing the extent to which the aerosolizable material is pulled by the heating element during removal of the heating element from the aerosolizable material. For example, the outer surface may be polished, e.g., electropolished, and / or the outer surface may be coated with a low-friction material. Exemplary low-friction materials will be known to those skilled in the art.

[0120] In some embodiments, the tobacco industry product 200 is sold, supplied, or otherwise provided separately from the device 100 with which the tobacco industry product 200 is usable. However, in some embodiments, the device 100 and one or more tobacco industry products 200 may be provided as a system, such as a kit or assembly, possibly together with additional components, such as cleaning tools.

[0121] To address various problems and advance the art, the present disclosure as a whole illustrates, by way of illustration and example, various embodiments by which the claimed inventions can be practiced and which provide an improved heating element for a non-combustion aerosol delivery device, an improved non-combustion aerosol delivery device, and an improved non-combustion aerosol delivery system. The advantages and features of the present disclosure are merely a representative sample of embodiments and are not exhaustive or exclusive. They are presented solely to aid in the understanding and teaching of the claimed or otherwise disclosed features. The advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be considered limitations of the present disclosure as defined in the claims or equivalents thereof, and it should be understood that other embodiments may be utilized and changes may be made without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. The present disclosure may encompass other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A heating element for a non-combustion aerosol delivery device, comprising: the heating element comprises a rod having a longitudinal axis, a distal end portion, and first and second tapered portions at respective longitudinal positions along the longitudinal axis; the second tapered portion extends from the distal end portion toward the first tapered portion, and a cross-sectional area of ​​the rod increases with distance from the distal end portion at each of the first tapered portion and the second tapered portion; a first angle between the longitudinal axis and an outer tapered surface of the first tapered section is less than a second angle between the longitudinal axis and an outer tapered surface of the second tapered section; The difference between the first angle and the second angle is between 5° and 10°.

2. The heating element of claim 1 , wherein the first angle is between 0.5° and 25°.

3. the heating element comprises a rod, the rod having a longitudinal axis and an outer tapered surface, the angle between the longitudinal axis and the outer tapered surface being between 0.5° and 25° along at least a majority of the length of the rod; the rod having a distal end portion and first and second tapered portions at respective longitudinal positions along the longitudinal axis; the second tapered portion extends from the distal end portion toward the first tapered portion, and a cross-sectional area of ​​the rod increases with distance from the distal end portion at each of the first tapered portion and the second tapered portion; the angle is a first angle between the longitudinal axis and an outer tapered surface of the first tapered section; the first angle is less than a second angle between the longitudinal axis and an outer tapered surface of the second tapered section; A heating element for a non-combustion type aerosol delivery device, wherein the difference between the first angle and the second angle is 5° to 10°.

4. A heating element according to any preceding claim, wherein the second tapered portion extends from the distal end portion towards the first tapered portion.

5. A heating element according to any one of claims 1 to 4, wherein the first tapered portion is longer in the direction of the longitudinal axis than the second tapered portion.

6. A heating element according to any one of claims 1 to 5, wherein the rod comprises a heating material that is heatable by the penetration of a fluctuating magnetic field.

7. A heating element according to any one of claims 1 to 6, wherein the rod is electrically conductive.

8. a heating chamber that receives at least a portion of a tobacco industry product that includes an aerosolizable material; a heating element comprising a rod projecting into the heating chamber and aligned or parallel to the axis of the heating chamber; a heating device for heating the rod, thereby heating the aerosolizable material when the tobacco industry product is in the heating chamber; the rod having a distal end portion and first and second tapered portions at respective axial positions along the axis; the second tapered portion extends from the distal end portion toward the first tapered portion, and a cross-sectional area of ​​the rod increases with distance from the distal end portion at each of the first tapered portion and the second tapered portion; a first angle between the axis and the outer tapered surface of the first tapered section is less than a second angle between the axis and the outer tapered surface of the second tapered section; A non-combustion aerosol delivery device, wherein the difference between the first angle and the second angle is 5° to 10°.

9. 9. The non-combustion aerosol delivery device of claim 8, wherein the axis is a central axis of the heating chamber.

10. 10. The non-combustion aerosol delivery device of claim 8 or 9, wherein the heating chamber is elongated and the axis is the longitudinal axis of the heating chamber.

11. The non-combustion aerosol delivery device of any one of claims 8 to 10, wherein the heating element comprises a heating element according to any one of claims 1 to 7.

12. A non-combustion type aerosol delivery device according to any one of claims 8 to 11; a tobacco industry product including an aerosolizable material, the tobacco industry product being insertable into the heating chamber of the non-combustion aerosol delivery device so that the second tapered portion and at least a portion of the first tapered portion penetrate into the tobacco industry product.

13. 13. The non-combustion aerosol delivery system of claim 12, wherein the tobacco industry product is insertable into the heating chamber of the non-combustion aerosol delivery device so that the second tapered portion and at least a portion of the first tapered portion penetrate the aerosolizable material.

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