Apparatus for heating aerosolizable materials

Abstract

An apparatus (100, 200) is described that is arranged to heat an aerosolizable material to volatilize at least one component of the aerosolizable material. The apparatus (100, 200) has a heating region (215) for receiving at least a portion of an article (110) that includes an aerosolizable material. The apparatus also has a magnetic field generator (240) including a helical inductor coil (241) for generating a varying magnetic field. The helical inductor coil (241) defines an inductor region (242) within the inductor coil (241). The apparatus (100) also has an elongated heating element (220) that is heatable by penetration of the varying magnetic field and that is arranged to heat the heating region (215). The elongated heating element (220) extends between the heating region (215) and the inductor region (242).

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. The present invention also relates to an elongated heating element for use in the apparatus for heating an aerosolizable material, an aerosol delivery device, and an aerosol delivery system comprising an article including the aerosol delivery device and an aerosol-generating material.

[0002] Smoking articles such as cigarettes, cigars, and the like burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning articles by creating products that release compounds in a non-combustible manner. Examples of such products are heating devices that release compounds by heating a material in a non-combustible manner. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. Overview

[0003] According to one aspect, an apparatus configured to heat an aerosolizable material to volatilize at least one component of the aerosolizable material is provided, the apparatus comprising: a heating region configured to receive at least a portion of an article including the aerosolizable material; a magnetic field generator including a helical inductor coil configured to generate a varying magnetic field, the helical inductor coil defining an inductor region within the inductor coil; and an elongated heating element heatable by penetration of the varying magnetic field and positioned to heat the heating region, the elongated heating element extending between the heating region and the inductor region.

[0004] The coil may be supported on a mount.

[0005] The coil may comprise a wire. The coil may comprise a conductive film.

[0006] The elongated heating element may define a longitudinal axis. The helical inductor coil may be axially spaced from the heating region.

[0007] The elongated heating element may project into the heating area.

[0008] The elongated heating element may stand upright from the base. The elongated heating element may have a sharp edge or tip at a free end. The elongated heating element may be a pin or a blade. The elongated heating element may be configured to extend into an article received by the heating zone.

[0009] The device may include a receptacle that defines a heating region. The helical inductor coil may not overlap the receptacle.

[0010] The receptacle may include an end wall defining a closed end of the heating region. The end wall may be between the heating region and the helical inductor coil.

[0011] The receptacle may include a peripheral wall defining a heating region, and a spacing between the peripheral wall and the heating element may be greater than a spacing between the helical inductor coil and the elongated heating element.

[0012] The maximum width of the spiral inductor coil may be less than the maximum width of the heating region.

[0013] The inner diameter of the helical inductor coil may be smaller than the outer diameter of the heating region.

[0014] The maximum outer width of the helical inductor coil may be less than the maximum outer width of the heating region.

[0015] The maximum outer diameter of the helical inductor coil may be less than the maximum outer diameter of the receptacle.

[0016] The heating element may include a first portion exposed to the heating zone and a second portion outside the heating zone, and the helical inductor coil may surround the second portion.

[0017] The first and second portions may be integrally formed. As used herein, the term "integrally formed" is intended to mean that their features are inseparable.

[0018] The second portion may be fluidly isolated from the heating region.

[0019] The first portion may be a heating portion, the second portion may be a base portion, and the heating portion and the base portion may be coaxial.

[0020] The heating portion and the base portion may be thermally conductively connected. As used herein, the term "conductively connected" does not necessarily mean that two features are directly connected; such a construction may include one or more additional features between the two features. The heating portion and the base portion may be directly thermally conductively connected. The heating portion and the base portion may be indirectly thermally conductively connected, for example, by an intermediate member. As used herein, the term "conductively connected" is intended to mean the primary means of heat transfer between the heating portion and the base portion.

[0021] The heating portion may have a thermal conductivity greater than the thermal conductivity of at least a portion of the base portion.

[0022] At least a portion of the heating portion may include a first material and at least a portion of the base portion may include a second material.

[0023] The first material may have a lower susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the second material.

[0024] The thermal conductivity value of the first material may be greater than the thermal conductivity value of the second material.

[0025] The radial width of at least a part of the second portion may be greater than the radial width of the first portion.

[0026] The second portion may comprise a collar.

[0027] The second portion may comprise a core. The collar may at least partially surround the core.

[0028] The core may be formed with the first portion as a unitary component, i.e., these features are formed together such that no joint is defined between them.

[0029] The first portion and the core may be elongated members. The elongated members may be rods.

[0030] The elongated member may be a heat pipe.

[0031] The collar may include a heater material that is heatable by the penetration of a varying magnetic field.

[0032] The collar may be tubular. The collar may be a foil layer. The collar may be a mesh. The susceptor may be a wire formed as a winding. The wire may have a serpentine configuration. The collar may be a solid member.

[0033] The thermal conductivity of at least a portion of the first portion may be greater than the thermal conductivity of at least a portion of the second portion.

[0034] At least a portion of the first portion may be less susceptible to heating due to the intrusion of a fluctuating magnetic field than at least a portion of the second portion.

[0035] At least a portion of the first portion of the heating element may comprise a non-ferrous material and at least a portion of the second portion may comprise a ferrous material.

[0036] The collar may comprise a ferrous material.

[0037] The heating element may comprise a heat pipe.

[0038] The heat pipe may extend between the heating region and the inductor region.

[0039] The inductor region may have an axial length that is at least 25% of the heating region.

[0040] According to one aspect, an apparatus configured to heat an aerosolizable material to volatilize at least one component of the aerosolizable material is provided, the apparatus comprising: a body having a cavity for receiving an article including the aerosol-generating material; a magnetic field generator assembly including a helical inductor coil; and a heater member having a first portion exposed to the cavity and positioned to heat the cavity, and a second portion received by the helical inductor coil to be heated by the magnetic field generator assembly, the first portion being offset from the helical inductor coil and positioned to be heated by conduction from the second portion.

[0041] Apparatus of this aspect may include one or more or all of the features described above, where appropriate.

[0042] According to one aspect, an elongated heating element is provided for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element defining a longitudinal axis and comprising an elongated heating portion and an elongated susceptor portion, the elongated heating portion protruding axially from the elongated susceptor portion.

[0043] The width of the elongated heating portion may be greater than the length of the elongated heating portion along the longitudinal axis.The width of the elongated susceptor portion may be greater than the length of the elongated heating portion along the longitudinal axis.

[0044] The elongated heating portion may comprise a first material and the elongated susceptor portion may comprise a second material.

[0045] The first material may have a higher conductivity than the second material.

[0046] According to one aspect, there is provided an aerosol delivery device comprising at least one of the apparatuses described above.

[0047] According to one aspect, there is provided an aerosol delivery device comprising at least one elongated heating element as described above.

[0048] According to one aspect, there is provided an aerosol delivery device comprising at least one of the apparatuses described above and at least one of the elongated heating elements described above.

[0049] The aerosol delivery device may be a non-flammable aerosol delivery device.

[0050] The device may be a tobacco heating device, also known as a non-combustion heating device.

[0051] According to one aspect, there is provided an aerosol delivery system comprising the aerosol delivery device described above and an article including an aerosol-forming material.

[0052] The item may be a consumable item.

[0053] The aerosol-forming material may be a non-liquid aerosol-forming material.

[0054] The article may be sized to be at least partially received within the heating region.

[0055] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0056] [Figure 1] FIG. 1 is a front perspective view of an aerosol delivery device. [Figure 2] FIG. 2 is a schematic diagram of the aerosol delivery device of FIG. 1. [Figure 3] 3 is a side view of a portion of the heating assembly of FIG. 2 having an article containing an aerosol-forming material. [Figure 4] FIG. 4 is a cross-sectional side view of a portion of the heating assembly of FIG. 3 having an article including an aerosol-forming material. [Figure 5] FIG. 4 is a schematic perspective view of the heating assembly of FIG. 3. [Figure 6] 3 is a schematic side view of another heating assembly of the aerosol delivery device of FIG. 2. [Figure 7] 3 is a schematic side view of a heating element of the aerosol delivery device of FIG. 2. Detailed Description

[0057] As used herein, the term "aerosol-forming material" includes materials that, upon heating, deliver volatile components, typically in the form of an aerosol. Aerosol-forming materials include any tobacco-containing material, and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-forming materials may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. Aerosol-forming materials may be in the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-forming materials may also be, for example, a combination or mixture of materials. Aerosol-forming materials are also sometimes known as "smoking materials."

[0058] Devices are known that heat aerosol-generating materials to volatilize at least one component of the aerosol-generating materials to form an inhalable aerosol, typically without burning or combusting the aerosol-generating materials. Such devices may be described as "aerosol-generating devices," "aerosol-delivery devices," "non-combustion heating devices," "tobacco heating product devices," or "tobacco heating devices," or similar. Similarly, so-called e-cigarette devices also exist, which typically vaporize aerosol-generating materials in liquid form, and such aerosol-generating materials may or may not contain nicotine. The aerosol-generating materials may be in the form of a wand, cartridge, or cassette that can be inserted into the device, or may be provided as part of such a wand, cartridge, or cassette. A heater for heating and volatilizing the aerosol-generating material may be provided as a "permanent" part of the device.

[0059] The aerosol delivery device can receive an article containing an aerosol-forming material for heating. In this context, an "article" refers to a component that contains or houses the aerosol-forming material in use, which is heated to volatilize the aerosol-forming material, and optionally other components in use. A user may insert the article into the aerosol delivery device before heating it to produce an aerosol that the user subsequently inhales. The article may, for example, be of a predetermined or specific size configured to be placed within a heating chamber of a device sized to receive the article.

[0060] 1 shows an example of an aerosol delivery device 100 for generating aerosol from an aerosol-generating medium / material. Device 100 can be used to heat a replaceable item 110 containing an aerosol-generating medium to generate an aerosol or other inhalable medium that can be inhaled by a user of device 100.

[0061] Device 100 includes a housing 102 that surrounds and houses the various components of device 100. Device 100 has an opening 104 at one end through which an item 110 can be inserted for heating by device 100. Item 110 may be fully or partially inserted into device 100 for heating by device 100.

[0062] Device 100 may include a user-operable control element 106, such as a button or switch, that when actuated, e.g., pressed, operates device 100. For example, a user may activate device 100 by pressing switch 106.

[0063] The device 100 defines a longitudinal axis 101 along which the article 110 may extend when inserted into the device 100 .

[0064] 2 is a schematic diagram of the aerosol delivery device 100 of FIG. 1, illustrating various components of the device 100. It will be understood that the device 100 may include other components not shown in FIG.

[0065] As shown in FIG. 2 , device 100 includes an apparatus 200 for heating an aerosolizable material. Apparatus 200 includes a heating assembly 201, a controller (control circuit) 202, and a power supply 204. Apparatus 200 includes a body assembly 210, which may include a chassis and other components that form part of the device. Heating assembly 201 is configured to heat the aerosol-generating medium of an article 110 inserted into device 100, thereby generating an aerosol from the aerosol-generating medium. Power supply 204 provides power to heating assembly 201, which converts the provided electrical energy into thermal energy for heating the aerosol-generating medium.

[0066] The power source 204 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries.

[0067] Battery 204 may be electrically coupled to heating assembly 201 to provide power under the control of controller 202 when needed to heat the aerosol-generating material. Control circuitry 202 may be configured to activate and deactivate heating assembly 201 based on a user operating control element 106. For example, controller 202 may activate heating assembly 201 in response to a user operating switch 106.

[0068] The end of device 100 closest to opening 104 is sometimes known as the proximal end (or mouth end) 107 of device 100, as it is closest to the user's mouth during use. During use, the user inserts item 110 into opening 104, operates user control 106 to begin heating the aerosol-generating material, and inhales the aerosol generated by the device, causing the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0069] The other end of the device furthest from opening 104 is sometimes known as the distal end 108 of device 100, as it is the end furthest from a user's mouth during use. When a user inhales the aerosol generated by the device, the aerosol flows in a direction toward the proximal end of device 100. The terms proximal and distal as applied to features of device 100 are described by reference to the relative positions of such features with respect to one another in the proximal-distal direction along axis 101.

[0070] The heating assembly 201 may include various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is a process of heating an electrically conductive heating element (such as a susceptor) via electromagnetic induction. The induction heating assembly may include an induction element, e.g., one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor (heating element) suitably positioned relative to the induction element, generating eddy currents within the susceptor. The susceptor has an electrical resistance to eddy currents, and the flow of eddy currents across this resistance causes the susceptor to heat via Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat may be generated by magnetic hysteresis losses in the susceptor, i.e., by the magnetic poles of the magnetic material changing orientation as a result of alignment with the varying magnetic field. Induction heating generates heat within the susceptor, allowing for rapid heating, as compared to heating by conduction, for example. Furthermore, no physical contact is required between the inductive element and the susceptor, allowing for greater freedom in construction and application.

[0071] Apparatus 200 includes a heating chamber 211 configured and dimensioned to receive an article 110 to be heated. Heating chamber 211 defines a heating region 215. In this example, article 110 is generally cylindrical, and heating chamber 211 is correspondingly generally cylindrical in shape; however, other shapes could be possible. Heating chamber 211 is formed by a receptacle 212. Receptacle 212 includes end walls 213 and a peripheral wall 214.

[0072] The heating chamber 211 is defined by the inner wall of the receptacle 212. The receptacle 212 acts as a support member. The receptacle constitutes a generally tubular member, extending along and around the longitudinal axis 101 of the device 100 and being substantially coaxial with the longitudinal axis 101. However, other shapes could be possible. The receptacle 212, and thus the heating chamber 211, is open at its proximal end so that an item 110 inserted into the opening 104 of the device 100 can be received by the heating chamber 211 through its proximal end. The receptacle 212 is closed at its distal end by an end wall 213. The receptacle 212 may comprise one or more conduits that form an air passageway. During use, the distal end of the item 110 may be positioned adjacent to or engaged with the end of the heating chamber 211. Air may enter heating chamber 211 through one or more conduits and flow through article 110 towards the proximal end of device 100 .

[0073] The receptacle 212 may be formed from an insulating material. For example, the receptacle 212 may be formed from a plastic such as polyetheretherketone (PEEK). Other suitable materials are possible. The receptacle 212 may be formed from a material that ensures that the heating assembly 201 remains rigid / solid when the assembly is operated. Using a non-metallic material for the receptacle 212 may help limit heating of other components of the device 100. The receptacle 212 may be formed from a rigid material to help support the other components.

[0074] Other configurations for the receptacle 212 may be possible. For example, in one embodiment, the end wall 213 is defined by a portion of the heating assembly 201, such as a circumferentially extending flange.

[0075] 2, the heating assembly 201 includes a heating element 220. The heating element 220 is configured to heat a heating region 215. The heating region 215 is defined in a heating chamber 211. In an embodiment, the heating chamber 211 defines a portion of the heating region 215 or an extent of the heating region 215.

[0076] Heating element 220 is heatable to heat heating region 215. Heating element 220 is an induction heating element. That is, heating element 220 comprises a susceptor that is heatable by the penetration of a varying magnetic field. Heating element 220 comprises a first portion, referred to herein as heating portion 221, and a second portion, referred to herein as base portion 222. At least a portion of base portion 222 acts as a susceptor.

[0077] The susceptor comprises a conductive material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from carbon steel. It will be appreciated that other suitable materials may be used, such as ferromagnetic materials such as iron, nickel, or cobalt.

[0078] The heating assembly 201 includes a magnetic field generator 240 configured to generate one or more varying magnetic fields that penetrate the susceptor and cause heating of the susceptor. The magnetic field generator 240 includes a helical inductor coil 241, shown schematically in FIG. 2, that acts as an inductor element.

[0079] In some examples, during use, the inductor coil is configured to heat the susceptor to a temperature between about 200°C and about 350°C, such as between about 240°C and about 300°C or between about 250°C and about 280°C.

[0080] Figures 3, 4, and 5 show in more detail one embodiment of the heating assembly 201. It will be understood that the heating assembly 201 may include other components not shown in Figures 3-5.

[0081] 3-5, the heating assembly 201 includes a heating element 220 and a magnetic field generator 240. A helical inductor coil 241 of the magnetic field generator 240 is shown in FIGS.

[0082] The heating element 220 extends into the heating region 215. The heating portion 221 acts as a protruding element and protrudes into the heating region 215. The heating element 220 is spaced from the peripheral wall 214. The heating assembly 201 is configured such that when the item 110 is received by the heating chamber 211, the heating portion 221 of the heating element 220 extends into the distal end of the item 110. The heating portion 221 of the heating element 220 is disposed within the item 110 during use, as shown in FIGS. 3 and 4 . The heating element 220 is configured to heat the aerosol-generating material of the item 110 from the inside, and for this reason is referred to as an internal heating element. To facilitate this, the internal heating element 220 is configured to pierce the item 110 inserted into the device 100.

[0083] In this embodiment, the heating portion 221 of the heating element 220 comprises a pointed edge or tip at its proximal end 223. The proximal end is the free end of the heating element 220. The heating portion 221 is a pin. Other shapes are also envisioned, for example, in some embodiments, the heating portion 221 is a blade. The heating portion 221 may extend from a distal end of the heating chamber 211 into the heating chamber 211 along the longitudinal axis 101 of the device (axially). In some embodiments, the heating portion 221 extends into the heating chamber 211 spaced apart from the axis 101. The heating portion 211 may be off-axis or non-parallel to the axis 101. While one heating portion 221 of the heating element 220 is shown, it will be understood that in some embodiments, the heating element 220 comprises multiple heating portions 221. In some embodiments, such heating portions are spaced apart from each other but parallel to each other.

[0084] The heating element 220 extends from the heating region 215. The heating element 220 extends to the exterior of the heating region 220. The heating element 220 is received through the receptacle 212. The heating element 220 extends through the end wall 213. The helical inductor coil 241 is disposed exterior to the receptacle 212. The helical inductor coil 241 is spaced apart from the end wall 213. A gap 216 is provided between the receptacle 212 and the helical inductor coil 241. In some embodiments, an insulating member (not shown) is provided in the gap 216. In some embodiments, the helical inductor coil 241 is attached to the end wall 213. In some embodiments, the inductor coil 241 is spaced apart from the end wall 213. A base portion 222 is shown exterior to the heating chamber 211. Heating element 220 may include an intermediate portion 225 between heating portion 221 and base portion 222. Intermediate portion 225 may extend between helical inductor coil 241 and heating chamber 211. Intermediate portion 225 extends through end wall 213. In some embodiments, intermediate portion 225 is omitted or forms part of one of heating portion 221 and base portion 222.

[0085] The helical inductor coil 241 extends around at least a portion of the base portion 222 and acts as a susceptor. The helical inductor coil 241 is configured to generate a varying magnetic field that penetrates the base portion 222.

[0086] Inductor coil 241 is a helical coil comprising a conductive material, such as copper. The coil is formed from wire, such as Litz wire, wound helically around a support member (not shown). The support member (not shown) may be omitted. The support member is tubular. Coil 241 defines a generally tubular shape. Helical coil 241 defines inductor region 242. Helical coil 241 defines inner diameter 243.

[0087] Inductor coil 241 has a generally circular profile. In other embodiments, inductor coil 241 may have a different shape, such as generally square, rectangular, or oval. The coil width may increase or decrease along its length.

[0088] The base portion 222 of the heating element 220 extends into the inductor coil 241. That is, the helical inductor coil 241 defines an enclosed space, an inductor region 242. The inductor region 242 is the space defined by the inductor coil 241 that can receive features therein and that make it heatable by the penetration of the varying magnetic field generated by the inductor coil 241.

[0089] Other types of inductor coils, such as flat spiral coils, are also known. The spiral coil allows for defining an elongated inductor region for receiving a susceptor, thereby realizing reception of a susceptor of a long length in the elongated inductor region. The length of the susceptor exposed to the varying magnetic field may be maximized. Providing an enclosed inductor region with a spiral coil configuration can assist in concentrating the magnetic field flux.

[0090] Litz wire contains multiple individually insulated individual wires that are twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in the conductor. Other wire types, such as solid wire, can also be used.

[0091] The configuration of the helical inductor coil may vary along its axial length, for example, the or each inductor coil may have substantially the same or different values ​​of inductance, axial length, radius, pitch, number of turns, etc.

[0092] The helical inductor coil 241 may extend around and be supported by a support member (not shown). The helical inductor coil 241 is disposed coaxially with the heating chamber 211 and the longitudinal axis 101.

[0093] When base portion 222 extends through inductor region 242, base portion 222 is susceptible to a varying magnetic flux along its length.

[0094] The heating element 220 includes a base portion 222 with a heating portion 221 protruding from the base portion 222. The heating portion 221 is heatable by the base portion 222 through thermal conduction. The heating portion 221 and the base portion 222 are thermally conductively connected. The base portion 222 has a larger radial extent than the heating portion 221. The base portion 222 is generally cylindrical, although other shapes are contemplated.

[0095] The elongated heating portion 221 extends at its distal end from a base portion 222. The elongated heating portion 221 and the base portion 222 are coaxial. The base portion 222 has an axial height. The axial height of the base portion 222 substantially corresponds to the axial length of the inductor region 242. Such a configuration helps maximize the magnetic flux intersecting the base portion 222.

[0096] The base portion 222 includes a core 224 and a collar 225. The core 224 is an extension of the heating portion 221. The core 224 and the heating portion 221 form part of the heating element 230. The core 224 is integrally formed with the heating portion 221 as a unitary component. The core 224 and the heating portion 221 of the base portion 222 form part of an elongated rod. In some embodiments, an intermediate portion 227 is defined between the base portion 222 and the heating portion 221. In such a configuration, the heating portion 221 is defined by the portion of the heating element 230 that extends to the heating region 215. The core 224 is defined by the portion of the heating element 230 that extends to the collar 225. The base portion 222 is defined by the portion of the element that extends to the inductor region 242.

[0097] The core 224 has a radial width corresponding to the heating portion 221. The rod has a generally constant cross-sectional area and profile along its length. In some embodiments, one or both of the cross-sectional area and profile may vary along the length. By forming the core 224 and the heating portion 221 together, heat conduction along the heating element 220 may be assisted. The core 224 is conductively connected to the collar 225. Accordingly, when the collar 225 is heated, heat transfer occurs from the collar 225 to the core 224 by conduction. The collar 225 forms an interference fit with the core 224. The collar 225 may be connected to the core 224 by different means.

[0098] The collar 225 surrounds the core 224. In some embodiments, the collar 225 partially surrounds the core 224. In this embodiment, the collar 225 is tubular. The collar 225 defines an outer layer of the core 224. The heating portion 221 protrudes above the collar 225.

[0099] The heating portion 221 has a thermal conductivity greater than that of the collar 225. The collar 225 is formed from a different material. The base portion 222 and the heating element 220 have different thermal conductivity characteristics. The collar 225 acts as a susceptor and is formed from a material that is susceptible to heating by the penetration of a fluctuating magnetic field. The collar 225 comprises an electrically conductive material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from carbon steel. It will be understood that other suitable materials may be used, for example, ferromagnetic materials such as iron, nickel, or cobalt.

[0100] As shown in FIGS. 3-5, collar 225 has a solid configuration. Collar 225 is shown as tubular. In some embodiments, the configuration of the collar varies. In one embodiment, the collar is a foil layer. The collar may be an outer layer of core 224. In some embodiments, the collar is a mesh. The collar acts as a susceptor, and in some embodiments, is a wire. The collar may include multiple wires. A wire construct 425 acting as a susceptor is shown in FIG. 7. Wire construct 425 forms a collar. The wire is formed as a winding around core 424 of heating element 420. The collar has a serpentine configuration. Wire construct 425 includes multiple longitudinally extending portions 426 and has end turns 427. It will be understood that the configuration of wire construct 425 may vary. For example, wire construct 425 forming a susceptor may have a helical configuration.

[0101] In one embodiment, the members forming the heating portion 221 comprise heat pipes. Heat pipes are elongated members that act to facilitate heat transfer along the length of the heating element 220.

[0102] The heat pipe 230 is a closed evaporative condensation system. The heat pipe comprises a sealed hollow tube. A wick is disposed within the tube. The interior wall of the heat pipe is lined with a capillary structure or wick. A thermodynamic working fluid having substantial vapor pressure at the desired operating temperature fills the pores of the wick in equilibrium between liquid and vapor. When heat is applied to the heat pipe, the liquid in the wick heats up, causing the fluid to evaporate. The evaporated fluid fills the hollow center of the heat pipe and diffuses throughout its length.

[0103] In the above context, tubular is intended to mean a member having a central inner diameter. Such heat pipes may be elongated members, plates, or may have another cross-sectional shape.

[0104] The heat pipe is formed from copper. The working fluid is water. Other configurations are contemplated. For example, the heat pipe may be formed from one of copper, aluminum, and austenitic nickel chromium. The heat pipe may be formed from stainless steel. The heat pipe may include a working fluid including water. The heat pipe may include a working fluid including one or more of acetone, carbon dioxide, and ammonia.

[0105] In some embodiments, the heat pipe comprises a working fluid that has an operating temperature in use between about 200°C and about 350°C, such as between about 240°C and about 300°C or between about 250°C and about 280°C.

[0106] With such a configuration, the heating element has an effective thermal conductivity of greater than 3000 W / mk, such as greater than 4000 W / mk, or greater than 5000 W / mk.

[0107] In some embodiments, the heating element has an effective thermal conductivity of 3000 to 100000 W / mk, for example 4000 to 10000 W / mk.

[0108] The heat pipe 230 has a diameter of about 3 mm. In some embodiments, the diameter of the heat pipe is between about 1 mm and 10 mm, such as between about 2 mm and 5 mm and between about 3 mm and 4 mm.

[0109] The heat pipe 230 has a length of about 50 mm. In some embodiments, the length of the heat pipe is between about 10 mm and 100 mm, such as between about 30 mm and 70 mm, and between about 40 mm and 60 mm.

[0110] The core 224 has a thermal conductivity greater than that of the collar 225. The core 224 is formed from a material having a high thermal conductivity, such as copper and aluminum.

[0111] The material of the heating portion 221 has a lower susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the collar 225. The material from which the collar 225 is made has a higher susceptibility to heating due to the penetration of a fluctuating magnetic field than the susceptibility of the heating portion 221. The material of the heating portion 221 is a non-ferrous material. The material of the collar 225 is one of a ferromagnetic material and a paramagnetic material.

[0112] The high thermal conductivity of the heating portion 221 aids in heat transfer. Accordingly, when the collar 225 is heated, the heat transfer along the heating portion 221 is maximized. This aids in more uniform heating of the elongated heating element along its axial length.

[0113] As noted above, in some embodiments, the base portion 222 comprises a core and a collar, but the base portion defines the susceptor, with the core portion not extending into the susceptor. In other embodiments, the collar is an extension of the heating portion and has a constant cross-sectional profile along the length of the heating element 220 between the heating portion 221 and the core 224, as described below.

[0114] The elongated inductor region 242 is axially offset from the heating region 215. Offsetting the helical inductor coil 241 from the receptacle 212 can help minimize the radial extent of the helical inductor coil 241. The helical inductor coil 241 is offset from the heating portion and does not extend around the heating chamber. Accordingly, the dimensions of the inductor coil are not constrained by the dimensions of the heating chamber.

[0115] The spacing between the peripheral wall and the heating element is greater than the spacing between the helical inductor coil and the heating element, thereby providing efficient spacing from the helical coil to the susceptor and a desired size of article to be received by the device.

[0116] In some embodiments, the maximum width of the spiral inductor coil is less than the maximum width of the heating zone, and the insulation construction around the inductor coil may be strengthened accordingly.

[0117] As shown in Figure 6, an alternative configuration of the heating assembly 301 is shown. It will be understood that the heating assembly 301 may include other components not shown in Figure 6. The configuration of the device 100 is generally as described above and therefore will not be described in detail. The configuration of the heating elements differs, as will be described below.

[0118] 6, the base portion does not include a collar that forms the susceptor as described above. In this configuration, an elongated member having a constant cross-sectional width forms the susceptor. That is, the heating element 320 is formed from a material that is susceptible to heating by the penetration of a varying magnetic field along its axial length.

[0119] The base portion 322, formed from a susceptor material, is integrally formed with the heating portion 321 as a single component. In this embodiment, the base portion 322 has a uniform cross-sectional profile with the heating portion 321. That is, the base portion 322 has a radial width corresponding to the heating portion 321. The base portion 322 is an extension of the heating portion 321. Forming the base portion 322 and the heating portion 321 together can assist in heat conduction along the heating element.

[0120] Inductor region 342 is offset from heating region 315, with heating element 320 extending between the two regions.

[0121] The heating element 320 acts as a susceptor and is formed from a material susceptible to heating by the penetration of a fluctuating magnetic field. A portion of the heating element formed from the susceptor material is spaced from the inductor region. The susceptor may be formed from carbon steel. It will be appreciated that other suitable materials may be used, such as ferromagnetic materials such as iron, nickel, or cobalt.

[0122] Apparatuses for heating aerosolizable materials that use inductively heated susceptor elements are known. However, such apparatuses generally use an arrangement in which the susceptor element is disposed within a heating zone configured to receive an article, and an induction coil is disposed around the heating zone (i.e., around the susceptor element in the heating zone). Thus, when the susceptor element is inductively heated by the induction coil, the region of the susceptor element that is inductively heated corresponds to the region that releases heat into the article.

[0123] With such a construction, the coil is sized to receive the heating zone and the susceptor, the susceptor of the heating zone being configured to act as a susceptor and transfer heat to the article.

[0124] The arrangements described herein allow for the induction process to occur in a separate area from the heating of the article by providing an elongated heating element having a first portion of the heating area for receiving the article and a second portion outside the heating area and surrounded by an induction coil. The first portion of the heating area can be optimized for heat transfer to the consumable item, and the second portion can be optimized for induction.

[0125] By spacing the coil away from the heating area, the radial size of the coil may be smaller than the size of the heating area, thereby optimizing the radial dimensions of the coil for induction and allowing the width of the device to be minimized as much as possible.

[0126] The use of elongated susceptor elements that extend substantially linearly into the heating and induction zones allows for straightforward configuration of the induction and article heating characteristics by adjusting the relative lengths of the first and second portions of the respective heating and inductor zones. For example, the length of the second portion that extends into the inductor zone can be increased as needed, e.g., to achieve a particular maximum temperature, simply by increasing the length and number of turns of the coil element.

[0127] By providing an elongated heating element having first and second portions, each portion having a length along a longitudinal axis that is greater than the width of the portion, it is possible to have a low weight while providing the aforementioned benefits. One example of such an elongated heating element may be a heat pipe, which has advantageous heat transfer properties as discussed above.

[0128] Considering these length parameters, it may be desirable for at least a certain percentage of the elongated heating element to extend into the inductor region to provide sufficient induction heating, for example, the elongated heating element axially overlaps the heating region such that less than 90% of the axial length of the elongated heating element axially overlaps the heating region.

[0129] In some embodiments, the maximum length percentage of the heating element in the heating chamber is up to about 90%, such as up to about 80%, or up to about 75%.

[0130] To transfer the inductively generated heat, it may be desirable to realize that at least a certain percentage of the elongated heating element is positioned behind the inductor region with an inductor coil, for example, the induction coil extends longitudinally along the longitudinal axis of the elongated heating element, and the longitudinal overlap of the elongated heating element and the induction coil is less than 60% of the axial length of the elongated heating element.

[0131] In some embodiments, the maximum percentage of the length of the heating element that extends into the inductor coil is up to about 60%, such as up to about 50%, up to about 40%.

[0132] The balance between inductive heating of the elongated heating element and the delivery of heat to the item in the heating zone is a significant challenge, and it can be advantageous to achieve at least a certain percentage of the elongated heating element extending within the inductor zone, for example, the inductor zone of a coil having an axial length at least 25% of the axial length of the heating zone.

[0133] The minimum length of the inductor coil relative to the length of the heating chamber is at least about 15%, such as at least about 20%, at least about 25%.

[0134] At least 25%, optionally at least 50%, optionally at least 60%, optionally at least 70% of the heating element is outside the inductor region.

[0135] In each configuration, the inductor coil is configured to generate a varying magnetic field that penetrates the base portion, which acts as a susceptor, causing heating of the base portion and thus indirect conductive heating of the heating portion.

[0136] In the above-described embodiment, the helical inductor coil is spaced from the heating region, thereby forming a barrier to limit exposure of the varying magnetic field to the heating region and components surrounding the heating region. Such a configuration may limit the heating induced in any susceptor material introduced into the heating chamber.

[0137] In the above-described embodiment, the heating portion is an internal heater. That is, the heating portion protrudes into the heating chamber and is positioned to be received by the article. In another embodiment, the heating portion is an external heater. In such a configuration, the heating element may be a generally tubular element extending along the longitudinal axis 101 and being substantially coaxial with the longitudinal axis 101. The heating element may extend at least partially around an axial portion of the heating chamber. The heating element may extend continuously around the entire circumference of the heating chamber, or may extend only partially around the chamber. For example, one or more interruptions, such as holes, gaps, or slots, may be provided in the heating element. The heating element may be configured and dimensioned to extend around an article received by the heating chamber. Thus, the heating element may be positioned around the article during use. The heating element may thus be configured to heat the aerosol-generating material of the article 110 from the outside, and for this reason is referred to as an external heating element. The heating element may have a circular cross-section, for example, corresponding to the circular cross-section of the article 110. Other cross-sectional shapes may also be possible.

[0138] The heating element may extend any suitable distance along the heating zone. In such embodiments, the heating element may form a receptacle. The base portion is disposed at an end of the tubular member. The outer heating element may form the tubular member at one end. In such embodiments, the base portion may extend axially or radially inward, or both. The base portion may define an end wall. In some embodiments, the base collar is a collar around the tubular member.

[0139] The above-described embodiments should be understood as illustrative of the present invention. Additional embodiments of the present invention are also contemplated. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other features described, or with one or more features of any other embodiment, or with any combination of any other embodiment. Furthermore, equivalents and modifications not described above may be employed without departing from the scope of the present invention, which is defined in the appended claims.

Claims

1. 1. An apparatus configured to heat an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a heating region configured to receive at least a portion of an article including an aerosolizable material; a magnetic field generator including a helical inductor coil configured to generate a varying magnetic field, the helical inductor coil defining an inductor region within the inductor coil; an elongated heating element heatable by penetration of the fluctuating magnetic field and arranged to heat the heating region; Equipped with the elongated heating element extends between the heating region and the inductor region; the elongated heating element defining a longitudinal axis, the helical inductor coil being axially spaced from the heating region; the elongated heating element projects into the heating region; a receptacle defining the heating region, the helical inductor coil not overlapping the receptacle; Device.

2. The apparatus of claim 1 , wherein the receptacle comprises an end wall defining a closed end of the heating region, the end wall being between the heating region and the helical inductor coil.

3. 3. The apparatus of claim 1, wherein the receptacle comprises a peripheral wall defining the heating region, and wherein a spacing between the peripheral wall and the heating element is greater than a spacing between the helical inductor coil and the elongated heating element.

4. The apparatus of any one of claims 1 to 3, wherein the maximum width of the spiral inductor coil is smaller than the maximum width of the heating zone.

5. 5. The apparatus of claim 1, wherein the heating element comprises a first portion exposed to the heating zone and a second portion external to the heating zone, and the helical inductor coil surrounds the second portion.

6. The device of claim 5 , wherein a radial width of at least a portion of the second portion is greater than a radial width of the first portion.

7. The device of claim 5 , wherein the second portion comprises a collar.

8. 8. The apparatus of claim 7, wherein the collar includes a heater material heatable by penetration of the varying magnetic field.

9. The apparatus of any one of claims 5 to 8, wherein the thermal conductivity of at least a part of the first portion is greater than the thermal conductivity of at least a part of the second portion.

10. 10. The device according to any one of claims 5 to 9, wherein at least part of the first portion has a lower susceptibility to heating due to penetration of the fluctuating magnetic field than at least part of the second portion.

11. An apparatus according to any preceding claim, wherein the heating element comprises a heat pipe.

12. 1. An apparatus configured to heat an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a body having a cavity for receiving an article containing an aerosol-forming material; a magnetic field generator assembly including a helical inductor coil; A heater element; The heater element comprises: a first portion exposed to the cavity and positioned to heat the cavity; a second portion received by the helical inductor coil to be heated by the magnetic field generator assembly; Equipped with the first portion is offset from the helical inductor coil and positioned to be heated by conduction from the second portion; The apparatus, wherein the helical inductor coil extends around at least a portion of the second portion.

13. 1. An apparatus configured to heat an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a heating region configured to receive at least a portion of an article including an aerosolizable material; a magnetic field generator including an inductor coil configured to generate a varying magnetic field, the inductor coil defining an inductor region within the inductor coil; an elongated heating element heatable by penetration of the fluctuating magnetic field and arranged to heat the heating region; Equipped with the elongated heating element extends between the heating region and the inductor region; the elongated heating element defining a longitudinal axis, the inductor coil being axially spaced from the heating region; The apparatus wherein the elongated heating element axially overlaps the heating region such that less than 90% of the axial length of the elongated heating element axially overlaps the heating region.

14. 1. An apparatus configured to heat an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a heating region configured to receive at least a portion of an article including an aerosolizable material; a magnetic field generator including an inductor coil configured to generate a varying magnetic field, the inductor coil defining an inductor region within the inductor coil; an elongated heating element heatable by penetration of the fluctuating magnetic field and arranged to heat the heating region; Equipped with the elongated heating element extends between the heating region and the inductor region; the elongated heating element defining a longitudinal axis, the inductor coil being axially spaced from the heating region; The apparatus, wherein the inductor coil extends longitudinally along the longitudinal axis of the elongated heating element, and wherein a longitudinal overlap of the elongated heating element and the inductor coil is less than 60% of the axial length of the elongated heating element.

15. 1. An apparatus configured to heat an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: a heating region configured to receive at least a portion of an article including an aerosolizable material; a magnetic field generator including an inductor coil configured to generate a varying magnetic field, the inductor coil defining an inductor region within the inductor coil; an elongated heating element heatable by penetration of the fluctuating magnetic field and arranged to heat the heating region; Equipped with the elongated heating element extends between the heating region and the inductor region; the elongated heating element defining a longitudinal axis, the inductor coil being axially spaced from the heating region; The apparatus wherein the inductor region of the coil has an axial length that is at least 25% of the axial length of the heating region.

16. 1. An elongated heating element for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the elongated heating element defining a longitudinal axis and comprising an elongated heating portion and an elongated susceptor portion, the elongated heating portion projecting axially from the elongated susceptor portion; the elongated susceptor portion is configured to be received within a helical coil; The helical coil extends around at least a portion of the elongated susceptor portion.

17. An aerosol delivery system comprising the device of any one of claims 1 to 15 and an article containing an aerosol-forming material.

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