Aerosol delivery device and method of operation thereof

Abstract

An aerosol delivery device (101) for generating an aerosol from an aerosol-generating material is provided. The device comprises a receptacle (212) defining a heating zone (215) for receiving at least a portion of an article (110) including the aerosol-generating material, a heating assembly (201) including a heating element (320, 420) arranged to heat the article in the heating zone, and a detector arrangement (180) configured to detect a characteristic indicative of a density of the aerosol-generating material of the portion of the article received in the heating zone. The device further comprises a control module (244) in communication with the detector arrangement and configured to control operation of the device according to the characteristic indicative of the density.

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device for generating an aerosol from an aerosol-forming material. The present invention further relates to a system comprising the aerosol delivery device and an article including the aerosol-forming material configured to be at least partially received in the aerosol delivery device.

[0002] Methods and devices for extracting compounds from materials have long been used to provide users with the pleasant sensation or medicinal benefits of inhaling such compounds. Attempts have been made to provide products that release compounds without combustion. Examples of such products include heating devices that release compounds by heating rather than burning a material. The material may include, for example, nicotine. Overview

[0003] According to some embodiments described herein, an aerosol delivery device for generating an aerosol from an aerosol-generating material is provided, the device comprising: a receptacle defining a heating zone for receiving at least a portion of an article including the aerosol-generating material; a detector arrangement configured to detect a characteristic indicative of the density of the aerosol-generating material of the portion of the article received in the heating zone; and a control module in communication with the detector arrangement and configured to control operation of the device according to the characteristic indicative of the density.

[0004] The detector arrangement may comprise a sensor.

[0005] The detector arrangement may comprise a photosensor arrangement.

[0006] The optical sensor arrangement may include an optical emitter and an optical sensor.

[0007] The control module may be configured to determine the characteristic indicative of density based at least in part on input from the optical sensor arrangement.

[0008] The detector arrangement may be configured to determine an image.

[0009] The image may be an optical image.

[0010] The control module may be configured to determine a characteristic of the image.

[0011] The control module may be configured to determine the density characteristic based at least in part on a characteristic of the image.

[0012] The detector arrangement may be an X-ray imaging arrangement configured to output an X-ray image.

[0013] The control module may be configured to determine a characteristic of the x-ray image based at least in part on a gray-to-black contrast in the x-ray image.

[0014] The control module may be configured to determine a characteristic of the x-ray image based at least in part on a pattern recognition analysis of the x-ray image.

[0015] The control module may be configured to determine a characteristic of the x-ray image based at least in part on a dot count analysis of the x-ray image.

[0016] The control module may be configured to determine the density characteristic based at least in part on a characteristic of the x-ray image.

[0017] The aerosol delivery device may include a heating assembly including a heating element positioned to heat an item within a heating zone.

[0018] The aerosol delivery device may include a protruding member that protrudes into the heating zone and is configured to pierce at least a portion of an article that includes the aerosol-forming material when the article is received in the heating zone.

[0019] The protruding member may comprise a heating element.

[0020] The aerosol delivery device may include a load sensor configured to determine an axial force acting on the projection member.

[0021] The protruding member may be elongated. The protruding member may be a pin-shaped member. The receptacle may have a base, and the protruding member may rise from the base of the heating zone.

[0022] The control module may be configured to determine a characteristic of density based at least in part on an output from the load sensor.

[0023] The detector arrangement may be configured to determine a density characteristic for each of two or more distinct regions of the article.

[0024] The control module may be configured to operate two or more separate regions of the heating element independently.

[0025] The control module may be configured to control operation of two or more separate regions of the heating element based at least in part on a density characteristic for each of the two or more regions of the article.

[0026] The detector arrangement may comprise a detector module arranged to determine a characteristic indicative of airflow rate through the device in use, and the control module configured to determine the density characteristic based at least in part on the characteristic indicative of airflow rate through the device.

[0027] The characteristic indicative of airflow through the device may include at least one of a change in temperature and a rate of change of temperature of a temperature sensitive component of the device.

[0028] The temperature sensing component may comprise a heating element.

[0029] The detector module may be configured to use measurements of changes in electrical resistance of the temperature sensitive component to determine at least one of a change in temperature and a rate of change of temperature.

[0030] The detector module may be configured to determine a characteristic indicative of air flow rate through the device by measuring the pressure drop across the heating zone during use.

[0031] The detector arrangement may comprise a pressure sensor. The detector arrangement may comprise at least two pressure sensors. The detector module may be configured to measure the pressure drop across the heated zone using each pressure sensor or output from each pressure sensor in use.

[0032] The pressure sensor may be a barometer.

[0033] The control module may be programmed with preset heating profiles.

[0034] The control module may be configured to control airflow through the device in response to determining the density characteristic.

[0035] The control module may be configured to control operation of the heating assembly in response to determining the density characteristic.

[0036] The control module may be configured to modify a heating profile of the device in response to determining the density characteristic.

[0037] The control module may be configured to determine the type, model or manufacturer of the article in response to determining the density characteristic.

[0038] According to some embodiments described herein, there is provided an aerosol delivery system comprising any of the aerosol delivery devices described above and an article including an aerosol-generating material arranged to be at least partially received in the aerosol delivery device.

[0039] According to some embodiments described herein, a method of operating an aerosol delivery device to generate an aerosol from an aerosol-generating material is provided, the method including detecting a characteristic of at least a portion of an article received in a heating zone defined by a receptacle of the device, the characteristic indicative of a density of the aerosol-generating material in the portion of the article, and controlling operation of the device according to the characteristic indicative of the density.

[0040] Controlling operation of the device may include controlling operation of a heating assembly that includes a heating element positioned to heat a portion of an article received in a heating zone.

[0041] According to some embodiments described herein, there is provided a computer program product comprising instructions that, when executed by a processor, cause the processor to perform any of the methods described above.

[0042] According to some embodiments described herein, there is provided a computer-readable medium storing the above-described computer program product.

[0043] According to some embodiments described herein, a non-transitory computer-readable medium is provided that includes computer-readable instructions that, when executed by a processor, cause the medium to perform any of the methods described above. [Brief explanation of the drawings]

[0044] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 is a front perspective view of an aerosol generation system including an aerosol generation device and an article inserted into the device. [Figure 2] FIG. 2 is a schematic diagram of the aerosol generation system of FIG. 1. [Figure 3]FIG. 2 is a schematic diagram of the aerosol generation system of FIG. 1 including a tubular receptacle heating element defining a heating zone. [Figure 4] 2 is a schematic diagram of the aerosol generation system of FIG. 1 including a heating element protruding into a heating zone. [Figure 5] 2 is a schematic diagram of the aerosol generation system of FIG. 1 including a heating element protruding into the heating zone and a load sensor in communication with the heating element. Detailed Description

[0045] As used herein, the term "aerosol-forming material" refers to a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. Aerosol-forming materials may be in the form of, for example, a solid, liquid, or gel, which may or may not contain active substances and / or flavorings. Aerosol-forming materials may include any plant-based material, such as tobacco-containing materials, including 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, or the like. Aerosol-forming materials may be, for example, a combination or mixture of materials. Aerosol-forming materials are sometimes referred to as "smoking materials."

[0046] The aerosol-forming material may include a binder and an aerosol-forming agent. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-forming material may or may not be soluble. In some embodiments, the aerosol-forming material is substantially free of plant material. In some embodiments, the aerosol-forming material is substantially free of tobacco.

[0047] The aerosolizable material may be or include an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within its interior. In some embodiments, the aerosol-generating material may include, for example, about 50%, about 60%, or about 70% to about 90%, about 95%, or about 100% amorphous solid by weight.

[0048] The aerosol-generating material may include an aerosol-generating film. The aerosol-generating film may include or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially free of tobacco.

[0049] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not burned or incinerated to facilitate delivery of at least one substance to a user.

[0050] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0051] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a puff-on device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0052] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0053] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of multiple aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0054] Generally, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0055] In some embodiments, the present disclosure relates to consumables that include an aerosol-generating material and are configured for use in a non-combustion aerosol delivery device. These consumables may also be referred to as articles throughout this disclosure.

[0056] In some embodiments, a non-combustion aerosol delivery system (e.g., a non-combustion aerosol delivery device) can include a power source and a controller. The power source can be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source comprises a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat conducting material proximate to the heat generating power source.

[0057] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0058] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may include one or more other components, such as an aerosol-forming material, an aerosol-forming material storage region, an aerosol-forming material delivery component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0059] The aerosol-generating device can accept an article containing an aerosol-generating material for heating. An "article" in this context refers to a component that includes or contains the aerosol-generating material during use, and is heated during use to volatilize the aerosol-generating material and optionally other components. A user can insert the article into the aerosol-generating device, after which the article is heated to generate an aerosol, which is then inhaled by the user. The article can be, for example, of a predetermined or specific size configured to be placed in a heating chamber of the device, the heating chamber being dimensioned to accept the article.

[0060] 1 shows an example of an aerosol-generating system 100. The system 100 includes an aerosol-generating device 101 for generating an aerosol from an aerosol-generating material and a replaceable item 110 containing the aerosol-generating material. The device 101 may be used to heat the replaceable item 110 containing the aerosol-generating material to generate an aerosol or other inhalable material that can be inhaled by a user of the device 101.

[0061] The device 101 comprises a housing 103 that surrounds and contains the various components of the device 101. The housing 103 is elongated. The device 101 has an opening 104 at one end through which an item 110 may be inserted for heating by the device 101. The item 110 may be fully or partially inserted into the device 101 for heating by the device 101.

[0062] The device 101 may include a user-operable control element 106, such as a button or switch, which, when operated (e.g., pressed), operates the device 101. For example, a user may activate the device 101 by pressing the switch 106.

[0063] The device 101 defines a longitudinal axis 102 along which the article 110 can extend when inserted into the device 101. The opening 104 is centered on the longitudinal axis 102.

[0064] Figure 2 is a schematic diagram of the aerosol generation system 100 of Figure 1, showing various components of the device 101. It should be understood that the device 101 may include other components not shown in Figure 2, and that some components shown in Figure 2 may not be present in some embodiments.

[0065] 2, device 101 includes an apparatus for heating aerosol-generating material 200. 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 material of an article 110 inserted into device 101 so that an aerosol is generated from the aerosol-generating material. Power supply 204 supplies electrical power to heating assembly 201, which converts the supplied electrical energy into thermal energy for heating the aerosol-generating material.

[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), alkaline batteries, etc.

[0067] Power supply 204 may be electrically coupled to heating assembly 201 to provide power when needed and to heat the aerosol-generating material under the control of controller 202. 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 101 closest to opening 104 is sometimes referred to as the proximal end (or mouthpiece) 107 of device 101, as it is closest to the user's mouth during use. In use, a user inserts item 110 into opening 104, operates user control 106 to initiate heating of the aerosol-generating material, and inhales the aerosol generated within the device, causing the aerosol to flow through item 110 along a flow path toward the proximal end of device 101.

[0069] The other end of the device, furthest from opening 104, is sometimes referred to as the distal end 108 of device 101, as it is the end farthest from the user's mouth in use. As a user inhales aerosol generated within the device, the aerosol flows in a direction toward the proximal end of device 101. The terms proximal and distal as applied to features of device 101 are described with reference to the relative positioning of such features to one another in the proximal-distal direction along axis 102.

[0070] The heating assembly 201 may include various components for heating the aerosol-generating material of the article 110, for example, via an induction heating process or a resistance heating process. Induction heating is a process in which an electrically conductive heating element (such as a susceptor) is heated by electromagnetic induction. The induction heating assembly may include an induction element, such as 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. This varying magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents within the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore, the flow of eddy currents against this resistance heats the susceptor via Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis loss in the susceptor, i.e., by the magnetic dipoles of the magnetic material varying as a result of aligning with the varying magnetic field. Induction heating allows for rapid heating because heat is generated within the susceptor, as compared to, for example, heating by conduction. Furthermore, there is no need for any physical contact between the inductive element and the susceptor, allowing for greater flexibility in design and application. Resistance heating instead utilizes the Joule heating effect caused by the electrical resistance of a material in response to the application of direct electrical current.

[0071] The apparatus 200 includes a heating chamber 211 configured and dimensioned to receive the item 110 to be heated. The heating chamber 211 defines a heating zone 215. In this example, the item 110 is generally cylindrical, and the heating chamber 211 is correspondingly generally cylindrical in shape. However, other shapes are possible. The heating chamber 211 is formed by a receptacle 212. The receptacle 212 includes an end wall 213 and a peripheral wall 214. The end wall 213 serves as a base for the receptacle 212. In an embodiment, the receptacle 212 is an integral component. As used herein, the term "integral component" means multiple features formed together such that no joints are defined therebetween. In other embodiments, the receptacle 212 comprises two or more components.

[0072] The heating chamber 211 is defined by the inner surface of a receptacle 212. The receptacle 212 serves as a support member. The receptacle 212 comprises a generally tubular member. The receptacle 212 extends substantially coaxially along and around the longitudinal axis 102 of the device 101. However, other shapes are possible. The receptacle 212 (and heating zone 215) is open at its proximal end so that the heating chamber 211 can receive an item 110 inserted into the opening 104 of the device 101. 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 part of the air passageway. In use, the distal end of the item 110 may be disposed adjacent to or engaged with the end of the heating chamber 211. Air can flow through one or more conduits that form part of the air passageway, into the heating chamber 211 , through the article 110 and towards the proximal end of the device 101 .

[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 also possible. The receptacle 212 may be formed from a material that ensures that the heating assembly 201 remains rigid / solid when the assembly is operating. Using a non-metallic material for the receptacle 212 may help prevent other components of the device 101 from heating. The receptacle 212 may be formed from a rigid material to help support the other components.

[0074] Other constructions for receptacle 212 are possible. For example, in embodiments, end wall 213 is defined by a portion of heating assembly 201. In embodiments, receptacle 212 comprises a material that is heatable by penetration of a varying magnetic field. In some embodiments, receptacle 212 comprises a material that is heatable by resistive Joule heating.

[0075] 3, the heating assembly 201 may include a heating element 320 arranged to surround the heating zone 215. In such an arrangement, the heating element 320 forms the receptacle 212. The heating element 320 defines the peripheral wall 214. The heating element 320 is configured to heat the heating zone 215. The heating zone 215 is defined within a heating chamber 211. In an embodiment, the heating chamber 211 defines a portion of the heating zone 215 or the extent of the heating zone 215.

[0076] The heating element 320 is heatable to heat the heating zone 215. The heating element 320 may be an induction heating element or a resistance heating element. That is, the heating element 320 may include a susceptor that can be heated by the penetration of a varying magnetic field, or a resistance material that can be heated by directly passing an electric current from a power source. When the heating element 320 includes a susceptor, the susceptor includes an electrically conductive material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from carbon steel. It should be understood that other suitable materials may be used, for example, ferromagnetic materials such as iron, nickel, or cobalt.

[0077] As shown in FIG. 2 , the heating assembly 201 includes a magnetic field generator 250. The magnetic field generator 250 is configured to generate one or more varying magnetic fields that penetrate the heating element 320 to cause heating in the heating element 320. The magnetic field generator 250 includes an inductor coil arrangement 251. The inductor coil arrangement includes an inductor coil 252 that serves as the inductor element. The inductor coil 252 may be a helical coil, although other arrangements are contemplated. In embodiments, the inductor coil arrangement 251 includes two or more inductor coils. The two or more inductor coils in embodiments may be positioned next to each other and coaxially aligned along an axis.

[0078] In some examples, during use, the magnetic field generator 250 is configured to heat the heating element 320 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. In examples where the heating element is a resistive heating element, similar or identical temperatures may be reached by resistive heating.

[0079] The inductor coil 252 may be a helical coil comprising a conductive material such as copper.

[0080] 4 and 5, the heating element 420 extends into the heating zone 215. The heating element 420, functioning as a protruding element, protrudes into the heating zone 215. The heating element 420 rises from a base. The heating element 420 is spaced apart from the peripheral wall 214. The heating assembly 201 is configured such that the heating element 420 extends into the distal end of the article 110 when the article 110 is received by the heating chamber 211. The heating element 420 is disposed inside the article 110 during use. The heating element 420 is configured to heat the aerosol-generating material of the article 110 from the inside and is therefore referred to as an internal heating element.

[0081] The heating element 420 extends from the distal end of the heating chamber 211 into the heating chamber 211 along the longitudinal axis 102 of the device (axially). In embodiments, the heating element 420 extends into the heating chamber 211 at a distance from the axis 102. The heating element 420 may be off-axis or non-parallel to the axis 102. While one heating element 420 is shown, it should be understood that in embodiments, the heating assembly 201 comprises multiple heating elements 420. Such heating elements in embodiments are spaced apart from one another but parallel.

[0082] If the heating element 320, 420 of any of the described embodiments utilizes magnetic susceptibility heating, the inductor coil 252 may be located outside the receptacle 212. The inductor coil may surround the heating zone 215. A helical inductor coil may extend around at least a portion of the heating element 320, 420 to act as a susceptor. The helical inductor coil is configured to generate a varying magnetic field that penetrates the heating element 320, 420. The helical inductor coil is positioned coaxially with the heating chamber 211 and the longitudinal axis 102.

[0083] While the illustrated embodiment shows a device including either heating elements 320 disposed around the heating zone 215 or at least one heating element 420 disposed within the heating zone 215, any of the described embodiments may utilize both heating elements 320 surrounding the heating zone 215 and one or more heating elements 420 within the heating zone 215.

[0084] The heating element 420 protrudes into the heating zone 215 and is received in the item 110. FIG. 2 shows the item 110 received in the device 101. The item 110 is sized to be received in the receptacle 212. The outer dimensions of the item 110 perpendicular to the longitudinal axis of the item 110 substantially correspond to the inner dimensions of the chamber 211 perpendicular to the longitudinal axis 102 of the device 101 to allow the item 110 to be inserted into the receptacle 212. In an embodiment, a gap 216 is defined between the outer side 111 of the item 110 and the inner side 217 of the receptacle 212. The gap 216 can serve as an air passageway along at least a portion of the axial length of the chamber 211. The insertion end 112 of the item 110 is positioned adjacent to the base of the receptacle 212.

[0085] Figure 2 shows the basic structure of device 101. Figure 2 shows an article 110 placed within a heating zone 215 of device 101. The heating zone is in an in-use configuration, capable of heating the aerosol-forming material in the article, and allowing a user to draw the aerosolized material from the article / device.

[0086] One problem with the device and article systems described herein is that the articles themselves often cannot be manufactured with absolute uniformity. This problem typically stems from the use of organic materials in the aerosol-generating material, such as cured tobacco leaf products. Articles for use with the devices described herein may include compressed strips of cured tobacco leaf or strips of tobacco-derived material, such as band-cast reconstituted tobacco. It can be appreciated that the precise placement of such small strips of aerosol-generating material when compressed cannot be easily predicted or controlled. Such variations in the placement of the aerosol-generating strips within the article inevitably result in a non-uniform density profile within the article. This non-uniformity means that the manufactured article may vary in terms of its internal distribution and density. While this does not typically render the article unsuitable for its intended purpose, known devices may not account for such variations, resulting in the article not being consumed most efficiently. For example, when the same heating power / profile is applied to articles with different overall densities, the lower-density article may be exposed to more than optimal heat and consumed too quickly. In this manner, the aerosolized material may not be consistently delivered over the intended period of time. On the other hand, if an expected denser product is consumed, the aerosol-generating material may not be completely consumed at the end of the allotted time period, or the heating element may not be powered sufficiently to effectively generate an aerosol from the relatively dense material, resulting in wasted aerosol-generating material and / or a less than desirable user experience.

[0087] In addition to variations in overall density, if the density of the article varies across locations, i.e., if one portion of the article contains areas with a higher density of compressed strips of aerosol-forming material compared to other portions, the higher density areas will experience a different rate of generation of aerosolized material compared to areas with a lower density. This again can result in wasted aerosol-forming material and can also result in a less than desirable user experience due to inconsistent and / or ineffective aerosol generation.

[0088] Another problem with such devices is that the densities of the articles for use in the device may vary between models and / or manufacturers (third-party articles). If the heating assembly 201 cannot distinguish between these different articles, heating of the articles may not be optimized. The device's ability to distinguish between different article types, and therefore adjust its operation accordingly, can be used to prevent or encourage the use of third-party or alternative model articles in the device.

[0089] The density variations between articles discussed above also result in variations in airflow through the article / device during operation. For example, lower density articles generally promote greater airflow. This airflow can either detract from or further promote heating of the aerosol-generating material, depending on the specific configuration of the device and its heating assembly 201. In articles with varying density regions, airflow may tend to flow only or mostly through the low-density regions, leaving higher-density regions underexposed to the airflow and therefore underutilized. This variation in the intensity and amount of aerosol generation further reduces the user experience and increases waste.

[0090] To address these issues, a device 101 is provided that includes a detector arrangement 180. The detector arrangement 180 is configured to detect a characteristic indicative of the density of the aerosol-generating material in the article. A control module 244 is also provided within the device's control circuitry 202, and the control module may control / alter the operation of the heating assembly 201 based on the detected characteristic indicative of the density. A processor 220 is provided. The processor 220 is part of the control module 244 configured to control the device 101. The processor 220 is part of the control module 244 configured to control the heating assembly 201 and the detector arrangement 180. The control module 244 is configured to control the heating assembly 201 via the output of the detector arrangement 180. The control module 244 includes a memory 230. The processor 220 is operable to control the heating assembly 201 to control the heating of the heating zone. The processor 220 is operable to control the detector arrangement 180 to determine a characteristic of the article 110 received in the heating zone 215. In some embodiments, the control module 244 is part of the heating assembly 201 and / or the detector arrangement 180 .

[0091] The density of an item 110 inserted into the device may be approximated in several ways. One such method requires the presence of a protruding member in the heating zone 215, the protruding member configured to be inserted into the item 110 when the item 110 is inserted into the device 101. The protruding member may be, for example, the heating element 420 shown in Figures 4 and 5, although it is also contemplated to provide a similar element that is not a heating element 420 but is also configured to be inserted into the item 110. However, this embodiment is described below in relation to the heating element 420.

[0092] Device 101 in this embodiment may include either heating element 320 or 420, or both. As shown in FIG. 5 , heating element 420 includes load sensor 500. Load sensor 500 is configured to sense an axial force acting on heating element 420 in a direction toward distal end 213 of receptacle 212. During insertion of item 110 into device 101, and thus heating element 420 into item 110, item 110 offers some resistance to heating element 420 being inserted, so that an axial force is imparted to heating element 420 toward distal end 213 of the receptacle, and this axial force is sensed by load sensor 500.

[0093] It may be appreciated that the magnitude of this sensed axial force varies depending on the density of the article 110 into which the heating element 420 is inserted. The denser the article 110, the higher the axial force that must be applied to the article 110, and therefore to the load sensor 500, to fully insert the article 110 into the device 101. The sensed force is therefore indicative of the density of the article 110, and in particular the density of the aerosol-generating material therein. The force sensed by the load sensor 500 is passed electronically to the controller 202 and then used by the control module 244, which forms part of the controller 202. The controller 202 then uses a preset model or table to generate an approximation of the density of the article 110.

[0094] The force information passed to the controller 202 may be the maximum force experienced by the load sensor 500 during insertion of the item 110. This force information may also be the average force experienced by the load sensor 500 during insertion of the item 110. These parameters provide a unique approximation of the density of the item 110. In an embodiment, the load sensor 500 may record the sensed force information throughout the insertion of the item 110, i.e., obtain a relationship between the amount of the heating element 420 (as a linear distance) inserted into the item 110 and the sensed force at a selected number of points along the full insertion of the heating element 420. This relationship maps the distribution of the density of the item 110 at least along the entire length of the item 110 over which the heating element 420 extends. The device 101 may further include a sensor (not shown) configured to determine the length of the heating element 420 inserted into the item 110 at any given time to aid in density distribution mapping, since in this case the controller 202 has input for both the force and distance of insertion.

[0095] Another method for approximating the density of an article 110 inserted into the device 101 may utilize optical analysis. In some embodiments, the device may include an optical sensor arrangement 181 comprising optical emitters (not shown) positioned to emit light toward the article 110 when the article 110 is inserted into the device 101. For example, the optical sensor arrangement 181 may include two or more optical emitters, which may be positioned at multiple locations within the heating zone 215 and at various axial and circumferential positions around the article 110. The optical sensor arrangement may further include one or more optical sensors positioned within the device and positioned to detect light emitted by the one or more optical emitters that has passed through at least a portion of the article 110. The one or more optical components may be positioned at various locations along the length and around the periphery of the article 110. In one embodiment, the number of optical emitters and the number of optical sensors are equal, with each optical emitter paired with a optical sensor. The use of multiple pairs of light emitters and light sensors at opposing locations around the length and periphery of the article 110 can be used, using the respective intensities of light emitted by the pair of light emitters and sensed by the pair of light sensors, to generate information indicative of the density of the article 110 at different locations therein, which information is then sent to the controller 202. Alternatively, only one light emitter and light sensor pair can be provided, and this pair is used to determine the intensity of light passing through the article 110 from the light emitter to the light sensor. This pair results in a single intensity value that can be used by the controller 202 to determine a single approximation of the density of the article 110.

[0096] Alternatively, the optical sensor arrangement 181 may be configured to determine an optical image. The optical image may include a spatial intensity distribution of detected light from one or more light emitters that has passed through the article 110. The image may be electronically transmitted to the controller 202, where it may be analyzed to determine an approximation of the density distribution of the article 110. The controller 202 is configured to determine characteristics of the image, such as overall brightness (representing the sensed light intensity) or brightness distribution. In some embodiments, the optical sensor arrangement 181 is an X-ray imaging arrangement 182, where the one or more light emitters emit X-ray light and the one or more light sensors are configured to sense the X-ray light. In such embodiments, the controller 202 may be configured to measure the gray-to-black contrast of the image produced by the one or more light sensors. Alternatively or additionally, the controller 202 may be configured to use pattern recognition of the optical image produced by the one or more light sensors and / or to use dot count analysis to determine an approximation of the density of the article.

[0097] As an alternative to, or in addition to, the aforementioned methods for determining an approximation of the density of an item 110 inserted into the device 101, the device 101 may utilize the airflow through the device 101 during use to determine an approximation of the density of an item 110 inserted therein. One way this approximation can be performed is by providing a sensor arrangement capable of determining the resistance of the heating elements 320 and / or 420. This sensor arrangement may be, for example, a sensor arrangement comprising a voltmeter and an ammeter configured to determine the potential difference and current flowing across the heating elements 320 and / or 420 at any given time, thereby measuring the resistance of the heating elements 320 and / or 420. In embodiments in which the heating elements 320 and / or 420 are resistive heating elements, this sensor arrangement may be easily implemented because an energizing circuit is already operatively connected to the heating elements, through which current is passed during use of the device 101. It is known that the resistance of a conductor changes with the temperature of the conductor. It is also known that passing a relatively cold fluid through / through a relatively hot object will cool the object. Thus, the rate at which air flows through the heating zone 215 of the device 101 and contacts the heating elements 320 and / or 420 during use is proportional to the cooling of the heating elements 320 and / or 420. Using the known relationship between the temperatures of the heating elements 320 and / or 420, the controller 202 can determine an approximation of the magnitude of the airflow that will pass through the item 110 during use of the device 101. The controller 202 can then use the approximated airflow magnitude to determine an approximation of the density of the item 110. Generally, a higher airflow through the item 110 indicates a lower density of the item 110. The controller 202 may be pre-configured to recognize the normal range of airflow through the device 101 to determine whether the item 110 deviates from the normal range and, therefore, whether the item 110 is over or under-densified for the current device settings.

[0098] Another way that the airflow through the device 101 can be used to approximate the density of the article 110 within the device is to measure the pressure drop (or change in airflow magnitude) across the article 110. To accomplish this measurement, one or more sensors 190 can be provided in the device 101. Each sensor 190 may sense a parameter indicative of the airflow magnitude or ambient pressure at the sensor's location. The sensor 190 may be, for example, a microphone sensor that measures noise due to air turbulence. Additionally or alternatively, the sensor 190 is a pressure sensor, which may comprise a barometer. In some embodiments, a first sensor 190 is positioned proximate an air inlet of the article 110 or the device 101. A second sensor 190 is positioned further along the airflow path of the device 101 and article 110. For example, the second sensor 190 is proximate a distal end of the article 110 where air enters the article 110. The second sensor 190 may alternatively be located near the proximal end of the article 110 where the air exits the article 110. The second sensor 190 may be located within the article 110 when the article 110 is in the heating zone (e.g., on the heating element 420). Each sensor is in operative communication with the controller 202. The controller 202 is configured to receive sensor readings from each of the first and second sensors, which are indicative of a characteristic of the airflow magnitude or ambient pressure. The controller 202 is configured to compare the input from the first sensor 190 with the input from the second sensor 190 and generate a comparison result. The comparison result is indicative of the density of the article 110. In other embodiments, only one sensor 190 is included in the device. The controller 202 in these embodiments is configured to estimate the density of the article 110 based solely on the readings from this sensor. In devices with a mouthpiece defining an opening 104, the second sensor may be located within the mouthpiece in the airflow path immediately adjacent to the opening and the user's mouth in use.

[0099] The controller 202 of the device 101 may be programmed with a heating profile. This heating profile defines a preset relationship between airflow through the device and heating power applied to the article 110. In devices 101 that allow manual adjustment of airflow, the controller 202 may adjust the heating power of the heating elements 320 and / or 420 to accommodate changes in airflow. Similarly, when the heating power is manually increased by a user, the controller 202 may adjust the airflow through the device to accommodate changes in heating power. Such adjustments may be made by the controller 202 in the absence of manual adjustment. For example, the controller 202 may increase or decrease the heating power after detecting high airflow through the device, such as caused by a user drawing air forcefully. The controller 202 may also adjust the heating power of the device in response to a determination of the ambient air temperature to provide stable heating of the article 110 and, therefore, a stable level of aerosol generation. This preset relationship between airflow and heating power may be referred to as the heating profile of the device 101.

[0100] Using any of the above-described methods for approximating the density of the article 110, the controller 202 may use the density approximation to modify the heating profile of the device 101. For example, after detecting a denser-than-normal article 110, the heating profile may be adjusted by the controller 202 such that more heating power is supplied to the article for a given airflow setting of the device 101. Similarly, the controller 202 may adjust the airflow through the device 101 for such heating power in response to detecting such an article density. In this way, rather than simply adjusting the heating power or airflow of the device in response to an approximation of the density of the article 110, the controller 202 adjusts the heating profile itself such that the device 101 can operate with a modified airflow to heating power relationship. This means that the device 101 can automatically adjust its heating power in response to the measured airflow through the device, and vice versa, with this automatic adjustment relationship further optimized by the density measurement of the article 110.

[0101] It is also contemplated that some devices 101 do not operate with a defined heating profile and do not automatically adjust heating power in response to measured airflow through the device, or vice versa. In such devices 101, the controller 202 may be configured to simply adjust either the heating power or the airflow through the device, or both, in response to an approximation of the density of the items 110 inserted into the device. For example, the controller 202 may be configured to modify the magnitude of the airflow through the device 101 in proportion to the approximate density of the items 110. The controller 202 may additionally or alternatively be configured to modify the heating power of the heating assembly 201, i.e., to increase the operating temperature of the heating elements 320 and / or 420 in proportion to the approximate density of the items 110.

[0102] As discussed above, some methods for approximating the density of the article 110 not only determine the overall density value of the article 110, but also determine the spatial density distribution of the article 110. The analysis performed by the controller 202 in such embodiments may determine such spatial density distribution with various resolutions. For example, the article 110 can be conceptually divided into any number of cylindrical axial segments, and an approximation of the density of each axial segment can be determined. Alternatively, the controller 202 may be configured to analyze the density of the article 110 at each of two or more circumferential segments defined by the entire axial length of the article 110, two or more radii of an axial cross-section of the article 110, and the arc length between two adjacent defined radii. For example, analyzing the article 110 with respect to two circumferential segments is equivalent to dividing the article 110 into two semi-cylinders. The article 110 can be conceptually divided into any combination of axial and circumferential segments by the controller 202 or by any other geometric division, and the density across each segment can be assigned an approximation of that density. An advantage of performing a spatial density analysis is that the controller 202 can adjust device operating parameters, such as airflow and heating power, in localized regions of the heating zone 215. In other words, the device 101 can include multiple heating elements 320 and / or 420 that are themselves segmented, and the individually controlled heating of each heating element segment may provide heat to specific portions of the article 110 inserted into the device 101. The device 101 can additionally or alternatively include complex airflow paths through the heating zone 215 that may be manipulated to vary not only the overall airflow through the device 101, but also the direction and magnitude over specific regions of the heating zone 215. In one example, the controller 202 is configured to approximate the density of two clearly defined segments of the article 110 inserted into the heating zone 215. The controller 202 determines that a first of the article segments is denser than a second of the article segments.In this scenario, the controller 202 operates the heating assembly 201 to supply more heating power to a first heating element segment proximate the first article segment than to a second heating element segment proximate the second article segment. In another example, the controller 202 may adjust the airflow through the device 101 such that when a user draws air through the device 101, a greater amount of air passes through / through the higher density first article segment compared to the lower density second article segment. Of course, it should be understood that the controller 202 may have both of these functions.

[0103] In devices with heating profiles, the heating profile may be defined in the controller 202 in terms of local heating element segment and airflow path operating parameters. In such devices, the controller 202 may adjust the heating profile of the device 101 such that the relationship between the heating profile airflow and heating power is locally modified. In this manner, the modified heating profile adjusts the airflow and local heating power to accommodate changes in the density of the article 110, yet still allows for automatic adjustment of the airflow and heating power based on variable external parameters such as user suction strength, ambient temperature, and manual airflow / heating power adjustment. This combination of features optimizes the user experience by achieving greater efficiency in both the power consumption of the device 101 and the utilization of aerosol-generating material in the article. The user also experiences a more uniform delivery of aerosolized material while consuming the article 110.

[0104] In addition to the above-mentioned advantages resulting from all embodiments in which the density of the item 110 is determined and device operating parameters are adjusted in response, the ability of the device 101 to approximate the density of the item 110 inserted into the device also presents an additional advantage. For example, the density of the item 110 may be a unique identifier for a particular model of the item 110 or a brand of the item 110. If the controller 202 can identify a particular brand or model of the item 101 by approximating the density of the item 110, it can facilitate or prevent consumption of third-party items 110 by the device 101. Furthermore, the controller 202 may include pre-stored data used to identify a particular model and / or brand of the item 110 and then utilize a corresponding pre-set heating profile for identification to optimize heating and consumption of the item 110.

[0105] In any of the described embodiments, device 101 may be configured to heat article 110 by generating a varying magnetic field configured to heat a susceptor heating element disposed within article 110. That is, the article itself may further comprise a susceptor heating element. When within the heating zone, the susceptor heating element disposed within the article heats the article by generating heat in the presence of the varying magnetic field, thereby generating aerosolized material from the aerosol-forming material.

[0106] In some of the above-described embodiments, the heating component is an induction heating component. In other embodiments, other types of heating components, such as resistive heating, are used. The device configuration is generally as described above and will not be described in detail. In such configurations, the heating assembly 201 comprises a resistive heating generator, including components that heat the heating element through a resistive heating process. In this case, electrical current is applied directly to the resistive heating component, resulting in current flow through the heating component, which heats the heating component through Joule heating. The resistive heating component includes a resistive material configured to generate heat when an appropriate electrical current passes through it, and the heating assembly 201 includes electrical contacts for supplying the current to the resistive material.

[0107] In an embodiment, the heating element forms the resistive heating component itself, which transfers heat to the heating element, for example by conduction.

[0108] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as representative examples of embodiments and are not intended to be exhaustive and / or limiting. It is understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or as limitations on the equivalents of the claims, and that other embodiments may be used and changes may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably include, consist of, or consist essentially of any suitable combination of the disclosed elements, configurations, features, components, steps, means, etc., other than those specifically described herein. The present disclosure may also include other inventions not currently recited in the claims but which may be described in the future. [Item of invention] [Item 1] 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a receptacle defining a heating zone for receiving at least a portion of an article including an aerosol-forming material; a detector arrangement configured to detect a characteristic indicative of a density of aerosol-forming material of a portion of an article received in the heating zone; a control module in communication with the detector arrangement and configured to control operation of the device according to the characteristic indicative of density; An aerosol delivery device comprising: [Item 2] Item 1, wherein the detector arrangement comprises an optical sensor arrangement. [Item 3] Item 3. The optical sensor arrangement of item 2, wherein the optical sensor arrangement comprises a light emitter and an optical sensor. [Item 4] 4. The aerosol delivery device of claim 2 or 3, wherein the control module is configured to determine the characteristic indicative of density based at least in part on input from the optical sensor arrangement. [Item 5] 5. The aerosol delivery device of any one of items 1 to 4, wherein the detector arrangement is configured to determine an image. [Item 6] Item 6. The aerosol delivery device of item 5, wherein the control module is configured to determine characteristics of the image. [Item 7] 7. The aerosol delivery device of claim 6, wherein the control module is configured to determine the characteristic of density based at least in part on the characteristic of the image. [Item 8] 8. The aerosol delivery device according to any one of items 5 to 7, wherein the detector arrangement is an X-ray imaging arrangement configured to output an X-ray image. [Item 9] 9. The aerosol delivery device of any one of items 1 to 8, comprising a heating assembly including a heating element arranged to heat the item within the heating zone. [Item 10] 10. The aerosol delivery device of claim 9, comprising a protruding member protruding into the heating zone and configured to pierce at least a portion of an article containing an aerosol-generating material when the article is received in the heating zone. [Item 11] Item 11. The aerosol delivery device of item 10, wherein the protruding member comprises the heating element. [Item 12] Item 12. The aerosol delivery device of item 10 or 11, comprising a load sensor configured to determine an axial force acting on the protrusion member. [Item 13] Item 13. The aerosol delivery device of item 12, wherein the control module is configured to determine the characteristic of density based at least in part on an output from the load sensor. [Item 14] 14. The aerosol delivery device of any one of claims 1 to 13, wherein the detector arrangement comprises a detector module arranged to determine a characteristic indicative of airflow rate through the device in use, and the control module is configured to determine the characteristic of density based at least in part on the characteristic indicative of airflow rate through the device. [Item 15] Item 15. The aerosol delivery device of item 14, wherein the characteristic indicative of the airflow rate through the device comprises at least one of a change in temperature and a rate of change of temperature of a temperature-sensing component of the device. [Item 16] Item 15. The aerosol generating device of item 14, wherein the detector module is configured to determine a characteristic indicative of the air flow rate through the device by measuring the pressure drop across the heated zone during use. [Item 17] 17. The aerosol generating device of any one of items 1 to 16, wherein the control module is configured to modify the heating profile of the device in response to the determination of the characteristic of density. [Item 18] 18. An aerosol delivery system comprising: the aerosol delivery device according to any one of items 1 to 17; and an article containing an aerosol-generating material arranged to be at least partially received in the aerosol delivery device. [Item 19] 1. A method of operating an aerosol delivery device to generate an aerosol from an aerosol-generating material, the method comprising: detecting a characteristic of at least a portion of an article received in a heating zone defined by a receptacle of the device, the characteristic being indicative of a density of the aerosol-forming material in the portion of the article; controlling operation of the device according to the characteristic indicative of density; A method of operating an aerosol delivery device, comprising: [Item 20] 20. The method of claim 19, wherein controlling the operation of the device includes controlling the operation of a heating assembly including a heating element positioned to heat the portion of the article received in the heating zone.

Claims

1. 1. An aerosol delivery device for generating an aerosol from an aerosol-generating material, comprising: a receptacle defining a heating zone for receiving at least a portion of an article including an aerosol-forming material; a detector arrangement including an optical sensor arrangement configured to detect a characteristic indicative of a density of aerosol-generating material within a portion of an article received in the heating zone; a control module in communication with the detector arrangement and configured to control operation of the device according to the characteristic indicative of density; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the optical sensor arrangement comprises an optical emitter and an optical sensor.

3. The aerosol delivery device of claim 1 , wherein the control module is configured to determine the property indicative of density based at least in part on input from the optical sensor arrangement.

4. The aerosol delivery device of claim 1 , wherein the detector arrangement is configured to determine an image.

5. The aerosol delivery device of claim 4 , wherein the control module is configured to determine a characteristic of the image.

6. The aerosol delivery device of claim 5 , wherein the control module is configured to determine the characteristic of density based at least in part on the characteristic of the image.

7. 5. The aerosol delivery device of claim 4, wherein the detector arrangement is an X-ray imaging arrangement configured to output an X-ray image.

8. The aerosol delivery device of claim 1 , comprising a heating assembly including a heating element positioned to heat the item within the heating zone.

9. 10. The aerosol delivery device of claim 8, comprising a protruding member protruding into the heating zone and configured to pierce at least a portion of an article containing an aerosol-forming material when the article is received in the heating zone.

10. The aerosol delivery device of claim 9 , wherein the protruding member comprises the heating element.

11. The aerosol delivery device of claim 9 , comprising a load sensor configured to determine an axial force acting on the protrusion member.

12. 12. The aerosol delivery device of claim 11, wherein the control module is configured to determine the characteristic of density based at least in part on an output from the load sensor.

13. 2. The aerosol delivery device of claim 1, wherein the detector arrangement comprises a detector module arranged to determine a characteristic indicative of airflow rate through the device in use, and the control module is configured to determine the characteristic of density based at least in part on the characteristic indicative of airflow rate through the device.

14. 14. The aerosol delivery device of claim 13, wherein the characteristic indicative of airflow through the device comprises at least one of a change in temperature and a rate of change of temperature of a temperature-sensing component of the device.

15. 14. The aerosol delivery device of claim 13, wherein the detector module is configured to determine a characteristic indicative of air flow rate through the device by measuring a pressure drop across the heated zone during use.

16. The aerosol delivery device of claim 1 , wherein the control module is configured to modify a heating profile of the device in response to the determination of the characteristic of density.

17. An aerosol delivery system comprising the aerosol delivery device of any one of claims 1 to 16 and an article including an aerosol-generating material arranged to be at least partially received in the aerosol delivery device.

18. 1. A method of operating an aerosol delivery device to generate an aerosol from an aerosol-generating material, the method comprising: detecting, with an optical sensor arrangement, a characteristic of at least a portion of an article received in a heating zone defined by a receptacle of the device, the characteristic being indicative of a concentration of aerosol-generating material within the portion of the article; controlling operation of the device according to the characteristic indicative of density; , including a method of operation.

19. 20. The method of claim 18, wherein controlling the operation of the device includes controlling the operation of a heating assembly including a heating element positioned to heat the portion of the article received in the heating zone.

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