Apparatus for heating aerosol-generating materials

Abstract

An aerosol delivery device is provided comprising a receiving section for receiving a consumable and a support element configured to hold an aerosol generator against the receiving section, the support element comprising a surface and at least one means for holding the aerosol generator away from a surface of the support structure.

Description

[Technical Field]

[0001] The present invention relates to an apparatus configured to heat an aerosol-forming material. [Background technology]

[0002] In use, aerosol delivery systems generate an aerosol, inhalable aerosol, or vapor by releasing a compound from an aerosol-generating material, and may also be referred to as, for example, a non-combustible smoking article, an aerosol-generating assembly, or an aerosol delivery device. Summary of the Invention

[0003] According to some embodiments described herein, a receiving section for receiving consumables; an aerosol generator configured to provide heat to the receiving section; a support element configured to hold the aerosol generator relative to the receiving section; and and the support element comprises: The surface and and at least one means for holding the aerosol generator away from the surface of the support structure. An aerosol delivery device is provided.

[0004] The aerosol delivery device may further comprise an aerosol generator, which may be configured to provide heat to the receiving section.

[0005] Thus, according to some embodiments described herein: a generally cylindrical receiving section for receiving the consumable; an aerosol generator configured to provide heat to the receiving section; a generally cylindrical support element radially outward of the first wall, the generally cylindrical support element configured to hold the aerosol generator against the receiving section; and An aerosol delivery device is provided comprising:

[0006] In addition to, or as an alternative to, any of the above-described embodiments, a plurality of means for holding the aerosol generator may be provided, extending from the surface of the surface of the support element, such that at least one gap may be defined between the surface of the support structure and the aerosol generator.

[0007] Additionally or alternatively to any of the above embodiments, the device may comprise at least one temperature sensor in the gap, and / or at least one connector in the gap, and / or thermal insulation in the gap.

[0008] Additionally or alternatively to any of the above embodiments, at least one means for holding the aerosol generator on the support structure may comprise a different material than the surface of the support structure.

[0009] Additionally or alternatively to any of the above embodiments, the receiving section may be generally flat.

[0010] Additionally or alternatively to any of the above embodiments, the receiving section and the support structure may be generally cylindrical, with the support element being positioned radially outward of the aerosol generator.

[0011] According to some embodiments described herein, a generally cylindrical receiving section for receiving the consumable; a generally cylindrical support element radially outward of the receiving section, the generally cylindrical support element configured to hold the aerosol generator relative to the receiving section; and An aerosol delivery device is provided, comprising:

[0012] The aerosol delivery device may further comprise an aerosol generator, which may be configured to provide heat to the receiving section.

[0013] Thus, according to some embodiments described herein: a generally cylindrical receiving section for receiving the consumable; an aerosol generator configured to provide heat to the receiving section; a generally cylindrical support element radially outward of the receiving section, the generally cylindrical support element configured to hold the aerosol generator relative to the receiving section; and An aerosol delivery device is provided, comprising:

[0014] Additionally or alternatively to any of the above embodiments, the support structure may be omega shaped.

[0015] Additionally or alternatively to any of the above embodiments, the aerosol generator may include a resilient material such that the aerosol generator biases a support element that holds the aerosol generator in place.

[0016] Additionally or alternatively to any of the above embodiments, the aerosol generator may include an FeCr alloy.

[0017] Additionally or alternatively to any of the above embodiments, the aerosol generator may be held relative to a support structure by at least one attachment means.

[0018] Additionally or alternatively to any of the above described embodiments, the attachment means may be fastening means and / or clamping means.

[0019] Additionally or alternatively to any of the above-described embodiments, a first wall may be disposed between the aerosol generator and the receiving section.

[0020] Additionally or alternatively to any of the above-described embodiments, the support element may comprise a plastic and / or ceramic material.

[0021] Additionally or alternatively to any of the above-described embodiments, the support element may comprise a first portion and a second portion that are movable relative to one another between a first position and a second position.

[0022] The first and second portions may be coupled about an axis such that the first and second portions are rotatable relative to one another between a first position and a second position.

[0023] Additionally or alternatively to any of the above embodiments, the support element may include a reflective material or coating configured to reflect heat towards the receiver.

[0024] In addition to or alternatively to any of the above-described embodiments, the support structure may include at least one connector portion through which the connector can pass so that the connector can be held in a fixed position relative to the support element and the aerosol generator.

[0025] Additionally or alternatively to any of the above-described embodiments, the support element may comprise at least one mounting portion through which the aerosol generator extends.

[0026] In addition to or alternatively to any of the above-described embodiments, the aerosol generator may be a first aerosol generator configured to supply heat to the first receiving section, and the aerosol delivery device may include a second aerosol generator configured to supply heat to the second receiving section.

[0027] There may be a second support element configured to hold a second aerosol generator against the second receiving section.

[0028] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0029] [Figure 1A]1 is a cross-sectional view of an example of an apparatus for heating an aerosol-forming material. [Figure 1B] FIG. 1B is a cross-sectional view taken along line BB in FIG. 1A. [Figure 2] FIG. 1 is a diagram of an exemplary flat heater configuration for use in an apparatus for heating an aerosol-forming material. [Figure 3] FIG. 2 is a diagram of an exemplary omega-shaped support structure for supporting an aerosol generator of an apparatus for heating an aerosol-forming material. [Figure 4] 1 is a diagram of an exemplary generally cylindrical support structure for supporting an aerosol generator of an apparatus for heating an aerosol-forming material. [Figure 5A] 1 is a cross-sectional view of an example of an apparatus for heating an aerosol-forming material, including a support structure for holding an aerosol generator. [Figure 5B] FIG. 1 is a perspective view of an exemplary support structure. [Figure 6] FIG. 1 is a diagram of an exemplary support structure for supporting a flat heater arrangement for use in an apparatus for heating an aerosol-forming material. [Figure 7A] FIG. 1 illustrates an exemplary hinged support structure. [Figure 7B] FIG. 2 is a detailed view of an exemplary support structure. [Figure 8A] FIG. 10 is a diagram of an exemplary assembly using a hinged support structure. [Figure 8B] FIG. 10 is a diagram of an exemplary assembly using a hinged support structure. [Figure 8C] FIG. 10 is a diagram of an exemplary assembly using a hinged support structure. [Figure 8D] FIG. 10 is a diagram of an exemplary assembly using a hinged support structure. [Figure 9] FIG. 1 is a diagram of an exemplary aerosol generator within a support structure. [Figure 10] 10 is a diagram of another exemplary structure in which the consumable is within a receiving section. [Figure 11] FIG. 10 is a diagram of another exemplary support structure. DETAILED DESCRIPTION OF THE INVENTION

[0030] [Detailed explanation] Typically, devices that heat an aerosol-forming material to volatilize at least one component of the aerosol-forming material to form an inhalable aerosol without burning or combusting the aerosol-forming material are sometimes described as "non-combustion heating" devices, or "tobacco heating products," or "tobacco heating devices," or the like. Similarly, there are so-called e-cigarette devices, which typically vaporize aerosol-forming material in liquid form, which may or may not contain an active substance such as nicotine. Of course, devices can be configured to heat any aerosol-forming material, including non-tobacco products.

[0031] An aerosol-generating material is a material capable of generating an aerosol when excited, for example, by heating, irradiation, or in any other manner. The aerosol-generating material can be, for example, in the form of a solid, liquid, or gel, and may or may not contain an active substance and / or flavoring. In some embodiments, the aerosol-generating material can comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid can be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material can comprise, for example, about 50%, 60%, or 70% by weight of an amorphous solid to about 90%, 95%, or 100% by weight of an amorphous solid.

[0032] The aerosol-generating material may include one or more active agents and / or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0033] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy to liberate one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator can be configured to expose the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0034] A consumable is an article containing or consisting of an aerosol-generating material, some or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a paper wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that releases heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0035] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that the penetration of the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0036] Although examples of circular cross-sections are illustrated and may be described herein with reference to "circumferential" walls or other terms relating to circles and cylinders, it will be understood that these may have any cross-section, and the teachings herein are equally applicable to devices of any shape and their respective perimeters. For example, the walls may instead have a square cross-section, or similarly have any other common or uncommon shape. Additionally, the support structures contemplated herein may be equally applicable to flat aerosol generators, such as aerosol generators configured to heat flat consumables.

[0037] 1A is a cross-sectional view of an example of an apparatus for heating an aerosol-generating material, generally designated 100. Apparatus 100 may include a receiving section 130 that receives a consumable (not shown) to be heated, a first circumferential wall 110 that defines receiving section 130, and a second circumferential wall 140 that surrounds first circumferential wall 110. As shown in FIG. 1, first circumferential wall 110 is spaced apart from second circumferential wall 140. In this manner, first circumferential wall 110 may be defined as the circumferential wall of a furnace configured to heat the consumable placed therein.

[0038] In the example herein, the first circumferential wall 110 can be heated by the aerosol generator 120, which in the example of Figures 1A and 1B is a sheet wrapped around the first circumferential wall. Advantageously, the first circumferential wall can protect the aerosol generator 120 from damage due to the insertion of a consumable item. This is particularly beneficial when the aerosol generator 120 is made of a brittle material.

[0039] However, it will be appreciated that the circumferential wall 110 need not be a separate entity. In this manner, the aerosol generator 120 itself may define the furnace, and thus the receiving section 130, and may be configured to directly receive the consumables without any intervening structures. In this manner, the aerosol generator 120 may directly heat the receiving section 130, thereby providing more efficient heating of the received consumables.

[0040] Figure 1B is a cross-sectional view taken along line BB in Figure 1A. As can be seen in the drawing, the aerosol generator 120 can extend at least substantially around the first circumferential wall and thus any consumables received within the first circumferential wall.

[0041] The aerosol generator 120 can be heated in any suitable manner. For example, the aerosol generator 120 can be a resistive aerosol generator that can heat up when an electric current is passed through it. Alternatively, the aerosol generator 120 can be an induction aerosol generator (such as a susceptor) configured to generate heat in the presence of a magnetic field.

[0042] As noted above, the teachings herein are not limited to cylindrical devices. For example, the device may have a square cross-section or any other common or unusual cross-section. Alternatively, the device may be configured to receive a flat or substantially flat consumable, such as in device 200 of FIG. 2 . In this case, first wall 210 may provide a flat receiving section 211 onto which the consumable may be placed. The wall may be heated by a similarly shaped aerosol generator 220. Again, the first wall need not be a separate entity; rather, the aerosol generator may be thought of as receiving the consumable directly.

[0043] An insulating member may surround or form the second circumferential wall 140. For example, the insulating member may include an inner circumferential wall that forms the second circumferential wall.

[0044] The aerosol generators provided herein may be provided in the form of flexible sheets and therefore may not conform well to the desired shape of the receiving section. For example, the aerosol generator may include a metallic material, such as one or more of aluminum, copper, manganin, steel, constantan, nichrome, stainless steel, nickel, and fecralloy (RTM). Such sheets may have some resilience when bent and therefore may spring open when released, making them difficult to fold into the desired shape. Therefore, it may be necessary to hold the aerosol generator in place within the device to ensure good thermal contact with the first wall / furnace and / or to maintain the appropriate shape for the aerosol generator itself to accurately define the receiving section.

[0045] Therefore, a rigid support structure may be provided for the aerosol generator. For example, as shown in FIG. 3, the aerosol generator 300 includes a support structure 350 that prevents the aerosol generator from springing open, thereby holding the aerosol generator 320 in good contact with the first wall 310 that defines the area where the consumable item can be placed. Of course, as mentioned above, the first wall 310 may not be present, in which case the support structure 350 holds the aerosol generator 320 in the appropriate shape so that the aerosol generator 320 itself defines the receptacle.

[0046] The support structure 350 may be omega-shaped (Ω), i.e., circular, with two flats 360 extending outward from the open portion of the circle (inside which the furnace may reside). Thus, the aerosol generator 320 may be configured to rest mostly within the circular portion of the support structure 350, in which case it may be secured to the support structure at the flats of the omega. Such an arrangement advantageously utilizes the natural elasticity of the material of the aerosol generator 320, since the outward resilience helps the aerosol generator 320 maintain its shape when radially surrounded. When held by such a support structure, the aerosol generator can precisely fit into a furnace (such as the first circumferential wall in FIGS. 1A and 1B ) that may be located within the support structure. Such an arrangement protects the aerosol generator while maintaining a snug fit within the support structure.

[0047] Furthermore, providing such an omega shape allows the aerosol generator 320 to be secured at the flat portion 360 by a mounting member that extends through the support structure 350 and the aerosol generator 320. Additionally, if the aerosol generator 320 is a resistive aerosol generator, the mounting member may serve as a terminal that allows electrical connection of a power source (not shown) to the aerosol generator 320.

[0048] 4 shows a similar arrangement for aerosol generator 400, but with support structure 450 that is open cylindrical or "C" shaped. Optionally, aerosol generator 420 may be held within support structure 450 using only its natural resilience. Alternatively, aerosol generator 420 may be coupled to support structure 450 at portion 460, which may be flat, by a mounting member. As mentioned above, the mounting member may additionally serve as a terminal that allows connection of aerosol generator 420 to a power source.

[0049] The mounting element 360 can be any type of suitable mounting element. As shown in FIG. 3, the mounting element 360 may be provided in the form of a fastener, for example using screws and / or bolts, optionally with corresponding nuts. Additionally or alternatively, the mounting element 360 may be a clamp arrangement, as shown in FIG. 4. Additionally or alternatively, the aerosol generator may be held against the support structure (and first wall) by its natural resilience. This natural resilience biases the aerosol generator against the support structure, thereby holding the aerosol generator in place.

[0050] As will be appreciated, the aerosol generator configurations of Figures 3 and 4 may be provided in the configuration of the general device shown in Figures 1A and 1B. As such, elements of aerosol generators 300 and 400 may replace similar elements in Figures 1A and 1B. Similarly, the support, like that of Figure 2, may be provided in a flat configuration or configured to provide a clamp / coil structure to support a flat aerosol generator.

[0051] In a further example, the support structure may include means for holding the aerosol generator away from the surface of the support structure. For example, the support structure may include fins extending laterally from the surface of the support to hold the aerosol generator away from the surface of the support structure, as shown in Figures 5A, 5B, and 6.

[0052] As will be appreciated, any means for maintaining a distance between the aerosol generator and the surface of the support may be utilized. For example, the means may comprise any structure extending laterally from the surface, such as a plurality of posts or other supports distributed along the length and / or width of the support. It will be appreciated that if the means is a fin, the fin need not extend across the entire length and / or width of the support. Rather, a plurality of fin-like formations may be provided.

[0053] Thus, although the means illustrated in Figures 5A, 5B and 6 are fins and may be described as such, it will be understood that the following teachings are applicable to any such means that serves the function of holding an aerosol generator away from the surface of a support structure, thereby minimizing contact (and any potential heat loss) between the support and the aerosol generator while keeping the aerosol generator securely in place.

[0054] Additionally, although the means for holding the aerosol generator is exemplified herein as being an integral part of the support structure, it will be understood that the holding means may be a separate component that provides the function of holding the aerosol generator at a distance from the surface of the support.

[0055] 5A is a cross-sectional view of an example of an apparatus for heating an aerosol-generating material, generally designated 500. Apparatus 500 may include a receiving section 530 that receives a consumable (not shown) to be heated, a first circumferential wall 510 that defines receiving section 530, and a second circumferential wall 540 that surrounds first circumferential wall 510. As shown in FIG. 1, first circumferential wall 510 is spaced apart from second circumferential wall 540. In this manner, first circumferential wall 530 may define a circumferential wall of a furnace configured to heat a consumable disposed therein.

[0056] In the examples herein, the first circumferential wall 510 may be heated by the aerosol generator 520, which in the example of FIG. 5A is a sheet that substantially surrounds the first circumferential wall 510. However, as will be understood, the circumferential wall 510 need not be a separate entity. In this manner, the aerosol generator 520 itself defines the furnace, and thus the receiving section 530, and may be configured to directly receive the consumable without any intervening structure.

[0057] 3 and 4, the apparatus 500 includes a support structure 550 to hold the aerosol generator 520 in place. As seen in the example of FIG. 5B, which shows a perspective view of the support structure 550, the support element 550 can form at least a partially generally cylindrical shape within which the aerosol generator 520 can be held in place. In the example of FIG. 5B, the support element has an omega "Ω" shape including a flat portion 565 extending therefrom, similar to that of FIG. 3. As will be appreciated, the support element may be generally cylindrical, similar to the structure of FIG. 4.

[0058] As will be understood by those skilled in the art, the term "substantially cylindrical" refers to any shape that at least partially comprises at least a semicircular or partially circular cross-section. For example, the cross-section of Figure 3 is considered to be substantially cylindrical because the cross-section of the omega circular portion defines a majority of a circle. Similarly, the "open" cylinder or "C" shape of Figure 4 is considered to be substantially cylindrical because its cross-section also defines a majority of a circle. Of course, a substantially cylindrical cross-section also encompasses a cylindrical cross-section.

[0059] As mentioned above, the teachings herein are not limited to cylindrical devices. For example, the device may have a square cross-section or any other common or uncommon cross-section. Alternatively, the device may be configured to receive a flat or substantially flat consumable, such as device 600 of FIG. 6 . In this case, first wall 610 may provide a flat receiving section 611 onto which the consumable may be placed. The wall may be heated by a similarly shaped aerosol generator 220. Again, first wall 610 need not be a separate entity; rather, the aerosol generator may be considered to receive the consumable directly.

[0060] 5A, 5B, and 6, the support structure 550, 650 includes a retaining means 551, 651 extending from a surface 552, 652 of the support to retain the aerosol generator away from the surface of the support structure. Such a structure limits heat seepage from the aerosol generator 520, 620 to the support structure because contact between the aerosol generator and the support structure is minimized by an unspecified amount (ns). In addition, the retaining means may be configured to direct generated heat toward the consumable received in the receiver. This improves the efficiency of the aerosol generator 520, 620 in heating the consumable element to be received by the device.

[0061] Additionally, the retaining means 551, 651 provides a gap 553, 653 that creates a pocket of air between the aerosol generator 510, 610 and the surface 552, 652 of the support structure, further helping to separate the support structure from the aerosol generator. Additionally or alternatively, the gap 553, 653 may comprise other components such as separate insulation (e.g., fiberglass and / or aerogel) and / or one or more temperature sensor(s) and / or allow for connectors to pass through.

[0062] 5A, 5B, and 6 are not shown, it will be understood that any such retaining means may be utilized. For example, a fastener may be used at flat portion 565 to hold the aerosol generator in place. Additionally or alternatively, a clamping arrangement similar to that of FIG. 4 may be used. Additionally or alternatively, the aerosol generator may be held in place by its natural resilience, which biases the aerosol generator against the support structure, thereby holding the aerosol generator in place relative to the support structure and the first wall.

[0063] The support structure described above may be made from any suitable material, and in some embodiments, the support structure may be made from a plastic material that can withstand the temperatures required to volatilize one or more components of the aerosol-forming material.

[0064] For example, the support structure may include polyetheretherketone (PEEK). Additionally or alternatively, the support structure may include one or more ceramic materials. For example, at least the retaining means may be made from a ceramic material that can withstand the high temperatures reached by the aerosol generator.

[0065] Additionally, it may be beneficial for the support structure and means for holding the aerosol generator to be made from a material with low thermal conductivity, thereby limiting the amount of heat that can be absorbed within the support and means for holding the aerosol generator and away from the receiving section, for example, the support structure and means for holding the aerosol generator are made from a material with a thermal conductivity of less than 0.1 W / mK.

[0066] Additionally or alternatively, the surfaces of the support structure may be coated with a suitable material. For example, surfaces 552, 652 may be coated on their internal surfaces (i.e., the surfaces facing the aerosol generator) with a reflective material so that any heat radiating from the exterior surfaces of the aerosol generator away from the receiving section is reflected back toward the receiving section. For example, a "reflective coating" may mean that the coating has an emissivity of 0.15 or less (i.e., 15% of the energy from radiation received by the coating at a 90-degree angle is absorbed, and the rest is reflected).

[0067] In the illustrated embodiment, the means for holding the aerosol generator is generally depicted as fins of constant cross-section extending from the surface of the support, but it will be understood that the means for holding the aerosol generator may be of any shape. In addition, the cross-section may decrease as the holding means extends toward the aerosol generator to reduce the overall amount of contact between the aerosol generator and the holding means, thereby reducing heat loss. Thus, in the examples of Figures 5A, 5B, and 6, the fins may be of triangular / trapezoidal cross-section.

[0068] The holding means and / or the entire support may be hollow, thereby reducing the weight and thermal mass of the support and holding means and limiting heat loss.

[0069] Advantageously, the retaining means can act as a shock absorbing member: for example, if the device is dropped, the retaining means can reduce the transmission of impact forces to the furnace and / or aerosol generator, which may be fragile and breakable.

[0070] The support structure may be provided as a single piece of material within which the remaining items (e.g., furnace and aerosol generator) can be placed. For example, the aerosol generator may be installed in the receiving section, where the natural elasticity of the material can bias the aerosol generator against the support member to hold it in place. Alternatively, for example, if the support member is omega-shaped, the support structure may be installed in a void within the support member.

[0071] Alternatively, the support structure may be provided in more than a single piece to facilitate easier manufacture of the support structure and / or easier attachment of other components of the device. For example, the support structure may be provided in several separate pieces that can be attached to one another. These separate pieces can be constructed from an "open" configuration into a closed configuration for use. For example, the support structure may be provided as several separate pieces that may be detachable to fit together. In the closed configuration, the support structure can assume any suitable shape to hold the aerosol generator in a fixed relationship with the receiving section and / or furnace. For example, in the closed configuration, the support structure can form an omega, cylindrical, or flat configuration, as described above. Similarly, the support structure may be provided in any other suitable shape.

[0072] Additionally / alternatively, the support structure and the retaining means may be provided separately, such that the retaining means is fitted to the support structure. In this manner, the retaining means may be replaceable and / or customizable depending on their desired function. For example, the retaining means may be replaced with retaining means of different materials and / or shapes depending on their desired characteristics. This allows for a more modular design of the device, where each component can be selected and / or replaced as needed.

[0073] One example of a support structure comprising multiple parts is shown in Figures 7A and 7B, where the support structure 750 is in the form of a hinged structure that facilitates easy opening and closing of the support structure. In these examples, the closed configuration has an omega shape as described above, but it will be understood that the support structure can have any desired shape for use. The opening and closing can allow for easier attachment of the aerosol generator and / or furnace (also referred to as the first wall in the examples of Figures 1A, 1B, 2, and 3). Additionally or alternatively, the opening can allow for easy introduction of consumables into the receiving section.

[0074] Referring to FIG. 7A , a support structure 750 includes first and second portions 755, 756 configured to mate with one another during use. For example, each portion can include attachment means 757 configured to interact with attachment means on the other portion so that the two portions can be attached to one another. In the example of FIG. 7A , the attachment means on each of the first and second portions is in the form of a portion into which a separate fastener (not shown) can be introduced, thereby securing the first and second portions 755, 756 to one another. Advantageously, such a fastener can act as an axis around which the first and second portions 755, 756 can pivot, thereby allowing the first and second portions 755, 756 to move relative to one another between the open and closed positions while still being held together. In this way, even in the “open” position, the extent to which the parts can come loose is minimized, thereby facilitating easier installation.

[0075] As can be seen in the drawings, each of the first and second portions 755, 756 includes a mounting portion 754. The mounting portion 754 defines an inlet (e.g., a hole or slot) through which the aerosol generator 720 can be introduced into the support structure. The inlet may be sized and shaped to closely correspond to the cross-section of the aerosol generator 720 so that the aerosol generator can be held by the inlet with an interference fit when the aerosol generator is in place. Alternatively, the inlet may be a clearance fit with respect to the aerosol generator 720 so that the aerosol generator can easily pass through the mounting portion 754 to avoid damage to the aerosol generator. In such cases, the aerosol generator 720 may be held by other means relative to the support 750, if necessary.

[0076] In the case of Figure 7A, the inlet is in the form of a slot, and the aerosol generator 720 is in the form of a sheet. Of course, these may be provided in other configurations depending on the shape / requirements of the aerosol generator. For example, if the aerosol generator is in the form of a round wire wrapped around the receiver, the inlet may be in the form of multiple holes, each shaped to receive the aerosol generator passing therethrough. Alternatively, the inlet may remain a single slot, with the wire passing through it multiple times. Of course, similar attachment / inlet arrangements may exist when the support structure is a single piece, as in the examples of Figures 3-6.

[0077] Advantageously, by providing the aerosol generator 720 through the lead-in portion, a portion of the aerosol generator is made available for other connections. For example, a connector may be connected to the portion 721 of the aerosol generator 720 that extends beyond the mounting portion 754. Such a connector may be threaded through the connector portion 758 on each of the first and second portions 755, 756 to connect to the respective ends of the aerosol generator. Again, the connector portion 758 may be provided so that the incoming connector has an interference fit with the connector portion 758. In this way, when mated, the connector may be held in place by its engagement with the connector portion such that the connector portion can hold the connector in place when the connector is pulled. In this way, the connector portion 758 functions as a stress relief, as any force externally applied to the connector provided therethrough may be exerted on the connector portion 758 rather than being transmitted through the connector to the connection between the connector and the aerosol generator, which may be fragile.

[0078] In the example of Figure 7A, the aerosol generator 720 is shown in two sections, illustrating the shape of the inner surface of the support structure 750, which includes a retaining means 751 extending from a surface 752, thereby providing a gap 753 between the aerosol generator 720 and the support structure. Of course, the aerosol generator may be provided as a single continuous sheet, which facilitates easier installation. Alternatively, the aerosol generator may be provided in two or more sections (as seen in Figure 7A) that are joined when the support structure is in the closed configuration. This can prevent damage to the aerosol generator during opening / closing of the support structure.

[0079] As seen in Figure 7A, the support is provided in an open configuration. As will be appreciated, the support structure can be further opened to form a larger cavity into which the furnace / first wall and / or consumables can be introduced.

[0080] Furthermore, as shown in FIG. 7A and in more detail in FIG. 7B (where the aerosol generator is illustrated as transparent for clarity), the support structure (particularly, void 753) can provide space for additional components. For example, void 753 can provide space for additional component 760, including connector 761, which can penetrate the support structure. For example, component 760 can be a temperature sensor that can monitor the temperature of the aerosol generator and provide the sensed temperature to an external component through connector 761. Such a temperature can be monitored to ensure that the temperature of the aerosol generator can reach a desired level, or similarly, that the aerosol generator is not dangerously hot. Such a temperature sensor can improve the reliability or safety of the aerosol delivery device. Of course, although only one single component 760 is illustrated in the example of FIG. 7B, multiple components may be provided. Similarly, no components may be provided therein. As mentioned above, the void may additionally or alternatively be filled with insulating material and / or insulating fluid.

[0081] Figures 8A-8D illustrate an exemplary assembly process for a support structure such as the hinged structure shown in Figures 7A and 7B. Reference numbers in these figures mirror those in Figures 7A and 7B, with like reference numbers indicating like features.

[0082] Figure 8A shows the hinged support structure 850 in an open position with the aerosol generator 820 attached. Figure 8B shows another view of the support structure in the open position to more clearly show the component 860 and the retaining means 851. Of course, while the retaining means 851 is shown in this example as a fin, as described above, the retaining means 851 may be any shape. Alternatively, the retaining means 851 may be absent; rather, the aerosol generator 820 may simply rest on the surface of the support structure.

[0083] As can be seen in the drawings, support structure 850 includes first portion 855 and second portion 856. First portion 855 and second portion 856 are attached to one another by their respective attachment means 857. Attachment means 857 includes fasteners 859 therethrough. Fasteners 859 act as pivots, allowing the first and second portions to move relative to one another. As can be seen in the drawings, in the open position, aerosol generator 820 can be more easily introduced through attachment portions 854, thereby reducing the chance of breaking the potentially fragile aerosol generator 820. Then, after the aerosol generator is in place, support structure 850 can be moved to the closed position. In such a position, the aerosol generator's natural resilience can push the aerosol generator radially outward, causing it to contact support structure retaining means 851 and thus form the desired shape defining a receptacle and / or space for the furnace / first wall therein.

[0084] The process of closing the support structure 850 to provide the aerosol generator 820 around the first wall / furnace 810 can be seen in Figures 8C and 8D. By providing the first wall / furnace 810 within the support structure 850, the first wall 810 can advantageously facilitate a closer fit of the aerosol generator 820 to the support structure and any retaining means provided therein. Such a first wall / furnace 810 can more precisely define a receptacle for receiving consumables, thereby protecting the aerosol generator 820 from damage.

[0085] As seen in FIG. 8C, the first wall / furnace 810 can be placed on the aerosol generator 820, and then the first and second parts 855, 856 of the support structure can be moved to a closed position, thereby fixing the first wall / furnace 810 and the aerosol generator 820 in place.

[0086] 8C and 8D further show the arrangement between connector 870, connector portion 858, and portion 821 of the aerosol generator that extends through mounting portion 854. Connector 870 is threaded through connector portion 858 on each of first and second portions 855, 856 and then coupled (in this case by solder, although any coupling may be provided) to each end of aerosol generator 821.

[0087] As mentioned above, when mated, the connector can be held in place by its engagement with the connector portion such that when force is applied to the distal end of the connector (i.e., the end away from the aerosol generator), connector portion 858 can hold the connector in place. In this way, connector portion 858 acts as a stress relief, as any force applied externally to the connector brought therethrough can be exerted on connector portion 858 rather than being transmitted through connector 870 to the interface between the connector and the aerosol generator, which can be fragile. This results in a more robust aerosol generating device.

[0088] Once in the closed position (i.e., the position in which the aerosol generating device can be used), the first and second parts 855, 856 of the support structure can then be secured to one another. The securing can be permanent (e.g., by welding, gluing, or other methods) or semi-permanent. This maintains maximum strength in the support, thereby improving the robustness of the device. Alternatively, the securing can be temporary (e.g., with clips or other methods), so that the support structure can be opened and closed when needed. This can facilitate more convenient use of the aerosol generating device, as the first wall / furnace 810 can be removed / cleaned as needed, and so can the aerosol generator as well.

[0089] An exemplary assembled apparatus 900 for heating an aerosol-generating material is seen in FIG. 9 . As seen in the drawing, the apparatus 900 includes a single-piece support structure 950, as described above. FIG. 9 illustrates an example in which there is no separate first wall / furnace; therefore, the receptacle is defined only by the inner surface of the aerosol-generating material 920. The lack of a separate first wall / furnace means that heat generated by the aerosol generator is delivered directly to the consumable received in the receptacle, potentially resulting in faster and more efficient heating. The apparatus 900 may alternatively include any of the features shown in FIGS. 8A-8D , such as additional component(s) utilizing a connector 961. While not seen in FIG. 9 , the aerosol generator 920 may be delivered through an inlet (e.g., a hole or slot) through the mounting portion 954, wrapped along the inner surface of the support structure 900, and then delivered through a similar inlet (e.g., a hole or slot) in the mounting portion 954 on the other side of the omega-top opening. Alternatively, a single fitting may be provided across the omega cavity with two separate inlets for the aerosol generator to enter at one and exit at the other.

[0090] As shown in FIG. 10 , an apparatus 1000 for heating an aerosol-generating material may include first and second aerosol generators 1021, 1022. Support structures 1051, 1052 corresponding to each aerosol generator 1021, 1022 may be provided, respectively. Similarly, each aerosol generator 1021, 1022 may be provided within the same support structure. As will be appreciated, each aerosol generator defines its own receiving section in which a consumable may be placed. The receiving sections may be aligned such that the aerosol generators are positioned to heat the same consumable 150, as shown in FIG. 10 , or they may be positioned to receive separate consumables in their own receiving sections.

[0091] The support structures and aerosol generators may be arranged as in any of the examples described above. The aerosol generators and support structures may be similar or different depending on their desired functions. For example, it may be desirable for a portion of the consumable 1500 to heat up quickly. In such cases, it may be beneficial for at least one of the aerosol generators to be provided without a first wall / furnace structure between the consumable and the at least one aerosol generator. If the first aerosol generator 1021 is provided without a furnace, it may be desirable for the second aerosol generator 1022 to be provided with a furnace, which may help center the consumable 1500 in the device 1000. Thus, if the consumable is first introduced into the device 1000 through the second aerosol generator 1022 and support structure 1052, and then the consumable remains in the center of the device, the chance of the consumable colliding directly with the first aerosol generator and damaging it is reduced, even if the first aerosol generator is provided without a furnace.

[0092] Similarly, it may be desired that different portions of the consumable(s) be heated at different times, in which case the aerosol generator may provide heat at different times.

[0093] Of course, one or more components may be omitted from such device 1000. If the aerosol generators require electrical connections (e.g., for resistive heating), each aerosol generator 1021, 1022 may be connected to the same set of connectors. Similarly, if each support structure is a hinged support structure, the support structures may be attached through their mounting points by a single fastener.

[0094] Furthermore, the aerosol generator does not necessarily form part of any of the devices described above, but rather may be formed as part of a consumable to be received by the device, in which case the holding means may hold the consumable to be internally heated, still offering the advantage of more efficient heating as the holding means provides thermal insulation for the consumable.

[0095] 11 shows another arrangement of an apparatus 1100 for heating an aerosol-generating material, including another exemplary support structure 1150. In this arrangement, a receiving section is defined between a surface 1153 of the support structure 1150 and the aerosol generator 1120. In this manner, a consumable 1190 can be placed between the surface of the support structure and the aerosol generator. Furthermore, the apparatus 1100 can further include a means 1155 for providing relative motion between the aerosol generator 1120 and the support structure 1150, thereby moving the aerosol generator relative to the surface 1153 of the support structure 1150. The means 1155 can form part of the support structure 1150 or can be a separate component. In this manner, the aerosol generator 1120 can be moved away from the support structure 1150 by the means 1155 to introduce the consumable 1190 into the apparatus 1100. The aerosol generator 1120 can then be moved toward the support structure 1150 to hold the consumable 1190 in a fixed position relative to the aerosol generator 1120, for example, by clamping the consumable 1190 between the support structure 1150 and the aerosol generator.

[0096] The support structure may again comprise one or more retaining means 1151 configured to hold the aerosol generator 1120 (and consumable 1190) away from a surface 1153 of the support structure. Such a configuration advantageously again provides the benefits discussed above in that a gap between the surface 1153 of the support structure 1150 and the aerosol generator 1120 separates the support structure from the aerosol generator 1120. Additionally, such retaining means 1151 may be configured to ensure that the consumable 1190 conforms to any shape of the aerosol generator 1120 when in use. This can be seen in the example of FIG. 11 , where the aerosol generator 1120 has a curved shape, but the consumable 1190 typically has a flat shape. When the means 1155 for providing relative movement between the aerosol generator 1120 and the support structure 1150 brings the aerosol generator 1120, with the consumable 1190 therebetween, into contact with the holding means 1151, the consumable bends to conform to the shape of the aerosol generator 1120. In this way, the aerosol generator can heat the consumable 1190 more efficiently. To assist in this, one or more surfaces of the holding means 1151 that contact the consumable 1190 may be shaped to substantially correspond to the shape of the aerosol generator.

[0097] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. It is to be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not intended to be limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and that other embodiments may be utilized and changes may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not claimed herein but which may be claimed in the future.

Claims

1. a receiving section for receiving consumables; A support structure comprising: configured to receive an aerosol generator comprising a resilient material, whereby, in use, the aerosol generator biases the support structure to hold the aerosol generator in a fixed position; the support structure configured to hold the aerosol generator against the receiving section; and the support structure comprises: The surface and and at least one means for holding an aerosol generator away from the surface of the support structure. Aerosol delivery device.

2. 10. The aerosol delivery device of claim 1, wherein a plurality of means for holding an aerosol generator are provided, extending from the surface of the support structure, such that at least one gap is defined between the surface of the support structure and the aerosol generator.

3. The aerosol delivery device of claim 2 , further comprising at least one temperature sensor in the gap, and / or at least one connector in the gap, and / or thermal insulation in the gap.

4. 4. The aerosol delivery device of claim 1, wherein at least one means for holding an aerosol generator on the support structure comprises a material different from the surface of the support structure.

5. The aerosol delivery device of any one of claims 1 to 3, wherein the receiving section is substantially flat.

6. The aerosol delivery device of any one of claims 1 to 3, wherein the receiving section and the support structure are generally cylindrical.

7. The aerosol delivery device of claim 6 , wherein the support structure is disposed radially outward of the receiving section.

8. a generally cylindrical receiving section for receiving the consumable; a generally cylindrical support structure radially outward of the receiving section, configured to receive an aerosol generator comprising a resilient material, whereby, in use, the aerosol generator biases the support structure to hold the aerosol generator in a fixed position; the support structure configured to hold the aerosol generator against the receiving section; An aerosol delivery device comprising:

9. An aerosol delivery device described in any one of claims 1 to 3 or 8, wherein the support structure is omega-shaped.

10. 9. The aerosol delivery device of any one of claims 1 to 3 or 8, wherein the support structure comprises a plastic and / or ceramic material.

11. 9. The aerosol delivery device of claim 1, wherein the support structure comprises a first portion and a second portion that are movable relative to each other between a first position and a second position.

12. 12. The aerosol delivery device of claim 11, wherein the first portion and the second portion are coupled about an axis so as to be rotatable relative to one another between the first position and the second position.

13. 9. The aerosol delivery device of claim 1, wherein the support structure includes a reflective material or coating configured to reflect heat toward the receiving section.

14. 9. The aerosol delivery device of claim 1, further comprising an aerosol generator, the aerosol generator configured to provide heat to the receiving section.

15. 15. The aerosol delivery device of claim 14, wherein the aerosol generator is held relative to the support structure by at least one attachment means.

16. 15. The aerosol delivery device of claim 14, further comprising a first wall disposed between the aerosol generator and the receiving section.

17. 15. The aerosol delivery device of claim 14, wherein the support structure comprises at least one connector portion through which the connector can pass so that the connector can be held in a fixed position relative to the support structure and the aerosol generator.

18. 15. The aerosol delivery device of claim 14, wherein the support structure comprises at least one mounting portion through which the aerosol generator extends.

19. the aerosol generator is a first aerosol generator configured to supply heat to a first receiving section; the aerosol delivery device includes a second aerosol generator configured to provide heat to a second receiving section; 15. The aerosol delivery device of claim 14.

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