Induction heating assembly for an aerosol generating device

Abstract

An induction heating assembly (11, 111) for an aerosol-generating device (10) includes a heating chamber (18) for receiving at least a portion of an aerosol-generating substrate (102), an induction coil (58) positioned outside the heating chamber (18) for generating an electromagnetic field, and a holder (36) positioned inside the heating chamber (18). The induction heating assembly (11, 111) further includes an inductively heatable susceptor (48) mounted in the holder (36), the inductively heatable susceptor (48) having an inner surface (48a) and an outer surface (48b), and a temperature sensor (64) mounted to the holder (36) in contact with the outer surface (48b) of the inductively heatable susceptor (48).

Description

[Technical Field]

[0001] The present disclosure relates generally to an induction heating assembly for an aerosol-generating device, and more particularly to an induction heating assembly for heating an aerosol-generating substrate to generate an aerosol that is inhaled by a user of the aerosol-generating device. Embodiments of the present disclosure also relate to an aerosol-generating device that includes an induction heating assembly. The present disclosure is particularly applicable to portable (handheld) aerosol-generating devices. Such devices heat an aerosol-generating substrate, such as tobacco or other suitable material, by conduction, convection, and / or radiation, rather than combustion, to generate an aerosol that is inhaled by a user. [Background technology]

[0002] In recent years, the popularity and use of risk-reducing or risk-modifying devices (also known as aerosol-generating or vapor-generating devices) has grown rapidly as an alternative to the use of traditional tobacco products. A variety of devices and systems are available that heat or warm an aerosol-generating substance to generate an aerosol for inhalation by the user.

[0003] Commonly available risk reduction or risk modification devices are substrate-heated aerosol-generating devices, or so-called heated non-combustion devices. This type of device generates an aerosol or vapor by heating an aerosol-generating substrate, typically to a temperature in the range of 150°C to 300°C. Heating the aerosol-generating substrate to a temperature within this range without burning or combusting the aerosol-generating substrate generates a vapor that typically cools and condenses to form an aerosol that is inhaled by the user of the device.

[0004] Currently available aerosol-generating devices can provide heat to the aerosol-generating substrate using one of many different techniques. One such technique is to provide an aerosol-generating device that employs an induction heating system. In such devices, an induction coil is provided within the device, and an inductively heatable susceptor is provided to heat the aerosol-generating substrate. When a user activates the device, electrical energy is supplied to the induction coil, which in turn generates an alternating electromagnetic field. The susceptor couples with this electromagnetic field to generate heat, which is transferred, for example by conduction, to the aerosol-generating substrate, which heats up and generates an aerosol. Summary of the Invention [Problem to be solved by the invention]

[0005] It is generally desirable to rapidly heat and maintain an aerosol-generating substrate at a temperature high enough to generate vapor. The temperature of the aerosol-generating substrate must be carefully controlled to generate an aerosol with suitable properties, and therefore it is desirable to be able to precisely control the heating temperature. The present disclosure seeks to address this need. [Means for solving the problem]

[0006] According to a first aspect of the present disclosure, there is provided an induction heating assembly for an aerosol generating device, comprising: a heating chamber for receiving at least a portion of the aerosol-generating substrate; an induction coil positioned outside the heating chamber to generate an electromagnetic field; a holder positioned within the heating chamber; an inductively heatable susceptor mounted in a holder, the inductively heatable susceptor having an inner surface and an outer surface; a temperature sensor attached to a holder in contact with the outer surface of the induction heatable susceptor; An induction heating assembly is provided, including:

[0007] According to a second aspect of the present disclosure, there is provided an aerosol generating device comprising: an induction heating assembly according to a first aspect; a power supply arranged to provide power to the induction coil; An aerosol generating device is provided, comprising:

[0008] The induction heating assembly is configured to heat the aerosol-generating substrate without burning the aerosol-generating substrate to volatilize at least one component of the aerosol-generating substrate, thereby generating a heated vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol-generating device. The aerosol-generating device is typically a handheld, portable device.

[0009] Generally speaking, a vapor is a substance that is in the gas phase below its critical temperature, meaning that it can be condensed into a liquid by increasing the pressure without decreasing the temperature, while an aerosol is fine solid particles or liquid droplets suspended in air or another gas. However, it should be noted that the terms "aerosol" and "vapor" can be used interchangeably herein, particularly with respect to the form of inhalable medium generated for inhalation by a user.

[0010] Mounting the temperature sensor in a holder ensures good thermal contact between the temperature sensor and the outer surface of the inductively heatable susceptor, which ensures that the temperature sensor can provide an accurate measurement of the temperature of the inductively heatable susceptor.

[0011] The induction coil may extend around the heating chamber such that, during use of the aerosol generating device, good electromagnetic coupling is achieved between the electromagnetic field generated by the induction coil and the inductively heatable susceptor, thereby ensuring that the inductively heatable susceptor is efficiently heated to the desired temperature.

[0012] The heating chamber may have a longitudinal axis defining a lengthwise direction. The inductively heatable susceptor may be elongated in the longitudinal direction of the heating chamber. The elongated inductively heatable susceptor heats efficiently in the presence of an electromagnetic field, and the elongated shape ensures that the aerosol-generating substrate is heated rapidly and uniformly along its length, thereby maximizing the energy efficiency of the aerosol-generating device.

[0013] The holder can include a proximal end and a distal end, and the temperature sensor can be attached to the holder between the proximal and distal ends, for example, the temperature sensor can be attached to the holder at substantially a midpoint between the proximal and distal ends.

[0014] The holder may include a rim at a proximal end and may include an elongated sensor mounting element extending longitudinally from the rim. The elongated sensor mounting element may have a first end positioned at the rim and a second end distal to the rim. The temperature sensor may be mounted to the second end of the elongated sensor mounting element. The elongated sensor mounting element facilitates mounting of the temperature sensor to the holder. Mounting the temperature sensor to the second end of the elongated sensor mounting element facilitates good contact between the temperature sensor and the outer surface of the inductively heatable susceptor. Manufacturability and ease of assembly of the induction heating assembly are also improved.

[0015] The second end of the elongated sensor mounting element may be biased toward the outer surface of the inductively heatable susceptor, thereby causing the temperature sensor to contact the outer surface of the inductively heatable susceptor. The biasing force may be provided by a material from which the elongated sensor mounting element is formed, such as a resilient plastic material. This ensures good contact between the temperature sensor and the outer surface of the inductively heatable susceptor. This good contact, in turn, ensures that the temperature sensor can provide an accurate measurement of the temperature of the inductively heatable susceptor.

[0016] The temperature sensor may be attached to the elongated sensor mounting element and sandwiched between the elongated sensor mounting element and the outer surface of the inductively heatable susceptor. Thus, the temperature sensor may be attached to the holder and fixed in place relative to the outer surface of the inductively heatable susceptor prior to positioning the holder within the heating chamber. Thus, ease of assembly of the induction heating assembly may be further improved.

[0017] The heating chamber may include a chamber wall that may define an interior volume of the heating chamber. The chamber wall may have an interior surface.

[0018] The temperature sensor may be positioned between and compressed between the inner surface of the chamber wall and the outer surface of the inductively heatable susceptor, such that the inner surface of the chamber wall lightly presses the temperature sensor against the outer surface of the inductively heatable susceptor, ensuring good contact between the temperature sensor and the outer surface of the susceptor, which in turn ensures that the temperature sensor can provide an accurate measurement of the temperature of the inductively heatable susceptor.

[0019] The induction heating assembly may include a plurality of said inductively heatable susceptors, which may be mounted on a holder and extend around the inner surface of the chamber wall. By providing a plurality of inductively heatable susceptors, more rapid and uniform heating of the aerosol-generating substrate may be achieved.

[0020] The chamber wall may include a coil support structure formed in or on the outer surface to support the induction coil. The coil support structure facilitates mounting of the induction coil and allows for optimal positioning of the induction coil relative to the inductively heatable susceptor. This allows for efficient heating of the inductively heatable susceptor, thereby improving the energy efficiency of the induction heating assembly and the aerosol generating device. The provision of the coil support structure also facilitates manufacturing and assembly of the induction heating assembly.

[0021] The coil support structure may include a coil support groove. The coil support groove may extend helically around the outer surface of the chamber wall. The coil support groove is particularly suitable for receiving a helical induction coil. Thus, a helical induction coil may extend around the heating chamber. The induction coil may comprise Litz wire or Litz cable. However, it will be appreciated that other materials may be used. The circular cross section of the helical induction coil may facilitate insertion of the aerosol-generating substrate into the heating chamber and may ensure uniform heating of the inductively heatable susceptor and, therefore, the aerosol-generating substrate.

[0022] The induction coil may be arranged, in use, to operate with a varying electromagnetic field having a magnetic flux density of about 20 mT to about 2.0 T (at its highest density point).

[0023] The heating chamber may be generally tubular, and the or each inductively heatable susceptor may be mounted in a holder such that the or each inductively heatable susceptor extends around the generally tubular heating chamber. The heating chamber may be generally cylindrical, and the or each inductively heatable susceptor may be mounted in a holder such that the or each inductively heatable susceptor extends around the generally cylindrical heating chamber. The heating chamber may therefore be configured to receive a generally cylindrical aerosol-generating substrate, which may be advantageous because aerosol-generating substrates in the form of aerosol-generating articles are often packaged and sold in cylindrical form. The induction heating assembly may include two inductively heatable susceptors. Each of the inductively heatable susceptors may be longitudinally elongated and have a generally semicircular cross-section.

[0024] The heating chamber and / or holder may comprise a substantially electrically non-conductive and non-magnetically permeable material. For example, the heating chamber and / or holder may comprise a heat-resistant plastic material such as polyetheretherketone (PEEK). The heating chamber and / or holder are not heated by the electromagnetic field generated by the induction coil during operation of the aerosol generating device, ensuring that energy input to the inductively heatable susceptor is maximized. This, in turn, helps ensure that the energy efficiency of the induction heating assembly and the aerosol generating device is maximized. The aerosol generating device also remains cool to the touch, ensuring maximum user comfort.

[0025] The temperature sensor may be selected from the group consisting of a thermocouple, a thermistor, and a resistance temperature detector (RTD), although other types of temperature sensors may also be employed.

[0026] The inductively heatable susceptor may comprise a metal. The metal is typically selected from the group consisting of stainless steel and carbon steel. However, the inductively heatable susceptor may comprise any suitable material, including, but not limited to, one or more of aluminum, iron, nickel, stainless steel, carbon steel, and alloys thereof, such as nickel-chromium or nickel. When an electromagnetic field is applied in the vicinity of the susceptor, the inductively heatable susceptor generates heat due to eddy currents and magnetic hysteresis losses, which result in energy conversion from electromagnetic to thermal.

[0027] The aerosol generating device can include a power supply and controller, including, for example, control circuitry, that can be configured to operate at high frequencies. The power supply and circuitry can be configured to operate at frequencies between about 80 kHz and 1 MHz, optionally between about 150 kHz and 250 kHz, and optionally about 200 kHz. Depending on the type of inductively heatable susceptor used, the power supply and circuitry can be configured to operate at higher frequencies, such as in the MHz range.

[0028] The aerosol-generating substrate may comprise any type of solid or semi-solid material. Exemplary types of aerosol-generating solids include powders, granules, pellets, pieces, strands, particles, gels, strips, loose-leaf, cut filler, porous materials, foam materials, or sheets. The aerosol-generating substrate may comprise a plant-derived material, particularly tobacco. Advantageously, the aerosol-generating substrate may comprise, for example, reconstituted tobacco containing tobacco and any one or more of cellulose fiber, tobacco stem fiber, and inorganic fillers such as CaCO3.

[0029] Thus, aerosol-generating devices may be referred to as "heated tobacco devices," "heated-non-combustion tobacco devices," "devices for vaporizing tobacco products," etc., and are to be interpreted as devices suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol-generating substrate.

[0030] The aerosol-generating substrate may form part of the aerosol-generating article and may be surrounded by a paper wrapper.

[0031] The aerosol-generating article may be substantially stick-shaped and generally resemble a cigarette, with a tubular region having an aerosol-generating substrate arranged in a suitable configuration. The aerosol-generating article may include a filter segment, e.g., comprising cellulose acetate fibers, at the proximal end of the aerosol-generating article. The filter segment may constitute a mouthpiece filter and may be coaxially aligned with the aerosol-generating substrate. Some designs may also include one or more vapor-collection regions, cooling regions, and other structures. For example, the aerosol-generating article may include at least one tubular segment upstream of the filter segment. The tubular segment may function as a vapor-cooling region. The vapor-cooling region may advantageously allow heated vapor generated by heating the aerosol-generating substrate to cool and condense, for example, through the filter segment, to form an aerosol with properties suitable for inhalation by a user.

[0032] The aerosol-forming substrate may contain an aerosol-forming agent. Examples of aerosol-forming agents include polyhydric alcohols such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-forming substrate may contain from about 5% to about 50% aerosol-forming agent by dry weight. In some embodiments, the aerosol-forming substrate may contain from about 10% to about 20% aerosol-forming agent by dry weight, and in some cases, about 15% aerosol-forming agent by dry weight.

[0033] Upon heating, the aerosol-forming substrate may release volatile compounds, which may include flavor compounds such as nicotine or tobacco flavorings. [Brief explanation of the drawings]

[0034] [Figure 1] 1 is a schematic cross-sectional view of an aerosol generation system including an aerosol generating device and an aerosol-generating article ready to be positioned within a heating chamber of the aerosol generating device. [Figure 2] 2 is a schematic cross-sectional view of the aerosol generation system of FIG. 1, showing an aerosol-generating article positioned within the heating chamber of the aerosol-generating device. [Figure 3] A cutaway schematic perspective view of a first example of an induction heating assembly of the aerosol generating device of Figures 1 and 2, showing an inductively heatable susceptor and a holder positioned within a heating chamber, together with a temperature sensor attached to the holder. [Figure 4] FIG. 4 is a schematic perspective view of the holder, inductively heatable susceptor, and temperature sensor of FIG. 3 without the heating chamber. [Figure 5] 5 is an exploded view of the holder, inductively heatable susceptor, and temperature sensor of FIG. 4. [Figure 6] FIG. 10 is a schematic perspective view of a second example of a portion of an induction heating assembly showing a holder and a temperature sensor attached to the holder. [Figure 7]7 is a schematic cross-sectional view of a portion of the induction heating assembly of FIG. 6, showing a holder positioned within the heating chamber of the aerosol generating device of FIGS. 1 and 2. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0035] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0036] 1 and 2, an example aerosol generation system 1 is shown schematically. The aerosol generation system 1 includes an aerosol generating device 10 and an aerosol-generating article 100 for use with the device 10. The aerosol generating device 10 includes a body 12 that houses the various components of the aerosol generating device 10. The body 12 can have any shape that is sized to fit the components described in the various embodiments herein and to be comfortably held in one hand by a user without assistance.

[0037] 1 and 2, the first end 14 of the aerosol generating device 10 is conveniently described as the distal end, bottom end, proximal end, or lower end of the aerosol generating device 10. The second end 16 of the aerosol generating device 10 is conveniently described as the proximal end, top end, or upper end of the aerosol generating device 10, shown in the upper part of Figures 1-2. During use, a user typically orients the aerosol generating device 10 with the first end 14 facing downward and / or distal to the user's mouth and the second end 16 facing upward and / or proximal to the user's mouth.

[0038] The aerosol generating device 10 includes an induction heating assembly 11 positioned within a body 12. The induction heating assembly 11 includes a heating chamber 18. The heating chamber 18 defines an interior volume in the form of a cavity 20 having a generally cylindrical cross-section for receiving the aerosol-generating article 100. The heating chamber 18 has a longitudinal axis defining its length and is formed of a heat-resistant plastic material, such as polyetheretherketone (PEEK). The aerosol generating device 10 further includes a power source 22, e.g., one or more batteries, which may be rechargeable, and a controller 24.

[0039] The heating chamber 18 is open toward the second end 16 of the aerosol generating device 10. In other words, the heating chamber 18 has a first end 26 that is open toward the second end 16 of the aerosol generating device 10. The heating chamber 18 is typically spaced apart from the inner surface of the body 12 to minimize heat transfer to the body 12.

[0040] The aerosol generating device 10 may optionally include a sliding cover 28 that is transversely movable between a closed position (see FIG. 1 ) that covers the open first end 26 of the heating chamber 18 to prevent access to the heating chamber 18, and an open position (see FIG. 2 ) that exposes the open first end 26 of the heating chamber 18 to provide access to the heating chamber 18. In some embodiments, the sliding cover 28 may be biased to the closed position.

[0041] The heating chamber 18, specifically the cavity 20, is arranged to receive a correspondingly shaped, generally cylindrical or rod-shaped aerosol-generating article 100. Typically, the aerosol-generating article 100 includes a pre-packaged aerosol-generating substrate 102. The aerosol-generating article 100 is a disposable, replaceable article (also known as a "consumable") that may include, for example, tobacco as the aerosol-generating substrate 102. The aerosol-generating article 100 has a proximal end 104 (or mouth end) and a distal end 106. The aerosol-generating article 100 further includes a mouthpiece segment 108 positioned downstream of the aerosol-generating substrate 102. The aerosol-generating substrate 102 and the mouthpiece segment 108 are coaxially aligned and positioned within a wrapper 110 (e.g., a paper wrapper) that holds the components in place to form the rod-shaped aerosol-generating article 100.

[0042] The mouthpiece segment 108 may include one or more of the following components (not shown in detail), arranged sequentially and coaxially in a downstream direction, i.e., from the distal end 106 toward the proximal (mouth) end 104 of the aerosol-generating article 100: a cooling segment, a central hole segment, and a filter segment. The cooling segment typically includes a hollow paper tube having a thickness greater than that of the wrapper 110. The central hole segment may include a hardened mixture containing cellulose acetate fibers and a plasticizer and functions to increase the strength of the mouthpiece segment 108. The filter segment typically includes cellulose acetate fibers and functions as a mouthpiece filter. As heated vapor flows from the aerosol-generating substrate 102 toward the proximal (mouth) end 104 of the aerosol-generating article 100, the vapor cools and condenses as it passes through the cooling segment and central hole segment, forming an aerosol with suitable properties for a user to inhale through the filter segment.

[0043] The heating chamber 18 has a sidewall (or chamber wall) 30 extending between a base 32 located at a second end 34 of the heating chamber 18 and the open first end 26. The sidewall 30 and the base 32 are connected to one another, and the sidewall 30 and the base 32 may be integrally formed as a single piece. In the illustrated embodiment, the sidewall 30 is tubular, more specifically cylindrical. In other embodiments, the sidewall 30 may have other suitable shapes, such as a tube having an oval or polygonal cross-section. In yet another embodiment, the sidewall 30 may be tapered.

[0044] In the illustrated embodiment, the base 32 of the heating chamber 18 is closed, e.g., sealed or airtight, i.e., the heating chamber 18 is cup-shaped. This ensures that air drawn in through the open first end 26 is prevented by the base 32 from exiting the second end 34, but is instead directed through the aerosol-generating substrate 102.

[0045] 3-5, the induction heating assembly 11 includes a holder 36, which is positioned within the cavity 20 of the heating chamber 18 and is also formed of a heat-resistant plastic material such as polyetheretherketone (PEEK). The holder 36 has a proximal end 38 and a distal end 40 and includes a rim 42 at the proximal end 38 that cooperates with a circumferential lip 44 at the open first end 26 of the heating chamber 18 (best seen in FIG. 3). The holder 36 includes two longitudinally extending susceptor mounts 46 extending from the rim 42 toward the distal end 40 of the holder 36. Two elongated, generally semicircular, inductively heatable susceptors 48 are attached to the holder 36 by the susceptor mounts 46 such that the inductively heatable susceptors 48 together form a tubular susceptor. Each of the inductively heatable susceptors 48 has an inner surface 48a and an outer surface 48b. The inductively heatable susceptor 48, more particularly the inner surface 48a of the inductively heatable susceptor 48, may contact the aerosol-generating substrate 102 to form a friction fit with the aerosol-generating substrate 102, more particularly with the wrapper 110 of the aerosol-generating article 100. In an alternative embodiment, the inductively heatable susceptor 48, more particularly the inner surface 48a, may be spaced apart from the aerosol-generating substrate 102.

[0046] The sidewall 30 of the heating chamber 18 has an inner surface 50 and an outer surface 52, and the inductively heatable susceptor 48 extends around the inner surface 50 of the sidewall 30. The outer surface 48b of the inductively heatable susceptor 48 faces the inner surface 50 of the sidewall 30 but is typically spaced apart from the inner surface 50 of the sidewall 30 so that air can flow between the outer surface 48b of the inductively heatable susceptor 48 and the inner surface 50 of the sidewall 30.

[0047] Induction heating assembly 11 includes an electromagnetic field generator 56 for generating an electromagnetic field. Electromagnetic field generator 56 includes a generally helical induction coil 58. Induction coil 58 has a circular cross section and extends helically around the generally cylindrical heating chamber 18. Induction coil 58 can be energized by power supply 22 and controller 24. Controller 24 includes, among other electronic components, an inverter arranged to convert direct current from power supply 22 to alternating high frequency current for induction coil 58.

[0048] The sidewall 30 of the heating chamber 18 includes a coil support structure 60 formed on the outer surface 52. In the illustrated example, the coil support structure 60 includes a coil support groove 62 that extends spirally around the outer surface 52. The induction coil 58 is positioned within the coil support groove 62, thereby providing a secure and optimal positioning relative to the inductively heatable susceptor 48.

[0049] The induction heating assembly 11 further includes a temperature sensor 64, which may be, for example, a thermocouple, a thermistor, a resistance temperature detector (RTD), or any other suitable temperature sensor. The temperature sensor 64 is operably coupled to the controller 24 by one or more connectors 65.

[0050] The temperature sensor 64 is attached to the holder 36 in contact with the outer surface 48b of one of the inductively heatable susceptors 48, allowing the temperature of the inductively heatable susceptor 48 to be measured by the temperature sensor 64. More specifically, the holder 36 includes a sensor mounting element 66 extending longitudinally from the rim 42 from the proximal end 38 toward the distal end 40. The sensor mounting element 66 has a first end 66a positioned on and integrally formed with the rim 42 and a second end 66b distal to the rim 42. The second end 66b of the sensor mounting element 66 is located substantially midway between the proximal end 38 and the distal end 40 of the holder 36. The temperature sensor 64 is mounted at the second end 66b of the sensor mounting element 66, for example, in the cutout portion, so that the temperature sensor 64 is mounted to the holder 36 substantially midway between the proximal end 38 and the distal end 40. Of course, other mounting positions are possible and will depend on the length of the sensor mounting element 66 in the longitudinal direction.

[0051] In some embodiments, the second end 66b of the sensor mounting element 66 can be biased toward the outer surface 48b of the inductively heatable susceptor 48 so as to contact the outer surface 48b. For example, the sensor mounting element 66 can be formed from a resilient plastic material that is biased toward the outer surface 48b. In the example shown in FIGS. 3-5, the temperature sensor 64 is positioned between the inner surface 50 of the sidewall 30 of the heat chamber 18 and the outer surface 48b of the inductively heatable susceptor 48. Thus, the temperature sensor 64 is clamped in place, as best seen in FIG. 3, and lightly pressed against the outer surface 48b of the inductively heatable susceptor 48 by the inner surface 50 of the sidewall 30 of the heat chamber 18, further ensuring good contact between the temperature sensor 64 and the inductively heatable susceptor 48.

[0052] To use the aerosol-generating device 10, a user displaces the sliding cover 28 (if present) from the closed position shown in Figure 1 to the open position shown in Figure 2. The user then inserts the aerosol-generating article 100 through the open first end 26 into the heating chamber 18, and more specifically, into the holder 36 positioned within the heating chamber 18. The aerosol-generating substrate 102 is received within the cavity 20, and the proximal end 104 of the aerosol-generating article 100 is positioned in the open first end 26 of the heating chamber 18, with at least a portion of the mouthpiece segment 108 protruding from the open first end 26 to allow engagement by the user's lips.

[0053] When a user activates the aerosol-generating device 10, the induction coil 58 is energized by the power supply 22 and controller 24, which supply an alternating current to the induction coil 58, thereby generating an alternating, time-varying electromagnetic field. This electromagnetic field couples with the inductively heatable susceptor 48, generating eddy currents and / or magnetic hysteresis losses within the susceptor 48 and causing the susceptor 48 to heat. Heat is transferred from the inductively heatable susceptor 48 to the aerosol-generating substrate 102 by, for example, conduction, radiation, and convection. This results in heating of the aerosol-generating substrate 102, without combustion or burning, thereby generating vapor. The generated vapor cools and condenses to form an aerosol that can be inhaled by a user of the aerosol-generating device 10 through the mouthpiece segment 108, and more particularly, through the filter segment.

[0054] Vaporization of the aerosol-generating substrate 102 is facilitated by the addition of air from the ambient environment, for example, through the open first end 26 of the heating chamber 18, which is heated as it flows between the outer surface 48b of the inductively heatable susceptor 48 and the inner surface 50 of the sidewall 30. More specifically, when a user draws air through the filter segment, air is drawn into the heating chamber 18 through the open first end 26, as shown by arrow A in FIG. 2, and the air is heated as it flows from the open first end 26 through the heating chamber 18 toward the closed second end 34. Upon reaching the closed second end 34 of the heating chamber 18, the air makes an approximately 180° turn and flows into the distal end 106 of the aerosol-generating article 100. The air, along with the generated vapor, is then drawn through the aerosol-generating article 100 from the distal end 106 toward the proximal (mouth) end 104, as shown by arrow B in FIG. 2.

[0055] The user can continue to inhale the aerosol as long as the aerosol-forming substrate 102 can continue to generate vapor, e.g., as long as there are vaporizable components remaining in the aerosol-forming substrate 102 for vaporization into a suitable vapor. The controller 24 can adjust the magnitude of the alternating current flowing through the induction coil 58 to ensure that the temperature of the inductively heatable susceptor 48, and therefore the temperature of the aerosol-forming substrate 102, does not exceed a threshold level. Specifically, at a certain temperature, depending on the configuration of the aerosol-forming substrate 102, the aerosol-forming substrate 102 will begin to burn. This is not a desired effect, and temperatures above this temperature are avoided.

[0056] To assist in this, the controller 24 is configured to receive an indication of the temperature of the aerosol-generating substrate 102, and more specifically, the temperature of the inductively heatable susceptor 48, from the temperature sensor 64 and use the temperature indication to control the magnitude of the alternating current supplied to the induction coil 58. In one example, the controller 24 may supply a current of a first magnitude to the induction coil 58 for a first period of time to heat the inductively heatable susceptor 48 to a first temperature. The controller 24 may then supply an alternating current of a second magnitude to the induction coil 58 for a second period of time to heat the inductively heatable susceptor 48 to a second temperature. The second temperature may be lower than the first temperature. Thereafter, the controller 24 may supply an alternating current of a third magnitude to the induction coil 58 for a third period of time to heat the inductively heatable susceptor 48 again to the first temperature. This may continue until the aerosol-generating substrate 102 is exhausted (i.e., has already generated all the vapor that it can generate by heating) or until the user stops using the aerosol-generating device 10. In another scenario, once the first temperature is reached, the controller 24 may reduce the magnitude of the alternating current supplied to the induction coil 58 to maintain the aerosol-generating substrate 102 at the first temperature throughout the session.

[0057] A single inhalation by a user is commonly referred to as a "puff." In some scenarios, it is desirable to emulate the experience of smoking a cigarette. This means that the aerosol-generating device 10 is typically capable of holding enough aerosol-generating substrate 102 to provide 10-15 puffs.

[0058] In some embodiments, the controller 24 is configured to count puffs and cut off current to the induction coil 58 after the user has taken 10 to 15 puffs. Counting puffs can be accomplished in a variety of different ways. In some embodiments, the controller 24 determines when the temperature drops during a puff as fresh, cool air flows past the inductively heatable susceptor 48, causing cooling of the susceptor 48, which is detected by the temperature sensor 64. In other embodiments, airflow is detected directly using a flow detector. Other suitable methods will be apparent to those skilled in the art. In other embodiments, the controller 24 additionally or alternatively cuts off current to the induction coil 58 after a predetermined time has elapsed since the first puff. This can serve both to reduce power consumption and to provide a backup for switching off the aerosol generating device 10 if the puff counter fails to properly register that the predetermined number of puffs has been taken.

[0059] In some examples, the controller 24 is configured to supply alternating current to the induction coil 58 to follow a predetermined heating cycle that takes a predetermined amount of time to complete. Once the cycle is complete, the controller 24 shuts off the supply of current to the induction coil 58. In some cases, this cycle may utilize a feedback loop between the controller 24 and the temperature sensor 64. For example, the heating cycle may be parameterized by a series of temperatures to which the inductively heatable susceptor 48 is heated or allowed to cool. The temperatures and durations of such heating cycles may be empirically determined to optimize the temperature of the aerosol-generating substrate 102. This may be necessary, for example, where the outer layer of the aerosol-generating substrate 102 is at a different temperature than the core, because direct measurement of the substrate temperature may be impractical or misleading.

[0060] The power source 22 is at least sufficient to raise the aerosol-generating substrate 102 in a single aerosol-generating article 100 to a first temperature, maintain it at the first temperature, and provide enough vapor for at least 10-15 puffs. More generally, in keeping with emulating the experience of smoking, the power source 22 will typically be sufficient to repeat this cycle (raising the aerosol-generating substrate 102 to a first temperature and maintaining the first temperature and vapor generation for 10-15 puffs) 10 or even 20 times, thereby emulating the user experience of smoking a packet of cigarettes before the power source 22 needs to be replaced or recharged.

[0061] In general, the efficiency of the aerosol-generating device 10 is improved if as much of the heat generated by the inductively heatable susceptor 48 as possible results in heating of the aerosol-generating substrate 102. To this end, the aerosol-generating device 10 is typically configured to provide heat in a controlled manner to the aerosol-generating substrate 102 while reducing heat flow to other parts of the aerosol-generating device 10. In particular, heat flow to parts of the aerosol-generating device 10 that are handled by the user is kept to a minimum, thereby keeping these parts cool and comfortable to hold.

[0062] 6 and 7, there is shown a second example of a portion of an induction heating assembly 111. The induction heating assembly 111 is similar to the induction heating assembly 11 described above with reference to Figures 3-5, and corresponding components are identified using the same reference numerals.

[0063] Within the induction heating assembly 111, the temperature sensor 64 is attached to a second end 66b of the sensor mounting element 66 such that the temperature sensor 64 is positioned between the sensor mounting element 66 and the outer surface 48b of the inductively heatable susceptor 48. The sensor mounting element 66 clamps the temperature sensor 64 in place against the outer surface 48b of the inductively heatable susceptor 48 (as best seen in FIG. 7 ), further ensuring good contact between the temperature sensor 64 and the inductively heatable susceptor 48.

[0064] While exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications to these embodiments can be made without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

[0065] Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

[0066] Unless the context clearly dictates otherwise, throughout this specification and the claims, the words "comprise," "comprising," and the like are to be construed in an inclusive sense, i.e., "including but not limited to," as opposed to an exclusive or exhaustive sense.

Claims

1. An induction heating assembly (11, 111) for an aerosol generating device (10), comprising: a heating chamber (18) for receiving at least a portion of the aerosol-generating substrate (102); an induction coil (58) positioned outside the heating chamber (18) for generating an electromagnetic field; a holder (36) positioned within the heating chamber (18); an inductively heatable susceptor (48) mounted in the holder (36), the inductively heatable susceptor (48) having an inner surface (48a) and an outer surface (48b); a temperature sensor (64) attached to the holder (36) in contact with the outer surface (48b) of the inductively heatable susceptor (48); An induction heating assembly (11, 111) comprising:

2. The induction heating assembly of claim 1, wherein the induction coil (58) extends around the heating chamber (18).

3. 3. The induction heating assembly of claim 1, wherein the heating chamber (18) has a longitudinal axis defining a length, and the inductively heatable susceptor (48) is elongated in the length direction of the heating chamber (18).

4. 4. The induction heating assembly of claim 1, wherein the holder includes a proximal end and a distal end, and the temperature sensor is attached to the holder between the proximal end and the distal end.

5. The holder (36) a rim (42) at said proximal end (38); an elongated sensor mounting element (66) extending in the longitudinal direction from the rim (42), the elongated sensor mounting element (66) having a first end (66a) positioned at the rim (42) and a second end (66b) distal to the rim (42); Including, The temperature sensor (64) is mounted to the second end (66b) of the elongated sensor mounting element (66).

5. An induction heating assembly according to claim 4, which is dependent on claim 3.

6. 6. The induction heating assembly of claim 5, wherein the second end (66b) of the elongated sensor mounting element (66) is biased toward the outer surface (48b) of the inductively heatable susceptor (48) so as to bring the temperature sensor (64) into contact with the outer surface (48b) of the inductively heatable susceptor (48).

7. 7. The induction heating assembly of claim 5, wherein the temperature sensor is mounted to the elongated sensor mounting element such that the temperature sensor is sandwiched between the elongated sensor mounting element and the outer surface of the inductively heatable susceptor.

8. 8. The induction heating assembly of claim 1, wherein the heating chamber (18) includes a chamber wall (30) defining an interior volume of the heating chamber, the chamber wall (30) having an inner surface (50).

9. 9. The induction heating assembly of claim 8, wherein the temperature sensor is positioned between the inner surface of the chamber wall and the outer surface of the inductively heatable susceptor.

10. 10. The induction heating assembly of claim 8 or 9, wherein the induction heating assembly includes a plurality of the inductively heatable susceptors (48) mounted to the holder (36) and extending around the inner surface (50) of the chamber wall (30).

11. 11. The induction heating assembly of claim 8, wherein the chamber wall includes a coil support structure formed in or on an outer surface for supporting the induction coil.

12. The induction heating assembly of claim 11, wherein the coil support structure (60) includes a coil support groove (62).

13. 13. The induction heating assembly of claim 10, wherein the heating chamber is generally tubular, and the inductively heatable susceptor is mounted in the holder such that the inductively heatable susceptor extends around the generally tubular heating chamber.

14. An induction heating assembly according to any preceding claim, wherein one or both of the heating chamber (18) and the holder (36) comprise a substantially electrically non-conductive and non-magnetically permeable material.

15. An induction heating assembly (11, 111) according to any one of claims 1 to 14, a power source (22) arranged to provide power to the induction coil (58); An aerosol generating device (10) comprising:

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