Aerosol providing device

Abstract

An aerosol providing device is described. One such device comprises a heater assembly. The heater assembly has a heating chamber arranged to accommodate at least a portion of an article containing an aerosol generating material, and a heating element configured to heat the portion of the article accommodated in the heating chamber. A base is provided at one end of the heating chamber. A spacer is also provided to space the article from the base when at least a portion of the article is accommodated in the heating chamber.

Description

Technology Field

[0001] The present invention relates to an aerosol providing device, a heating assembly for receiving at least a portion of an article comprising an aerosolizable material, and an aerosol providing system comprising an article comprising an aerosol generating material and an aerosol providing device. Background Technology

[0002] Smoking products, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these burning products by creating products that release compounds without burning. Examples of such products are heating devices that release compounds by heating materials rather than burning them. The materials can be, for example, tobacco or other non-tobacco products that may or may not contain nicotine.

[0003] According to an embodiment of the present disclosure, an aerosol providing device is provided, wherein the aerosol providing device comprises: a heating chamber arranged to accommodate at least a portion of an article comprising an aerosol generating material; a heater assembly having a heating element configured to heat the portion of the article accommodated in the heating chamber; a base at one end of the heating chamber; and a spacer configured to space the article from the base when at least a portion of the article is accommodated in the heating chamber.

[0004] The spacer may include a protrusion that protrudes into the heating chamber. The protrusion may be one of a plurality of protrusions.

[0005] Multiple protrusions may be distributed around the heating chamber. A protrusion or each protrusion may include a tab. A protrusion or each protrusion may extend from the base. A protrusion or each protrusion may be spaced apart from the base.

[0006] The spacer may include a step. The spacer may form a shoulder in the heating chamber.

[0007] The heating element can stand upright from the base. The heating element can protrude from the heating chamber. The heating element can be a blade.

[0008] The aerosol delivery device may include a receptacle defining a heating chamber. A base may form a part of the receptacle.

[0009] The aerosol delivery device may include a device housing, wherein the receptacle can be removed from the device housing.

[0010] The receptacle can be fixedly mounted to the device housing.

[0011] The receptacle may include a wall erected from the base to define the heating chamber. The wall may be tubular.

[0012] The receptacle can define an air passage to provide air flow to the heating chamber.

[0013] The air passage may include an air outlet into the heating chamber. The air outlet may be specified in the base.

[0014] The air outlet may be asymmetric with respect to the axis of the heating chamber.

[0015] The air outlet can be offset from the axis of the heating chamber.

[0016] The air passage may include an air outlet into the heating chamber. The air outlet may be positioned at least partially between the article locating surface of the base and the spacer.

[0017] The air outlet can be arranged to introduce air flow into the heating chamber radially with respect to the longitudinal axis of the receptacle.

[0018] The air outlet can be arranged to introduce air flow into the heating chamber in a coaxial direction with respect to the longitudinal axis of the receptacle.

[0019] The wall may include an outer wall and an inner wall, where an air passage is formed between the outer wall and the inner wall.

[0020] The base and the outer wall can be formed as a single unit. The base and the outer wall can form a cup. The cup can form a fluid barrier.

[0021] The air passage can be a closed channel.

[0022] The heating element may include a susceptor that can be heated by penetration by a changing magnetic field.

[0023] The heater assembly may include an inductor coil extending around a susceptor, wherein the inductor coil is configured to generate a changing magnetic field.

[0024] The heating element can surround the heating chamber.

[0025] The heating element can define the part of the receptacle.

[0026] The aerosol delivery device may include an opening at the proximal end of the heating chamber, where the base may be at the distal end of the heating chamber, and where the heating chamber may have a substantially uniform cross-section along the length of the receptacle.

[0027] The base may include a well configured to collect liquid collected in a heating chamber.

[0028] According to an embodiment, a heating assembly is provided, the heating assembly comprising: a receptacle for receiving at least a portion of an article comprising an aerosolizable material, the receptacle comprising: a base; a heating element extending from the base; and a projection for contacting the portion of the article when the portion of the article is received in a heating chamber, such that the article is maintained at a distance above the base.

[0029] According to an embodiment, an insert for an aerosol delivery device is provided, the insert comprises: a receptacle arranged to be at least partially removablely received in a device housing, the receptacle defines a heating chamber arranged to receive at least a portion of an article comprising an aerosol generating material, the receptacle comprises: a base at one end of the heating chamber; and a spacer configured to separate the article from the base when at least a portion of the article is received in the heating chamber, the insert comprises a heating element configured to heat the portion of the article received in the heating chamber.

[0030] According to an embodiment, an aerosol providing device is provided, and the aerosol providing device comprises: a heating chamber arranged to accommodate at least a portion of an article comprising an aerosol generating material; a heating assembly having a heating element configured to heat the portion of the article accommodated in the heating chamber; a wall defining at least a portion of the heating chamber; and a cavity formed in the wall.

[0031] The aerosol delivery device may include a base at one end of a heating chamber, wherein the wall includes the base and the cavity is in the base.

[0032] The aerosol delivery device may include a peripheral wall defining a heating chamber, wherein the wall includes a peripheral wall and the cavity is in the peripheral wall.

[0033] The cavity may be one of a plurality of cavities formed in the wall. The cavity or each cavity may be distributed around the heating element.

[0034] An aerosol delivery device may include a device housing and a receptacle arranged to be at least partially removablely received in the device housing, wherein the removable receptacle forms a heating chamber.

[0035] The receptacle can include a wall.

[0036] The aerosol delivery device may include a spacer configured to separate the article from the cavity when at least a portion of the article is received in the heating chamber.

[0037] According to an embodiment, an insert for an aerosol delivery device is provided, the insert comprising: a receptacle arranged to be at least partially removablely received in a device housing, the receptacle defining a heating chamber arranged to receive at least a portion of an article comprising an aerosol generating material, the receptacle comprising: a wall defining at least a portion of the heating chamber; and a cavity formed in the wall, the insert comprising: a heating element configured to heat a portion of the article received in the heating chamber.

[0038] The heating element can be fluid-sealed with a receptacle.

[0039] According to an embodiment, a heating assembly is provided, the heating assembly comprises: a heating chamber for receiving at least a portion of an article comprising an aerosolizable material; and a heating element, wherein the heating chamber has a base and a recess in the base for collecting fluid discharged from the article received in the heating chamber.

[0040] According to an embodiment, an aerosol delivery system is provided, the aerosol delivery system comprises: an aerosol delivery device, a heating assembly or insert as described above, and an article comprising an aerosol generating material, wherein the article is dimensioned to be at least partially accommodated within a heating assembly.

[0041] According to an embodiment, an aerosol providing device is provided, and the aerosol providing device comprises: a heating chamber arranged to accommodate at least a portion of an article comprising an aerosol generating material; a heating assembly having a heating element configured to heat the portion of the article accommodated in the heating chamber; and a base at one end of the heating chamber.

[0042] The device may be a tobacco heating device also known as a heat-not-burn device.

[0043] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, provided only as examples, with reference to the accompanying drawings. Brief explanation of the drawing

[0044] Figure 1 shows a perspective view of an example of an aerosol delivery device. Figure 2 shows a front cross-sectional view of the aerosol providing device of Figure 1. Figure 3 shows an enlarged front cross-sectional view of the part of Figure 2. FIG. 4a shows a perspective view of a heater assembly separated from the rest of the device. Figure 4b shows a cross-sectional view of the heater assembly of Figure 4a. Figure 5 shows an enlarged side cross-sectional view of a part of the heater assembly of Figure 4a. Figure 6 is an exploded perspective cross-sectional view of the receptacle of the heater assembly. Figure 7 shows an enlarged front cross-sectional view of a part of another heater assembly. FIG. 8 shows an enlarged front cross-sectional view of a part of another heater assembly with a consumable inserted into the heating chamber of the heater assembly. Specific details for implementing the invention

[0045] As used herein, the term “aerosol-generating material” includes materials that provide components that volatilize upon heating, typically in the form of an aerosol. The aerosol-generating material comprises any tobacco-containing material and may include, for example, one or more of tobacco, tobacco derivatives, puffed tobacco, reconstituted tobacco, or tobacco substitutes. The aerosol-generating material may also include other non-tobacco products that may or may not contain nicotine, depending on the product. The aerosol-generating material may be in the form of, for example, a solid, liquid, gel, wax, etc. The aerosol-generating material may also be, for example, a combination or blend of materials. The aerosol-generating material is also known as a “smoking-capable material.”

[0046] A device is known for heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material and forming an inhalable aerosol without typically burning or combusting the aerosol-generating material. Such a device is sometimes described as an "aerosol-generating device," an "aerosol-giving device," a "non-combustion heating device," a "tobacco heating product device," or a "tobacco heating device," or similar. Likewise, there are also so-called e-cigarette devices that vaporize an aerosol-generating material in liquid form that may or may not contain nicotine. The aerosol-generating material may be in the form of a rod, cartridge, or cassette that can be inserted into the device, or may be provided as a part thereof.

[0047] An aerosol delivery device may accommodate an article comprising an aerosol generating material for heating. In this context, "article" is a component that contains or accommodates, at use, an aerosol generating material that is heated to volatilize the aerosol generating material, and optionally, other components at use. A user may insert the article into the aerosol delivery device before it is heated to generate an aerosol that the user subsequently inhales. For example, the article may be of a predetermined or specific size configured to be placed within a heating chamber of a device of a size capable of accommodating the article.

[0048] FIG. 1 illustrates an example of an aerosol providing device (100) for generating an aerosol from an aerosol generating medium / material. Schematically, the device (100) may be used to heat a replaceable article (110), also known as a consumable, containing an aerosol generating medium to generate an aerosol or other inhalable medium that is inhaled by a user of the device (100).

[0049] The device (100) includes a housing (102) (including an outer cover (108)) that surrounds and accommodates various components of the device (100). The device (100) has an opening (104) at one end into which an article (110) can be inserted for heating by a heater assembly (200) (see FIG. 2). In use, the article (110) can be inserted completely or partially into the heater assembly (200), whereby it can be heated by one or more components of the heater assembly (200).

[0050] The device (100) may also include a user-operable control element (112), such as a button or switch, that operates the device (100) when pressurized. For example, the user can turn on the device (100) by operating the switch (112).

[0051] The device (100) defines the longitudinal axis (101).

[0052] FIG. 2 depicts a schematic front cross-sectional view of the device (100) of FIG. 1. The device (100) includes an outer cover (108), a first end member (106), and a second end member (116). The device (100) includes an aerosol generating assembly (111) comprising a chassis (109), a power source (118), and a heater assembly (200). The device (100) further includes at least one electronic module (122).

[0053] The outer cover (108) forms a part of the device shell. A first end member (106) is arranged at one end of the device (100), and a second end member (116) is arranged at the opposite end of the device (100). The first and second end members (106, 116) close the outer cover (108). The first and second end members (106, 116) form a part of the housing. In embodiments, the device (100) includes a lid (not shown) movable with respect to the first end member (106) to close the opening (104) when the article (110) is not in place.

[0054] The device (100) may also include electrical components such as a connector / port (120) capable of receiving a cable for charging the battery of the device (100). For example, the connector may be a charging port such as a USB charging port. In some examples, the connector may be used additionally or alternatively to transfer data between the device (100) and another device, such as a computing device.

[0055] The device (100) includes a chassis (109). The chassis (109) is housed by an outer cover (108). An aerosol generating assembly (111) includes a heater assembly (200), and in use, an article (110) may be inserted completely or partially into this heater assembly, whereby it may be heated by one or more components of the heater assembly (200). The aerosol generating assembly (111) and a power source (118) are mounted on the chassis (109). The chassis (109) is a one-piece component.

[0056] A one-piece component refers to a component of the device (100) that cannot be separated into two or more components after the assembly of the device (100). Being formed integrally relates to two or more features formed as a one-piece component during the manufacturing stage of the component.

[0057] The first and second end members (106, 116) together define at least partially the end surfaces of the device (100). For example, the lowest surface of the second end member (116) defines at least partially the lowest surface of the device (100). The edges of the outer cover (108) may also define part of the end surfaces. The first and second end members (116) close the open ends of the outer cover (108). The second end member (116) is located at one end of the chassis (109).

[0058] The end of the device (100) closest to the opening (104) may be known as the proximal end (or mouth end) of the device (100) because it is closest to the user's mouth during use. During use, the user inserts the item (110) into the opening (104) and operates the user control device (112) to begin heating the aerosol generating material and inhale the aerosol generated from the device. This causes the aerosol to flow through the device (100) along a flow path toward the proximal end of the device (100).

[0059] The other end of the device furthest from the opening (104) may be known as the distal end of the device (100), as it is the end furthest from the user's mouth during use. When the user inhales the aerosol generated from the device, the aerosol flows toward the proximal end of the device (100). The terms proximal and distal, as applied to the features of the device (100), will be described by referring to the relative positioning of these features relative to each other in the proximal-distal direction along the axis (101).

[0060] The power source (118) is a battery, for example, a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (e.g., a lithium-ion battery), a nickel battery (e.g., a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the aerosol generating assembly (111) and is under the control of a controller (121) to supply electric power when needed and to heat the aerosol generating material.

[0061] The power source (118) and the aerosol generating assembly (111) are arranged in an axial arrangement where the power source (118) is at the distal end of the device (100) and the aerosol generating assembly (111) is at the proximal end of the device (100). Other configurations are expected.

[0062] The electronic module (122) may include, for example, a printed circuit board (PCB) (123). The PCB (123) may support at least one controller (121), such as a processor, and memory. The PCB (123) may also include one or more electrical tracks for electrically connecting various electronic components of the device (100) together. For example, battery terminals (119a, 119b) may be electrically connected to the PCB (123) so that power can be distributed throughout the device (100). The connector (120) may also be electrically coupled to the battery (118) through the electrical tracks.

[0063] The aerosol generating assembly (111) is an induction heating assembly and includes various components for heating the aerosol generating material of the article (110) through an induction heating process. Induction heating is a process of heating an electrically conductive object (e.g., a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element, e.g., one or more inductor coils, and a device for passing a varying electric current, such as alternating current, through the induction element. The varying electric current of the induction element generates a varying magnetic field. The varying magnetic field penetrates the susceptor properly positioned with respect to the induction element and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and thus the flow of eddy currents against this resistance causes the susceptor to be heated by Joule heating. If the susceptor contains ferromagnetic materials such as iron, nickel, or cobalt, heat may be generated by the magnetic hysteresis losses of the susceptor—that is, by the changing orientation of magnetic dipoles in the magnetic material as a result of alignment with a changing magnetic field. During induction heating, compared to heating by conduction, for example, heat is generated within the susceptor, enabling rapid heating. Furthermore, since no physical contact is required between the induction heater and the susceptor, it allows for enhanced freedom in configuration and application.

[0064] A temperature sensor in the form of a thermocouple (150) is thermally connected to a susceptor and connected to an electronic module (122). In the described embodiment, a thermally conductive plate (140) is placed between the thermocouple (150) and the susceptor to facilitate thermal communication between the thermocouple (150) and the susceptor. In other examples, the plate (140) may be omitted.

[0065] The thermocouple (150) monitors the temperature of the susceptor while the device (100) is in use and supplies this information to the electronic module (122). This allows the electronic module (122) and the controller (121) to monitor and adjust the temperature of the susceptor as may be required during the use of the device (100), for example, by adjusting the amount of electric power supplied by the power source (118). The thermocouple (150) can be any suitable thermocouple, such as a platinum rhodium thermocouple (i.e., type B).

[0066] Compared to other devices for detecting temperature, the thermocouple (150) can facilitate more powerful, durable, power-efficient, and accurate temperature measurements. Nevertheless, in other examples within the scope of the present disclosure, the temperature sensor may be any other suitable temperature sensor, such as a resistance temperature detector, a thermistor, an infrared sensor, etc.

[0067] FIG. 3 shows an enlarged cross-sectional view of a part of an aerosol generating assembly (111) including a heater assembly (200) and an inductor coil assembly (127).

[0068] The aerosol generating assembly (111) includes an inductor coil assembly (127) and a heater assembly (200). The inductor coil assembly (127) extends around the heater assembly (200). The inductor coil assembly (127) includes a coil support (126). The inductor coil assembly (127) includes an inductor coil (124) that wraps around (i.e., surrounds) the heater assembly (200). The inductor coil (124) is placed in a groove (128) defined in the support (126). The groove (128) is helical. The groove (128) may be omitted, and the coil (124) may wrap around the outer surface of the coil support (126). The inductor coil assembly (127) is fixedly mounted in the device housing (102). The coil support (126) can form a part of the device housing (102).

[0069] The heating assembly (200) includes a heating element (210) for heating an article (110) during use. In the exemplary embodiment of FIG. 3, the heating element is a susceptor array (210) (hereinafter referred to as "susceptor"). The susceptor (210) of this example is a blade-shaped susceptor (210). An article (110) may be inserted on or around the susceptor (210). The blade-shaped susceptor (210) may have a constant rectangular cross-section along most of its axial length and then taper to a blade tip (212) at the free end. In other examples, the axial cross-section may vary along the axial length of the susceptor (210) to the blade tip (212).

[0070] Although a blade-shaped susceptor (210) is described, it should be understood that any other suitable shape or form of susceptor (210) may be used within the scope of this disclosure. For example, the susceptor (210) may be a pin shape having a constant circular cross-section along an axial length that tapers to a pin tip, for example, or a rod shape having a constant or varying cross-section along an axial length that omits the tip or tapered portion (e.g., a cylindrical rod or a square rod). In additional examples, the susceptor (210) may instead be a tubular member in which an article (110) / aerosol-generating material is contained. Such a susceptor is an external susceptor. In such an example, the susceptor may define a peripheral wall (e.g., an annular wall) that defines at least a part of a heating chamber in which the article (110) is contained and heated. In this example, instead of the article (110) surrounding the susceptor as in the blade-shaped embodiment discussed above, the susceptor surrounds the article (110). It will be understood that the cross-sectional profile of the external susceptor can be formed in various profile shapes.

[0071] In additional examples, multiple susceptors (e.g., two or more individual susceptors) may also be provided, and, as needed, may be different or similar configurations (e.g., pin shape, blade shape, rod shape, or tubular type, etc.).

[0072] The susceptor (210) is formed of an electrically conductive material suitable for heating by electromagnetic induction. In this example, the susceptor is formed of carbon steel. It will be understood that other suitable materials, such as ferromagnetic materials like iron, nickel, or cobalt, may be used.

[0073] In other embodiments, the feature acting as a heating element may not be limited to being inductively heated. Thus, the feature acting as a heating element may be heated by electrical resistance. Accordingly, the heater assembly (200) may include electrical contacts for electrical connection with a device for electrically activating the heating element by passing a flow of electrical energy through the heating element. In these embodiments, the induction coil assembly (127) may be omitted where appropriate.

[0074] The inductor coil (124) is manufactured from an electrically conductive material. In this example, the inductor coil (124) is manufactured from a helical Litz wire / cable wound to provide a helical inductor coil (124). The Litz wire comprises a plurality of individual wires that are individually insulated and twisted together to form a single wire. The Litz wires are designed to reduce the skin effect losses of the conductor. In an exemplary device (100), the inductor coil (124) is manufactured from a copper Litz wire having a circular cross-section. In other examples, the Litz wire may have cross-sections of other shapes, such as a rectangle. The inductor coil (124) is connected to a PCB (123) so that the activation of induction heating from it can be controlled using an electronic module (122) and a switch (112).

[0075] The number of inductor coils used may also vary. For example, it should be understood that while the aerosol generating assembly (111) illustrated in FIG. 3 includes an inductor coil assembly (127) having only a single coil (124), the inductor coil assembly (127) may feature any number of suitable coils. Additional coils may be used to provide different heating zones having different heating characteristics for the susceptor (210) (e.g., to provide different heating conditions in different regions along the axial length of the susceptor (210) and / or to provide different heating conditions to the susceptor (210) for different times or for different uses). Additional coils may also be provided to generate heating in additional susceptors that may be placed in the aerosol generating assembly (111) (not illustrated).

[0076] The heater assembly (200) includes a receptacle (230) (shown in more detail in FIG. 4a and FIG. 4b). The receptacle (230) defines a heating chamber (220) in which an article (110) is received during use. In the described embodiment, the receptacle (230) is an annular body that surrounds the susceptor (210) and provides an annular space between the receptacle and the susceptor (210) in which an article (110) is received and can be heated during use.

[0077] The coil support (126) and the opening (104) define a device chamber (105) within a device housing (102) that accommodates a receptacle (230). The receptacle (230) interacts with the device housing (102) to secure the heater assembly (200) in place. The coil support (126) forms a part of the device housing (102). In embodiments, the device chamber (105) is defined by a feature other than the coil support (126). The coil support (105) forms an inner wall. The inner wall is cup-shaped.

[0078] The receptacle (230) is disposed removablely within the chamber (105) so that it can be removed from it and replaced internally during use. This feature not only facilitates cleaning of the receptacle (230) (and its other heater assembly components) but also facilitates replacement of the receptacle (230) (and its other heater assembly components) in the event of breakage or failure.

[0079] In the described example, the receptacle (230) is placed entirely inside the chamber (105). In other examples, when the receptacle (230) is received in the chamber (105), a portion of the receptacle (230) (such as a flange or lip at its proximal end) may still extend outside the device chamber (105). In these examples, the receptacle (230) may therefore be 'partially removablely placed' in the chamber (105). The present disclosure covers all such examples.

[0080] FIGS. 4a and 4b illustrate a heater assembly (200) in more detail. The heater assembly (200) forms an insert. In this arrangement, the insert includes a receptacle (230) and a heating element (210). In embodiments, the insert includes a receptacle (230). The receptacle (230) includes a base (233) and a wall (231). The wall arrangement is erected from the base (233). An opening (239) is defined at the proximal end (233a) of the receptacle (230). The base (233) is formed at the distal end (233b). The wall (231) includes outer and inner walls (231a, 231b). The outer and inner walls (231a, 231b) are concentric with respect to the longitudinal axis (201) of the heater assembly (200). The outer wall (231a) forms the outer shell. The inner wall (231b) forms the inner shell. As shown in FIGS. 2 and 3, when the heater assembly (200) is inserted into the device housing chamber (205), the longitudinal axis (201) of the heater assembly (200) is substantially coaxial with the longitudinal axis (101) of the device (101).

[0081] The outer wall (231a) extends axially from the opening end (233a) to the opposing base end (233b) of the receptacle (230). The outer wall (231a) defines the base (233) itself and may be formed integrally with it. Alternatively, the base (233) may be attached separately to the outer wall (231a). The outer wall (231a) and the base (233) form a cup. The cup forms a fluid barrier. The opening end (233a) is so called because it is the end of the heater assembly (200) that is seated in the opening (104) of the device (100) when the receptacle is inserted into the device housing chamber (105). Accordingly, as discussed above with respect to the device (100), the opening end (233a) may also be referred to as the proximal end (or inlet end) of the heater assembly (200), while the base end (233b) may be referred to as the distal end of the heater assembly (200).

[0082] The base (233) defines a hole (238) within which a heating element (210) is received and which protrudes (axially) from it. The heating element (210) defines a heating element base (214) that forms an anchoring flange (216). The heating element base (214) may be pressed into the hole (238). However, any other suitable method of securing the heating element (210) in place within the receptacle (230) may be used, for example, welding, insert molding, interference fit, screw mounting, etc. The heating element (210) forms a fluid seal with the receptacle (230). The seal may be positioned to form a fluid seal between the heating element (210) and the receptacle (230). In the embodiments, the hole (238) may instead be a blind cavity / recess, or may be completely omitted depending on the fixing method used to attach the heating element (210) to its proper position within the receptacle (230).

[0083] In the described embodiment, the heating element (210) is a part of the receptacle (230) itself and is fixedly attached to the receptacle (230) so as to be supported by it. In this way, the heating element (210) can be removed from the device housing chamber (105) integrally with the receptacle (230) and as a part of the receptacle (230).

[0084] In alternative embodiments, the heating element (210) may be fixedly attached to the device housing (102) within the device housing chamber (105) instead of the receptacle (230). In this way, the receptacle (230) is removed from the device housing chamber (105), but the heating element (210) will remain fixed in place within the device housing chamber (105).

[0085] In any of the above alternatives, the heating element (210) may additionally be removed separately from the device housing (102) and / or the receptacle (230) itself. For example, the heating element (210) may be secured so as to be removable instead of being fixedly attached to either the receptacle (230) or the device housing (102) / chamber (105). For example, this may be done by being screwed inside, by being received by bayonet mounting inside, or by using connectors on the heating element (210) that can be forced-fitted and separated from corresponding connectors on the device housing (102) / chamber (105).

[0086] This can facilitate the cleaning and / or replacement of the heating element (210). This improvement in the replacement of the heating element (210) may be useful when the heating element (210) is damaged or fails and needs to be replaced, but it may also be useful for exchanging different heating elements (210) for different uses. For example, this is the case where a specific use or article (110) may require a heating element (210) of a different shape / type.

[0087] The inner wall (231b) is spaced apart from the outer wall (231a). An air path (250) is defined along the receptacle (230) from the opening end (233a) to the base end (233b). The air path extends axially. The air path has an air inlet (251) at the proximal end (233a). The air path (250) has an air outlet (252) at the distal end (233b).

[0088] The inner wall (231b) extends axially from the proximal end (233a) toward the base end (233b). The inner wall (231b) is spaced apart from the base (233). The inner wall (231b) stops axially in front of the base (233) to form an axial gap (G) between the inner wall (231b) and the base (233). In the described example, the axial gap (G) provides an annular gap around the heating element (210) between the base (233) and the inner wall (231b). The gap between the inner wall (231b) and the base (233) defines an air outlet (251). In embodiments, the inner wall (231b) extends to the base (233), and holes and / or cutouts are formed at the base end of the inner wall (231b) to define the air outlet (251), which will be described below.

[0089] The inner wall (231b) features a tapered surface (235) at the proximal end (233a). The tapered surface (235) tapers at an angle toward the longitudinal axis (201) from the proximal end (231b). The tapered surface (235) can help facilitate inserting the article (110) into the heater assembly (200) and the heating chamber (220). For example, it can facilitate the accurate alignment of the article (110) when it is inserted into the heating chamber (220) around the heating element (210).

[0090] The outer wall (231a) and the inner wall (231b) are spaced apart radially. The outer and inner walls (231a, 23b) are connected by ribs (236) that extend radially. The ribs (236) secure the inner wall (231b) in place within the outer wall (231a). A discrete number of ribs (236) exist between the outer wall (231a) and the inner wall (231b) around the perimeter of the walls (231a, 231b). In the illustrated example, there are four such ribs (236) spaced equally apart around the perimeter of the walls (231a, 231b). However, any suitable number and spacing of the ribs (236) may be used.

[0091] In the described embodiment, the ribs (236) extend axially for the length of the inner wall (231b). However, the ribs (236) may extend for any suitable axial distance between the walls (231a, 231b) sufficient to provide the support necessary to keep the walls (231a, 231b) concentrically in place relative to each other.

[0092] The combination of the outer wall (231a), the inner wall (231b), and the ribs (236) defines slots (234) at the proximal end (233a) and forms a passage (237) extending axially within the receptacle (230). The passages (237) define an air passage (250). The slots (234) define an air inlet (251).

[0093] The number and size of the slots (234) and passages (237) may be changed as needed depending on the size, spacing, and number of the ribs (236). Additionally, the slots (234) and passages (237) do not need to be specified at the proximal end (233a). For example, the ribs (236) may be located at any suitable axial location within the receptacle (230), for example, closer to the base (231b) or midway along the axial length of the walls (231a, 231b). Additionally, the slots (234) and passages (237) may instead provide a single (e.g., substantially annular) slot (234) / passage (237) extending axially between the inner wall (231a) and the outer wall (231b).

[0094] In the described embodiment, the passages (237) are used as air flow passages that allow communication of air flow from the outside of the device (100) to the heating chamber (220) and the aerosol generating materials inside during use. The inlet of air flow through the slots (234) and passages (237) from the proximal end (233a) is convenient because there is no possibility of blocking air flow to these areas when the user uses the device (100).

[0095] The passages (237) extend into an annular space provided by a gap (G) that allows air flow to be transferred from the passages (237) into the heating chamber (220) and through the aerosol generating material / article (110) contained therein during use.

[0096] The existence of passages (237) between the inner and outer walls (231a, 231b) may allow for resistance to airflow through the passages (237) and improved control of airflow. For example, this may allow for the use of airflow modification features (e.g., airflow compressors) placed in the passages (237) (e.g., between the walls (231a, 231b) and / or extending from the ribs (236)) to provide more consistent airflow and / or desirable airflow resistance to be delivered through the article (110) and to the user in use.

[0097] However, it should be understood that the present disclosure is not limited to the passages (237) being air flow passages. For example, the device (100) and / or the heater assembly (200) may provide any suitable alternative or additional arrangement of air flow passages to supply the air flow necessary for the use of the device (100). For example, the air flow passage(s) may be provided on the side of the device or defined between the inner wall (231b) and the article (110) itself. The air flow passage(s) may also be directed upward through the base (233) from the distal end of the device (100) instead or additionally.

[0098] The configuration of the outer and inner walls (231a, 231b) of the receptacle (230) can facilitate improvements in the amount of insulation provided between the heating element (210) and the device housing (102) (e.g., compared to a single-wall receptacle (230)). Additionally, as discussed above, if the passages (237) are used as air flow passages, this can facilitate another improvement in the amount of insulation provided between the heating element (210) and the device housing (102) (e.g., because the (relatively cold outside) air flow can absorb excess heat from the inner and outer walls (231a, 231b). The amount of insulation provided by the heater assembly (200) may be an important consideration for the device (100), as it may be necessary to prevent the device (100) from becoming too hot in the user's hand or temperatures from becoming a problem for other device components. By providing an air gap in the receptacle (230), it is possible to facilitate the improvement of the insulation required in the device housing, which can lead to a compact device housing.

[0099] As discussed above, the receptacle (230) is disposed removablely within the chamber (105) so that it can be removed from it and replaced internally during use. In embodiments, the receptacle (230) is fixedly mounted to the device housing (102). The receptacle (230) may form a part of the device housing (102). For example, the receptacle and the coil support may be formed integrally. The receptacle may be used instead of the coil support. In the described embodiments, the receptacle (230) is configured to interact with the chamber (105) in such a way that rotation of the receptacle (230) relative to the device housing (102) causes it to engage and disengage in response to rotation of the receptacle (230).

[0100] The receptacle (230) and the device housing (102) include complementary interlocking features configured to engage or disengage in response to rotation of the receptacle (230) relative to the device housing (102).

[0101] It should be understood that, within the context of the present disclosure, ‘to engage’ relates to an engagement that sufficiently holds the receptacle (230) in place within the device housing (102) for use of the device (100), and ‘to disengage’ relates to the disengagement of such engagement that allows the receptacle (230) to be removed from the device housing (102) (e.g., without needing to remove other components of the device housing (102) or destroy parts of the device housing (102). A tool (not shown) may be used in combination with the receptacle (230) to assist in the insertion and removal of the receptacle (230) from the device chamber (105).

[0102] The receptacle (230) defines a heating chamber (220) extending between the opening (239) and the base (233). Thus, the heating chamber (220) extends between the proximal end (233a) and the distal end (233b). The inner side (253) of the wall (231) defines the heating chamber (220). In this arrangement, the inner wall (231b) substantially defines the inner side (253). The base (233) has an inner surface (254) and an outer surface (255). The inner side (253) of the wall (231) and the inner surface (254) of the base (233) define the surface of the heating chamber (220). The base defines the floor of the heating chamber (220). The heating chamber (220) has a substantially uniform cross-section along the length of the receptacle (230) from the opening to the base (233).

[0103] The receptacle has a spacer configuration (260). The spacer configuration (260) separates the end of the article (110) from the base (233) when the article (110) is received in the heating chamber (220). When the article (110) is received in the heating chamber (220), a portion of the article (110) protrudes from the heating chamber (220). In embodiments, the entire article (110) is received by the heating chamber (220).

[0104] The spacer configuration (260) comprises an array of protrusions (261). The present embodiment, as illustrated in FIG. 4b, has three protrusions (261), but only one is illustrated. It will be understood that the number of protrusions may vary, and there may be one protrusion or multiple protrusions. The protrusion(s) (261) act as spacers. The protrusions (261) stand upright from the base (233). The protrusions (261) have height in the heating chamber (220). Each protrusion (261) has a uniform height. The protrusions (261) act as stoppers that limit the extent to which the article (110) is inserted into the heating chamber (220). The protrusions (261) extend within the heating chamber (220). The protrusions (261) define the article locating surface (262). The item locating surface (262) contacts the end of the item (110).

[0105] The heating element (210) stands upright from the base (233). Protrusions (261) are distributed around the heating element (210) within the heating chamber (220). In this embodiment, the protrusions (261) are spaced apart from the heating element (210). In embodiments, the protrusion(s) (261) may extend from the heating element (210). A spacer configuration (260) may surround the heating element (210).

[0106] The protrusions (261) are platforms. The protrusions (261) define an air gap (265) between the base (233) and the plane of the article locating surface (262). An air outlet (252) communicates with the air gap (265). When the article (110) is inserted into the heating chamber (220), the end of the article (110) comes into contact with the spacer configuration (260). Thus, the spacer configuration (260) limits the range to which the article (110) is inserted, thereby allowing an air gap (265) to be formed between the end of the article (110) and the base (233). This air gap facilitates an improvement in air flow to the end of the article (110). By providing the air gap, the spacer configuration (260) provides an improvement in the distribution of air flow across the end of the article (110).

[0107] The spacer configuration (260) may take different forms. For example, the protrusions (261) may be one or more rods, ribs, tabs, lips, and hooks. The spacer configuration (260) may form a shoulder in the heating chamber (220). One such spacer configuration (260) is illustrated in FIGS. 5 and FIGS. 6.

[0108] FIG. 5 illustrates a side cross-sectional view of a part of another heater assembly (200). FIG. 6 illustrates an exploded view of a receptacle (230) of another heater assembly (200). Since the heater assembly (200) of FIG. 5 and FIG. 6 generally has the same arrangement as the heater assemblies described above, a detailed description will be omitted. The heater assembly (200) includes a receptacle (230) and a heating element (210). The heating element (210) as shown in FIG. 5 is a fin heating element, but it will be understood that the arrangement of the heating element may differ. The receptacle (230) includes outer and inner walls (231a, 231b).

[0109] The cross-section of FIG. 5 is taken through the ribs (236), and thus the air passage (237) and air outlet (252) are omitted. In this embodiment, the inner wall (231b) includes legs (270) extending axially from the distal end. The legs (270) are spaced circumferentially around the inner wall (231b). Four legs (270) are shown, but the number of legs may vary. The legs (270) protrude from the body (271) of the inner wall (231b) and space the inner wall body (271) from the base (233). The distal ends (272) of the legs (270) are in contact with the base (233). In the embodiments, the legs (270) are spaced from the base (233). An inwardly extending flange (273) protrudes from each leg (270). The inwardly extending flange (273) is a protrusion. The inwardly extending flange (273) protrudes from the distal end of each leg (270), but the flange (273) may be spaced apart from the distal end (272) of each leg (270). The flanges (273) act as locating tabs. The flanges (273) form a spacer configuration (260). The spacer configuration (260) may take different forms. For example, the protrusions (273) may be one or more rods, ribs, tabs, lips, and hooks. The flanges each have a height. The flanges (273) define the height of the air gap (265) formed between the end of the article (110) and the floor of the heating chamber (220). Each flange (273) defines the article locating surface (274).

[0110] An air outlet (252) is defined between adjacent legs (270). The air outlet (252) is provided radially. In this embodiment, a protrusion or each protrusion abuts the base (233) to axially locate the inner wall (231b), and the distance between the article locating surface (274) and the base (233) is defined by the height of the flanges (273) acting as protrusions. In embodiments, the flanges are spaced apart from the base.

[0111] The flanges (273) form an external spacer. The flanges (273) act as a shoulder. The receptacle (230) also includes an internal spacer (275). The internal spacer (275) includes an internal shoulder (276) that stands upright from the floor of the heating chamber (220). The shoulder (276) includes a raised collar that extends around the heating element (210). The shoulder (276) defines an article locating surface (277). The shoulder (276) is axially offset from the internal surface (254) of the base (233). In each of the embodiments, the spacer configuration axially offsets the end of the article from the floor of the heating chamber (220).

[0112] The spacer arrangement facilitates separating the article from the floor of the heating chamber (220). In this arrangement, the provision of an air gap enables improved airflow through the receptacle (230). By separating the end of the article (110) from the base (233), this arrangement facilitates radial airflow into the heating chamber (220). The air path is maintained only within the receptacle (230). Thus, this facilitates condensate management in the device. Although the receptacle (230) is disposed removablely within the chamber (105) so that it can be removed from it and replaced internally during use, in the embodiments, the receptacle (230) is fixedly mounted to the device housing (102). In the embodiments, the receptacle (230) forms a part of the device housing (102). For example, the receptacle and the coil support may be formed integrally. The receptacle may be used instead of the coil support.

[0113] In the embodiments described above, the air outlet is described with a heating chamber and a radial flow arrangement. It will be understood that in the embodiments, the air outlet may provide a heating chamber and an axial flow arrangement. Such an arrangement is illustrated in FIG. 7. Since the heater assembly (200) of FIG. 7 has the same arrangement as the heater assemblies described above, a detailed description will be omitted.

[0114] Referring to the embodiment of FIG. 7, the receptacle (230) includes a base (233), and a portion of the air path (250) extends from the base (233). In this arrangement, the receptacle (230) is a single-wall arrangement in which the air path (250) extends through the base (233) between the outer surface (255) and the inner surface (254). In the embodiments, a double-wall arrangement is maintained in which the air path (250) extends from the wall (231) into the base (233).

[0115] Tabs (280) acting as protrusions protrude from the side wall (231). Tabs (280) protrude radially inward. The number of tabs may vary and may be one. The arched range of the tab or each tab may vary. Tabs (280) are spaced apart from the base (233).

[0116] The air outlet (252) communicates with the floor of the base (233). Although a single air outlet port is shown in the drawing, in the embodiments, multiple air outlet ports forming the air outlet (252) exist. The axis of the air outlet is defined by the center of the total flow from the base (233). The air outlet (252) is asymmetric with respect to the axis (201) of the heating chamber (220). By providing an air gap (265), a substantially uniform air flow is provided from the end of the article (110) through the article (110) despite the asymmetric arrangement of the air outlet (252). It will be understood that the different air flow paths described in each embodiment may be used with the different spacer arrangements described herein.

[0117] Now, with reference to FIG. 8, additional embodiments will now be described. Since the embodiment of FIG. 8 has the same arrangement as the heater assemblies described above, and in particular the embodiments of FIG. 5 and 6, a detailed description will be omitted.

[0118] The heater assembly (200) includes a receptacle (230) and a heating element (210). The heating element (210) as shown in FIG. 8 is a blade heating element, but it will be understood that the arrangement of the heating element may vary. The receptacle (230) includes outer and inner walls (231a, 231b). The heating element (210) stands upright in the heating chamber (230). The heating element (220) extends from the base (233). The base (233) and the outer wall (231a) form a cup.

[0119] The base (233) includes a well (290). The well (290) is configured to collect liquid from the heating chamber (230). The well (290) includes a cavity (291). The cavity (291) extends from the base (233). The number of cavities (291) may vary. The cavity or each cavity (291) extends archedly around the axis of the heating chamber (220). The cavity (291) is a blind recess. The cavity extends from the floor of the heating chamber (220). The well (290) may be formed in the wall (231) of the receptacle (230). The cavity (291) defines a recess within the heating chamber (220) and away from the airflow passing through the heating chamber (220). In this way, for example, it is possible for condensate to be collected in the cavity (291) and moved away from the airflow. Thus, a free air path free of condensate is facilitated.

[0120] By collecting condensate in the cavity (291) in the heating chamber, it is possible to facilitate separating the condensate from the air path and provide space for the condensate to evaporate and be discharged from the heating chamber (220).

[0121] The above embodiments should be understood as exemplary examples of the present invention. Further embodiments of the present invention are anticipated. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other described features, and may also be used in combination with one or more features of any other embodiment among the embodiments, or in any combination of any other embodiment among the embodiments. Furthermore, equivalents and modifications not described above may also be adopted without departing from the scope of the present invention as defined in the appended claims.

Claims

Claim 1 An aerosol providing device comprising: a device housing; and a heating assembly, wherein the heating assembly comprises: a heating chamber arranged to accommodate at least a portion of an article comprising an aerosol generating material; a heating element configured to heat the portion of the article accommodated in the heating chamber; a base at one end of the heating chamber; and a spacer configured to space the article from the base when at least a portion of the article is accommodated in the heating chamber, wherein the heating element stands upright from the base and protrudes from the heating chamber, and the spacer is contained in a receptacle removable from the device housing. Claim 2 The aerosol providing device according to claim 1, wherein the spacer includes a protrusion protruding into the heating chamber. Claim 3 In claim 2, the aerosol providing device, wherein the protrusion is one of a plurality of protrusions. Claim 4 In claim 3, the plurality of protrusions are distributed around the heating chamber, an aerosol providing device. Claim 5 In claim 2, the protrusion is an aerosol providing device extending from the base. Claim 6 In claim 2, the aerosol providing device, wherein the protrusion is spaced apart from the base. Claim 7 In claim 1, the spacer forms a shoulder in the heating chamber, an aerosol providing device. Claim 8 In claim 1, the base forms a part of the receptacle, an aerosol providing device. Claim 9 In claim 1, the receptacle is an aerosol providing device that defines an air passage for providing air flow to the heating chamber. Claim 10 In claim 9, the air passage includes an air outlet into the heating chamber, and the air outlet is an aerosol providing device defined in the base. Claim 11 In claim 10, the air outlet is asymmetric with respect to the axis of the heating chamber, an aerosol providing device. Claim 12 An aerosol providing device according to claim 9, wherein the air passage comprises an air outlet into the heating chamber, and the air outlet is at least partially disposed between the article locating surface of the base and the spacer. Claim 13 In claim 12, the air outlet is arranged to introduce an air flow into the heating chamber in a radial direction with respect to the longitudinal axis of the receptacle, an aerosol providing device. Claim 14 An aerosol providing device according to claim 1, wherein the heating element is a susceptor, and the heating assembly includes an inductor coil extending around the susceptor, and the inductor coil is configured to generate a changing magnetic field. Claim 15 An aerosol providing device according to claim 1, wherein the heating chamber has an opening at a proximal end, the base is at a distal end of the heating chamber, and the heating chamber has a substantially uniform cross-section along the length of the heating chamber. Claim 16 The aerosol providing device according to claim 1, wherein the base comprises a well configured to collect liquid collected in the heating chamber. Claim 17 A heating assembly comprising a receptacle for receiving at least a portion of an article comprising an aerosolizable material, wherein the receptacle comprises: an outer wall; an inner wall; an air flow passage between the outer wall and the inner wall; a base; a heating element extending from the base; and a protrusion for contacting the portion of the article when the portion of the article is received in the receptacle to keep the article spaced apart above the base, wherein the protrusion extends inwardly from the inner wall. Claim 18 An aerosol providing device comprising a heating assembly, wherein the heating assembly comprises: a heating chamber arranged to accommodate at least a portion of an article comprising a solid aerosol generating material; a heating element configured to heat the portion of the article accommodated in the heating chamber; a wall defining at least a portion of the heating chamber; a cavity formed in the wall; a base at one end of the heating chamber defining the floor of the heating chamber; and a spacer arranged to form an air gap between the one end of the article comprising the aerosol generating material and the floor of the heating chamber, wherein the wall comprises the base and the cavity is in the base and the cavity extends from the floor of the heating chamber. Claim 19 In claim 18, an aerosol providing device comprising a device housing and a receptacle arranged to be at least partially removablely received within the device housing, wherein the removable receptacle forms the heating chamber. Claim 20 A heating assembly comprising: a heating chamber for receiving at least a portion of an article comprising an aerosolizable material; and a heating element, wherein the heating chamber comprises a base defining the floor of the heating chamber and a recess within the base for collecting a fluid received in the heating chamber, and the heating assembly comprises a spacer arranged to form an air gap between one end of the article comprising the aerosolizing material and the floor of the heating chamber, wherein the recess extends from the floor of the heating chamber. Claim 21 An aerosol providing system comprising: an aerosol providing device according to claim 1; and an article comprising an aerosol generating material — said article is dimensioned to be at least partially accommodated within said heater assembly — an aerosol providing system. Claim 22 A heating assembly comprising a receptacle for receiving at least a portion of an article comprising an aerosolizable material, wherein the receptacle comprises: a base; a heating element extending from the base and protruding from the receptacle; and a protrusion for contacting the portion of the article when the portion of the article is received in the receptacle to keep the article spaced apart from the base, the heating assembly comprising the protrusion spaced apart from the heating element. Claim 23 An insert for an aerosol providing device comprising a receptacle arranged to be at least partially removablely received in a device housing, wherein the receptacle defines a heating chamber arranged to receive at least a portion of an article comprising an aerosol generating material, wherein the receptacle comprises: a wall defining at least a part of the heating chamber; and a cavity formed in the wall, wherein the wall is a base, and the base defines a hole for receiving a heating element. Claim 24 delete Claim 25 delete Claim 26 delete Claim 27 delete Claim 28 delete Claim 29 delete Claim 30 delete Claim 31 delete Claim 32 delete Claim 33 delete Claim 34 delete Claim 35 delete

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