Aerosol-generating device with configurable heating

Abstract

There is provided an aerosol-generating device (100) for use with an aerosol-generating article. The aerosol-generating device (100) comprises a housing. The housing comprises a recess (111) for receiving an aerosol-generating article. The housing comprises a heater assembly (112) configured to heat an aerosol-generating article when it is received in the recess (111). The heater assembly (112) comprises a plurality of heating zones which may be activated independently such that different portions of an aerosol-generating article received within the recess (111) may be selectively heated by a corresponding heating zone. The recess (111) has a depth of at least 2 millimetres.

Description

[0001] AEROSOL-GENERATING DEVICE WITH CONFIGURABLE HEATING

[0002] The present disclosure relates to an aerosol-generating device for use with an aerosolgenerating article. In particular, the present disclosure relates to an aerosol-generating device comprising a housing and a heater assembly configured to heat an aerosol-generating article. The heater assembly comprises a plurality of heating zones. The present disclosure also relates to an aerosol-generating system comprising an aerosol-generating device and an aerosolgenerating article configured to be used with the aerosol-generating device.

[0003] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco containing substrate, is heated rather than combusted are known in the art. In heated aerosolgenerating articles, the aerosol is generated by heating the aerosol-generating substrate.

[0004] One type of aerosol-generating system is an electrically operated smoking system. Known handheld electrically operated smoking systems typically comprise an aerosol-generating device comprising a rechargeable battery, control electronics and an electric heater for heating an aerosol-generating article designed specifically for use with the aerosol-generating device. In some examples, the aerosol-generating article comprises an aerosol-forming substrate, such as a tobacco rod or a tobacco plug, and the heater contained within the aerosol-generating device is inserted into or is located around the aerosol-forming substrate when the aerosol-generating article is inserted into the aerosol-generating device.

[0005] A heating element may be provided in an aerosol-generating device for generating an inhalable vapor. Such a device may heat the aerosol-generating substrate contained in the aerosol-generating article without burning the aerosol-generating substrate. In doing so, the aerosol-generating substrate may generate an aerosol which may be delivered to a user.

[0006] Such aerosol-generating articles may take the form of a conventional cigarette. Where this is the case, the aerosol-generating substrate may be wrapped in cigarette paper. This approach may be appropriate where the aerosol-generating substrate comprises strands or spaghettis of material, for example strands of cast leaf tobacco or strands of shredded tobacco.

[0007] However, this approach may not effectively retain other forms of aerosol-generating substrate, such as granulated or powdered aerosol-generating substrate. Such aerosolgenerating articles may be prone to leakage of the aerosol-generating substrates during storage, handling and use thereof. Leakage of the aerosol-generating substrates may be exacerbated by high environmental temperatures and humidities. Loss of aerosol-generating substrates through leakage may disadvantageously reduce the lifespan of the aerosol-generating article comprising the aerosol-generating substrate. Leakage of aerosol-generating substrates may negatively impact the overall performance of the aerosol-generating article. For example, leakage of aerosol-generating substrates may negatively impact the consistency of the inhalable aerosol generated by an aerosol-generating system comprising the aerosol-generating article.

[0008] In order to provide an aerosol-generating article in which loss or leaking of the aerosolgenerating substrate is reduced or prevented even when the aerosol-generating article is heated to the temperatures required to generate an aerosol from the aerosol-generating substrate, an aerosol-generating article comprising a container may be provided. Such an aerosol-generating article may be able to retain different forms of aerosol-generating substrate, such as granulated or powdered aerosol-generating substrate. Such an aerosol-generating article comprising a container may be readily handled and manipulated by a consumer when it is being used in combination with a suitable aerosol-generating device. However, aerosol-generating devices of the prior art may not be suitable for heating aerosol-generating articles comprising a container. For example, inserting a heating element into an aerosol-generating article comprising a container may disadvantageously cause the aerosol-generating substrate to leak out of the container. In addition, existing heaters configured to externally heat aerosol-generating articles may not provide efficient heating sufficient to generate a consistent aerosol from an aerosol-generating article comprising a container.

[0009] Aerosol-generating articles comprising a container may be larger than aerosol-generating articles of the prior art. Where this is the case, it may be advantageous to provide more customised heating of the aerosol-generating article which is not possible with aerosol-generating devices of the prior art.

[0010] There is a need to provide an aerosol-generating device which is suitable for use with an aerosol-generating article, such as an aerosol-generating article comprising a container.

[0011] There is a need to provide an aerosol-generating device which is able to provide an more consistent aerosol delivery over the course of an experience by a user.

[0012] There is a need to provide an aerosol-generating device in which the aerosol generation may be tailored depending on the nature of the aerosol-generating article.

[0013] According to a first aspect of the present disclosure, there is provided an aerosolgenerating device for use with an aerosol-generating article. The aerosol-generating device may comprise a housing. The housing may comprise a recess for receiving an aerosol-generating article. The housing may comprise a heater assembly configured to heat an aerosol-generating article when it is received in the recess. The heater assembly may comprise a plurality of heating zones which may be activated independently such that different portions of an aerosol-generating article received within the recess may be selectively heated by a corresponding heating zone. The recess may have a depth of at least 2 millimetres.

[0014] According to a first aspect of the present invention, there is provided an aerosol-generating device for use with an aerosol-generating article. The aerosol-generating device comprises a housing. The housing comprises a recess for receiving an aerosol-generating article, and a heater assembly configured to heat an aerosol-generating article when it is received in the recess. The heater assembly comprises a plurality of heating zones which may be activated independently such that different portions of an aerosol-generating article received within the recess may be selectively heated by a corresponding heating zone. The recess has a depth of at least 2 millimetres.

[0015] The provision of a plurality of heating zones which may be activated independently may allow specific areas of an aerosol-generating article received in the recess to be heated at different times. The provision of a plurality of heating zones which may be activated independently may allow specific areas of an aerosol-generating article received in the recess to be heated to different temperatures. The provision of a plurality of heating zones which may be activated independently may allow specific areas of an aerosol-generating article received in the recess to be heated for different periods.

[0016] This may allow for the heating profile to be tailored to specific areas of the aerosolgenerating article. This may be advantageous where the aerosol-generating article includes a plurality of different aerosol-generating substrates which require different heating profiles to generate aerosol.

[0017] This arrangement may also be advantageous in examples in which the aerosol-generating article includes a single aerosol-generating substrates since the activation of the plurality of heating zones may be staggered such that different sections of the aerosol-generating article are heated consecutively. This may prevent too much aerosol being generated at the start of the experience and may advantageously provide for more consistent aerosol generation over the course of a user experience.

[0018] In use, an aerosol-generating article may be received in the recess of the housing. At least a first of the plurality of heating zones may be activated at a first time to a first temperature. At least a second of the plurality of heating zones may be activated at a second time to a second temperature. In this way, the different portions of the aerosol-generating article may be heated to different temperatures at different times. Different portions of the aerosol-generating article may be selectively heated by a corresponding heating zone.

[0019] As used herein with reference to the present invention, the term “aerosol-generating substrate” denotes a substrate capable of releasing volatile compounds upon heating, which can condense to form an aerosol.

[0020] As used herein with reference to the present invention, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets. As used herein with reference to the present invention, the term “aerosol-generating article” denotes an article comprising an aerosol-generating substrate that is capable of releasing volatile compounds that can form an aerosol. An aerosol-generating article may be disposable.

[0021] As used herein with reference to the present invention, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating substrate to generate an aerosol. In some examples, the aerosol-generating device heats the aerosol-generating substrate to facilitate release of volatile compounds from the substrate.

[0022] As used herein with reference to the present invention, the term “aerosol-generating system” refers to the combination of an aerosol-generating device and an aerosol-generating article.

[0023] As used herein with reference to the present invention, the term “heater assembly” refers to an arrangement configured to generate heat to heat an aerosol-generating article. The heater assembly may be an electric heater assembly.

[0024] As used herein with reference to the present invention, the term “heating zones” refers to a portion of the “heater assembly” which may be activated to generate heat. The heater assembly comprises a plurality of heating zones which may be independently activated. In this way, a first heating zone of the plurality of heating zones may be on such that the first heating zone generates heat. At the same time, a second heating zone of the plurality of heating zones may be off.

[0025] The recess may comprise at least one air inlet to allow air to enter the recess and access the aerosol-generating article received within the recess. The at least one air inlet may be located at the upstream end of the recess. The recess may comprise at least one aerosol outlet to allow aerosol to leave the recess to be delivered to a user. The at least one aerosol outlet may be located at the downstream end of the recess.

[0026] The plurality of heating zones may be located at different positions. In this way, a first and a second portion of an aerosol-generating article may be heated independently by corresponding adjacent first and second heating zones.

[0027] The plurality of heating zones may be distributed along the longitudinal axis of the heater assembly.

[0028] As used herein with reference to the present invention, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating device or portion of the aerosol-generating device, which extends between the upstream and downstream ends of the aerosol-generating device or portion of the aerosol-generating device.

[0029] As used herein with reference to the present invention, the terms “upstream” and “downstream” describe the relative positions of elements, or portions of elements, of the aerosolgenerating device in relation to the direction in which the aerosol is transported through the aerosol-generating device during use.

[0030] The plurality of heating zones may comprise no more than 10 heating zones. The plurality of heating zones may comprise no more than 10 heating zones. For example, the plurality of heating zones may comprise no more than 7 heating zones, no more than 5 heating zones, or no more than 3 heating zones.

[0031] The plurality of heating zones may comprise at least 2 heating zones. The plurality of heating zones may comprise at least 3 heating zones. The plurality of heating zones may comprise at least 4 heating zones, or at least 5 heating zones.

[0032] The plurality of heating zones may comprise 2 heating zones. The plurality of heating zones may comprise 3 heating zones.

[0033] The plurality of heating zones may each comprise any actuatable means to generate heat.

[0034] The plurality of heating zones may comprise a plurality of individually actuatable electrical heating elements.

[0035] The plurality of individually actuatable electrical heating elements may comprise at least one resistive heating element.

[0036] Suitable materials for forming the at least one resistive heating element include but are not limited to: semiconductors such as doped ceramics, electrically ‘conductive’ ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys and composite materials made of a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and metals from the platinum group. Examples of suitable metal alloys include stainless steel, nickel-, cobalt- , chromium-, aluminium- titanium- zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese- and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, stainless steel, Timetai® and iron-manganese-aluminium based alloys.

[0037] The at least one resistive heating element may comprise one or more stamped portions of electrically resistive material, such as stainless steel. Alternatively, the at least one resistive heating element may comprise a heating wire or filament, for example a Ni-Cr (Nickel-Chromium), platinum, tungsten or alloy wire.

[0038] The at least one resistive heating element may comprise at least one electrically insulating substrate, wherein the at least one resistive heating element is provided on the at least one electrically insulating substrate.

[0039] The at least one electrically insulating substrate may comprise any suitable material. For example, the electrically insulating substrate may comprise one or more of: paper, glass, ceramic, anodized metal, coated metal, and Polyimide. The ceramic may comprise mica, Alumina (AI2O3) or Zirconia (ZrCh). The electrically insulating substrate may have a thermal conductivity of less than or equal to about 40 Watts per metre Kelvin, preferably less than or equal to about 20 Watts per metre Kelvin and ideally less than or equal to about 2 Watts per metre Kelvin. The at least one resistive heating element may comprise a heating element comprising a rigid electrically insulating substrate with one or more electrically conductive tracks or wire disposed on its surface. A current may be passed through the one or more electrically conductive tracks to heat the at least one resistive heating of the plurality of heating zones and the aerosolgenerating substrate received within the recess.

[0040] The plurality of individually actuatable electrical heating elements may comprise a plurality of individually actuatable electrical resistive heating elements.

[0041] The heater assembly may further comprise control electronics to individually activate the plurality of heating zones. For example, the control electronics may comprise a plurality of switches which may independently activate the electrical resistive heating elements of the plurality of heating zones.

[0042] The at least one resistive heating element may be a planar sinusoidal heating element. The provision of a sinusoidal heating element may advantageously allow the at least one resistive heating element to heat a large area of the aerosol-generating substrate when the corresponding heating zoner is independently activated.

[0043] The plurality of individually actuatable electrical heating elements may comprise at least one inductive heating element.

[0044] The inductive heating element may comprise an inductor coil. The inductive heating element may be connected to a power supply configured to provide high frequency oscillating current to the inductor coil. As used herein, a high frequency oscillating current means an oscillating current having a frequency of between about 500 kHz and about 30 MHz. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field on receiving a high frequency oscillating current from the power supply. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field in the recess.

[0045] The provision of heater comprising an inductive heating arrangement may advantageously be used in combination with an aerosol-generating article which comprises a susceptor element.

[0046] The susceptor element may comprise any suitable susceptor element.

[0047] In some embodiments the heater assembly may comprise at least one resistive heating element and at least one inductive heating element. In some embodiments the heater assembly may comprise a combination of resistive heating elements and inductive heating elements.

[0048] Each of the plurality of heating zones may have the same length.

[0049] As used herein with reference to the present invention, the “length” denotes the dimension of a component of the aerosol-generating device in the longitudinal direction.

[0050] The provision of each of the plurality of heating zones having the same length may advantageously allow consecutive activation of each of the plurality of heating zones to generate a substantially consistent aerosol. The plurality of heating zones may comprise a first heating zone having a first length, and a second heating zone having a second length, wherein the first length is greater than the second length.

[0051] Where the plurality of heating zones have different lengths, the second heating zone may be activated before the first heating zone. In this way, the shorter heating zone may provide an initial boost of aerosol generation to quickly provide an aerosol at the start of the user experience. The second heating zone may be activated for a specific period of time before the first heating zone is activated. Alternatively, the aerosol-generating device may comprise a puff detection means, and the second heating zone may be activated for a specific number of puffs or inhalations before the first heating zone is activated.

[0052] Where the plurality of heating zones have different lengths, the first heating zone may be activated after the first heating zone. In this way, the shorter heating zone may provide a final boost of aerosol generation to ensure aerosol is delivered to a user until the end of the user experience. The second heating zone may be activated for a specific period of time after the first heating zone is activated. Alternatively, the aerosol-generating device may comprise a puff detection means, and the second heating zone may be activated after a specific number of puffs or inhalations.

[0053] The first heating zone may be upstream of the second heating zone.

[0054] This may allow the shorter heating zone to be downstream of the longer heating zone. This may be particularly advantageous where the second heating zone is activated before the first heating zone since the most downstream portion of the aerosol-generated article is heated first to generate an initial burst of aerosol at the start of a user experience which is then quickly delivered to a user.

[0055] The first heating zone may be downstream of the second heating zone.

[0056] This may allow the longer heating zone to be downstream of the shorter heating zone. This may be particularly advantageous where the first heating zone is activated before the second heating zone since the most upstream portion of the aerosol-generated article is heated last to generate a final burst of aerosol at the end of a user experience.

[0057] At least one heating zone of the plurality of heating zones may have a length of at least 3 millimetres.

[0058] For example, at least one heating zone of the plurality of heating zones may have a length of at least 4 millimetres, at least 6 millimetres, or at least 10 millimetres.

[0059] At least one heating zone of the plurality of heating zones may have a length of no more than 20 millimetres.

[0060] For example, at least one heating zone of the plurality of heating zones may have a length of no more than 17 millimetres, no more than 15 millimetres, or no more than 13 millimetres. At least one heating zone of the plurality of heating zones may have a length of between about 3 millimetres and about 20 millimetres, between about 4 millimetres and about 17 millimetres, between about 6 millimetres and about 15 millimetres, or between about 10 millimetres and about 13 millimetres. At least one heating zone of the plurality of heating zones may have a length of about 12 millimetres.

[0061] The recess may have any length.

[0062] The recess may have a length of at least 10 millimetres. For example, the recess may have a length of at least 12 millimetres, at least 14 millimetres, at least 16 millimetres, or at least 18 millimetres.

[0063] The recess may have a length of no more than 30 millimetres. For example, the recess may have a length of no more than 28 millimetres, no more than 25 millimetres, no more than 20 millimetres, or no more than 18 millimetres.

[0064] The recess may have a length of between about 10 millimetres and about 30 millimetres, between about 12 millimetres and about 28 millimetres, between about 14 millimetres and about 25 millimetres, or between about 20 millimetres and about 16 millimetres.

[0065] The recess may have a length of about 14 millimetres. The recess may have a length of about 16 millimetres. The recess may have a length of about 18 millimetres.

[0066] The recess may have any depth.

[0067] The recess may have a depth of at least 2 millimetres. For example, the recess may have a depth of at least 3 millimetres, or at least 4 millimetres.

[0068] The recess may have a depth of no more than 20 millimetres. For example, the recess may have a depth of no more than 15 millimetres, no more than 10 millimetres, or no more than 6 millimetres.

[0069] The recess may have a depth of between 2 millimetres and 20 millimetres, between 2 millimetres and 15 millimetres, between 2 millimetres and 10 millimetres, or between 2 millimetres and 6 millimetres.

[0070] The recess may have a depth of between 3 millimetres and 20 millimetres, between 3 millimetres and 15 millimetres, between 3 millimetres and 10 millimetres, or between 3 millimetres and 6 millimetres.

[0071] The recess may have a depth of between 4 millimetres and 20 millimetres, between 4 millimetres and 15 millimetres, between 4 millimetres and 10 millimetres, or between 4 millimetres and 6 millimetres.

[0072] The recess may have a depth of about 3.5 millimetres.

[0073] As used herein with reference to the present invention, the term “depth” is used to describe the shortest orthogonal dimension of the recess. The depth of the recess extends in the direction parallel to the direction in which aerosol-generating articles may be inserted into and removed from the recess, between the opening of the recess and the inner surface of the recess. The depth of the recess is perpendicular to the length of the recess.

[0074] The recess may be aligned such that the depth of the recess is not aligned with the longitudinal axis of the aerosol-generating device.

[0075] The recess may have any width.

[0076] The recess may have a width of at least 5 millimetres, or at least 6 millimetres. The recess may have a width of no more than 15 millimetres, or no more than 10 millimetres.

[0077] The recess may have a width of between about 5 millimetres and about 15 millimetres, or between about 6 millimetres and about 10 millimetres. The recess may have a width of about 8 millimetres.

[0078] As used herein with reference to the present invention, the term “width” is used to describe the second longest orthogonal dimension of the recess. The width of the recess is perpendicular to the length and the depth of the recess.

[0079] The device may further comprise at least one heat conducting element provided on an inner wall of the recess.

[0080] The provision of at least one heat conducting element on an inner wall of the recess may help to distribute the heat from the heater assembly around the inner wall of the recess. This may advantageously improve the efficiency of the heating of an aerosol-generating article received within the recess. Specifically, the provision of at least one heat conducting element may advantageously ensure that portions of the aerosol-generating article which are spaced apart from the heater assembly may be efficiently heated to generate an aerosol. This may advantageously improve the consistency of aerosol generated by the aerosol-generating device. In addition, the provision of at least one heat conducting element may ensure a greater proportion of the aerosol-generating substrate can be utilised to generate an aerosol.

[0081] The at least one heat conducting element may comprise a plurality of individual heat conducting elements.

[0082] The provision of a plurality of individual heat conducting elements may allow heating of specific portions of an aerosol-generating article received within the recess in use. This may advantageously allow the aerosol-generation to be tailored depending on the nature of the aerosol-generating article.

[0083] Each of the plurality of individual heat conducting elements may have the same length. Each of the plurality of individual heat conducting elements may have the same width. Each of the plurality of individual heat conducting elements may have the same surface area.

[0084] At least one heating zone may have a corresponding heat conducting element such that at least one portion of an aerosol-generating article received within the recess may be selectively heated by the at least one heating zone and the corresponding heat conducting element. The provision of at least one heating zone having a corresponding heat conducting element may advantageously allow a greater proportion of an aerosol-generating substrate to be selectively heated by the at least one heating zone and the corresponding heat conducting element. This may advantageously improve the aerosol generation from the portion of the aerosol-generating article heated by the heating zone and the corresponding heat conducting element.

[0085] The at least one heating zone may be longitudinally aligned with the corresponding heat conducting element.

[0086] By aligning the at least one heating zone with the corresponding heat conducting element, the specific portions of the aerosol-generating article can be efficiently heated by both the heating zone and the corresponding heat conducting element. In addition, aligning the at least one heating zone with the corresponding heat conducting element may advantageously improve heat conduction from the at least one heating zone and the corresponding heat conducting element.

[0087] As used herein with reference to the present invention, the term “longitudinally aligned” refers to a heating zone and a heat conducting element which are arranged such that either the upstream end of the heating zone is at the same position in the longitudinal direction as the upstream end of the corresponding heat conducting element, or the downstream end of the heating zone is at the same position in the longitudinal direction as the downstream end of the corresponding heat conducting element.

[0088] The at least one heating zone may be the same length as the corresponding heat conducting element.

[0089] This provision may maximise heat transfer from the at least one heating zone to other portions of the recess. This may advantageously improve aerosol generation from the portion of the aerosol-generating article heated by the heating zone and the corresponding heat conducting element.

[0090] Each heating zone may have a corresponding heat conducting element such that different portions of an aerosol-generating article received within the recess may be selectively heated by the a corresponding heating zone and heat conducting element.

[0091] For example, the aerosol-generating device may comprise a heater assembly including three heating zones and three corresponding heat conducting elements. Each of the three heating zones may have the same length as the corresponding heat conducting element. Each of the three heating zones may be longitudinally aligned with the corresponding heat conducting element.

[0092] This may advantageously improve the ability of the aerosol-generating device to control the heating and aerosol generation from an aerosol-generating article received within the recess.

[0093] The housing may comprise a heating wall, the heating wall comprising the heater assembly, and wherein the heating wall is a planar wall. The provision of a planar heating wall may advantageously improve the heat transfer from the heater assembly to the aerosol-generating article.

[0094] The heating wall may be movable relative to the recess between a closed position in which the recess is substantially closed by the heating wall, and an open position to allow access to the interior of the recess.

[0095] This provision may advantageously allow a user to access the interior of the recess to insert and remove aerosol-generating articles.

[0096] According to a second aspect of the disclosure, there is provided an aerosol-generating system comprising: an aerosol-generating device according to the first aspect of the disclosure; and an aerosol-generating article.

[0097] The aerosol-generating article may be received within the recess of the aerosolgenerating device.

[0098] The aerosol-generating article may be any aerosol-generating article. The aerosolgenerating article may comprise a container, the container comprising a first wall and a second wall. The first wall and second wall may together define a substrate compartment. An aerosolgenerating substrate may be provided in the substrate compartment.

[0099] The first wall may comprise a different material to the second wall. The first wall may comprise a flexible cellulosic material. The second wall may have a higher stiffness than the first wall. Alternatively, the first wall may have a higher stiffness than the second wall.

[0100] At least a portion of the first wall may be porous. As used herein with reference to the present invention, the term “cellulosic material” refers to a material which is made from or is a derivative of cellulose.

[0101] The first wall may comprise any cellulosic material. The first wall may comprise a nonwoven material.

[0102] As used herein with reference to the present invention, the term “non-woven” refers to a manufactured sheet, web or batt of directionally or randomly orientated fibres, bonded by friction, and / or cohesion and / or adhesion, excluding products which are woven, knitted, tufted, stitch- bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibres may be of natural or man-made origin.

[0103] The first wall may comprise a moulded paper material.

[0104] The second wall may be non-porous. The second wall may comprise a substantially planar material. The second wall may comprise a paper material.

[0105] The aerosol-generating substrate may comprise at least one alkaloid.

[0106] As used herein with reference to the present invention, the term “alkaloid compound” is used to describe any one of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Generally, an alkaloid contains at least one nitrogen atom in an amine-type structure. This or another nitrogen atom in the molecule of the alkaloid compound can be active as a base in acid-base reactions. Most alkaloid compounds have one or more of their nitrogen atoms as part of a cyclic system, such as for example a heterocylic ring. In nature, alkaloid compounds are found primarily in plants, and are especially common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and fungi. In the context of the present invention, the term “alkaloid compounds” is used to describe both naturally derived alkaloid compounds and synthetically manufactured alkaloid compounds. Suitable alkaloid compounds for use in an aerosol-generating element in accordance with the invention include, but are not limited to, nicotine and anatabine.

[0107] In preferred embodiments, the aerosol-generating substrate comprises nicotine or anatabine.

[0108] In particularly preferred embodiments, the aerosol-generating substrate comprises nicotine.

[0109] As used herein with reference to the invention, the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt. In embodiments in which the aerosol-generating substrate comprises a nicotine base or a nicotine salt, the amounts of nicotine recited herein are the amount of free base nicotine or amount of protonated nicotine, respectively.

[0110] The aerosol-generating substrate may comprise natural nicotine or synthetic nicotine.

[0111] The aerosol-generating substrate may comprise one or more monoprotic nicotine salts.

[0112] As used herein with reference to the invention, the term “monoprotic nicotine salt” is used to describe a nicotine salt of a monoprotic acid.

[0113] The aerosol-generating substrate may comprise nicotine.

[0114] The aerosol-generating substrate may comprise an aerosol-former. The aerosolgenerating substrate may contain any amount of aerosol-former. The aerosol-generating substrate may comprise at least 50 weight percent, at least 60 weight percent, or at least 70 weight percent aerosol-former. The aerosol-generating substrate may comprise about 80 weight percent aerosol-former.

[0115] The aerosol-generating substrate may comprise a polyhydric alcohol.

[0116] The polyhydric alcohol acts as the aerosol-former for the aerosol-generating substrate. Polyhydric alcohols suitable for use in the aerosol-generating substrate include, but are not limited to, propylene glycol, triethylene glycol, 1 ,3-butanediol, and glycerin. Preferably, in an aerosolgenerating substrate in accordance with the invention the polyhydric alcohol is selected from the group consisting of glycerin, propylene glycol, and combinations thereof. In particularly preferred embodiments the polyhydric alcohol is glycerin.

[0117] The aerosol-generating substrate may comprise granules. The granules may have any diameter. The aerosol-generating substrate may comprise granules with a diameter of greater than or equal to 100 micrometres, greater than or equal to 250 micrometres, or greater than or equal to 500 micrometres. The aerosol-generating substrate may comprise granules with a diameter of less than or equal to 5 millimetres, less than or equal to 4 millimetres, or less than or equal to 3 millimetres.

[0118] The aerosol-generating substrate may comprise granules with a diameter of between 500 micrometres and 3 millimetres. The aerosol-generating substrate may comprise granules with a diameter of about 1 .5 millimetres.

[0119] The substrate compartment may contain any mass of aerosol-generating substrate. For example, the substrate compartment may contain at least 80 milligrams of aerosol-generating substrate, at least 85 milligrams of aerosol-generating substrate, or at least 90 milligrams of aerosol-generating substrate.

[0120] The substrate compartment may contain at no more than 300 milligrams of aerosolgenerating substrate, no more than 250 milligrams of aerosol-generating substrate, or no more than 200 milligrams of aerosol-generating substrate.

[0121] The substrate compartment may contain between 80 milligrams and 300 milligrams of aerosol-generating substrate, between 85 milligrams and 250 milligrams of aerosol-generating substrate, and between 100 milligrams and 200 milligrams of aerosol-generating substrate.

[0122] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0123] Example Ex 1.1. An aerosol-generating device for use with an aerosol-generating article, the aerosol-generating device comprising: a housing, the housing comprising: a recess for receiving an aerosol-generating article.

[0124] Example Ex 1.2. An aerosol-generating device according to Example Ex 1.1., wherein the housing comprises a heater assembly configured to heat an aerosol-generating article when it is received in the recess.

[0125] Example Ex 1.3. An aerosol-generating device according to Example Ex 1.1. or Ex 1 .2., wherein the heater assembly comprises a plurality of heating zones which may be activated independently such that different portions of an aerosol-generating article received within the recess may be selectively heated by a corresponding heating zone.

[0126] Example Ex 1 .4. An aerosol-generating device according to any preceding Example, wherein the recess has a depth of at least 2 millimetres.

[0127] Example Ex 1.An aerosol-generating device for use with an aerosol-generating article, the aerosol-generating device comprising: a housing, the housing comprising: a recess for receiving an aerosol-generating article, and a heater assembly configured to heat an aerosol-generating article when it is received in the recess, the heater assembly comprising a plurality of heating zones which may be activated independently such that different portions of an aerosol-generating article received within the recess may be selectively heated by a corresponding heating zone, wherein the recess has a depth of at least 2 millimetres. Example Ex 2. An aerosol-generating device according to Example Ex 1 , wherein the plurality of heating zones are distributed along the longitudinal axis of the heater assembly.

[0128] Example Ex 3. An aerosol-generating device according to Examples Ex 1 or Ex 2, wherein the plurality of heating zones comprises no more than 10 heating zones.

[0129] Example Ex 4. An aerosol-generating device according to any preceding Example, wherein the plurality of heating zones comprises at least 3 heating zones.

[0130] Example Ex 5. An aerosol-generating device according to any preceding Example, wherein the plurality of heating zones comprises a plurality of individually actuatable electrical heating elements.

[0131] Example Ex 6. An aerosol-generating device according to Example Ex 5, wherein the plurality individually actuatable electrical heating elements comprises at least one resistive heating element.

[0132] Example Ex 7. An aerosol-generating device according to Example Ex 6, wherein the at least one resistive heating element is a planar sinusoidal heating element.

[0133] Example Ex 8. An aerosol-generating device according to Example Ex 5, wherein the plurality of individually actuatable electrical heating elements comprises at least one inductive heating element.

[0134] Example Ex 9. An aerosol-generating device according to any preceding Example, wherein each of the plurality of heating zones have the same length.

[0135] Example Ex 10. An aerosol-generating device according to any one of Examples Ex 1 to Ex 8, wherein the plurality of heating zones comprises a first heating zone having a first length, and a second heating zone having a second length, wherein the first length is greater than the second length.

[0136] Example Ex 11 . An aerosol-generating device according to Example Ex 10, wherein the first heating zone is upstream of the second heating zone.

[0137] Example Ex 12. An aerosol-generating device according to Example Ex 10, wherein the first heating zone is downstream of the second heating zone.

[0138] Example Ex 13. An aerosol-generating device according to any preceding Example, wherein at least one heating zone of the plurality of heating zones has a length of at least 3 millimetres.

[0139] Example Ex 14. An aerosol-generating device according to any preceding Example, wherein the at least one heating zone of the plurality of heating zones has a length of no more than 20 millimetres.

[0140] Example Ex 15. An aerosol-generating device according to any preceding Example, wherein the recess has a length of at least 10 millimetres.

[0141] Example Ex 16. An aerosol-generating device according to any preceding Example, wherein the recess has a length of no more than 30 millimetres. Example Ex 17. An aerosol-generating device according to any preceding Example, wherein the device further comprises at least one heat conducting element provided on an inner wall of the recess.

[0142] Example Ex 18. An aerosol-generating device according to Example Ex 17, wherein the at least one heat conducting element comprises a plurality of individual heat conducting elements.

[0143] Example Ex 19. An aerosol-generating device according to Example Ex 18, wherein at least one heating zone has a corresponding heat conducting element such that at least one portion of an aerosol-generating article received within the recess may be selectively heated by the at least one heating zone and the corresponding heat conducting element.

[0144] Example Ex 20. An aerosol-generating device according to Example Ex 19, wherein the at least one heating zone is longitudinally aligned with the corresponding heat conducting element.

[0145] Example Ex 21. An aerosol-generating device according to Example Ex 19 or Ex 20, wherein the at least one heating zone is the same length as the corresponding heat conducting element.

[0146] Example Ex 22. An aerosol-generating device according to any one of Examples Ex 19 to Ex 21 , wherein each heating zone has a corresponding heat conducting element such that different portions of an aerosol-generating article received within the recess may be selectively heated by the a corresponding heating zone and heat conducting element.

[0147] Example Ex 23. An aerosol-generating device according to any preceding Example, wherein the housing comprises a heating wall, the heating wall comprising the heater assembly, and wherein the heating wall is a planar wall.

[0148] Example Ex 24. An aerosol-generating device according to Example Ex 23, wherein the heating wall is movable relative to the recess between a closed position in which the recess is substantially closed by the heating wall, and an open position to allow access to the interior of the recess.

[0149] Example Ex 25. An aerosol-generating system comprising: an aerosol-generating device according to any preceding Example; and an aerosol-generating article.

[0150] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0151] Figure 1 shows a side on cross sectional view of an aerosol-generating device according to the present invention;

[0152] Figure 2 shows a plan view of a first heater assembly of an aerosol-generating device according to the present invention;

[0153] Figure 3 shows a plan view of a second heater assembly of an aerosol-generating device according to the present invention; Figure 4 shows a plan view of a third heater assembly of an aerosol-generating device according to the present invention;

[0154] Figure 5 shows a plan view of a fourth heater assembly of an aerosol-generating device according to the present invention; and

[0155] Figure 6 shows a side on cross sectional view of an aerosol-generating article to be used with an aerosol-generating device according to the present invention.

[0156] An aerosol-generating device 100 according to the present invention is shown in Figure 1. The device 100 is intended for use with an aerosol-generating article (not shown in Figure 1). The device 100 comprises a housing 110. The housing 110 comprises a recess 111 for receiving an aerosol-generating article. The housing 110 comprises a heater assembly 112 configured to heat an aerosol-generating article when it is received in the recess 111.

[0157] The housing 110 comprises a planar heating wall 113, the heating wall 113 comprising the heater assembly 112. The heating wall 113 is movable relative to the recess 111 between a closed position, shown in Figure 1 , in which the recess is substantially closed by the heating wall, and an open position, not shown, to allow access to the interior of the recess 111.

[0158] The recess 111 has a length of about 20 millimetres. The recess 111 has a depth of about 3.5 millimetres. The recess has a width of about 8 millimetres.

[0159] The recess 111 includes an air inlet 116 at the upstream end 114 of the recess 111 to allow air to enter the recess 111. The recess 111 includes an aerosol outlet 119 at the downstream end 115 of the recess 111 to allow air to leave the recess 111. The airflow through the air inlet 116 and aerosol outlet 119 is shown by arrows 118.

[0160] The device 100 further comprises three heat conducting elements 110 provided on the inner wall of the recess. Each heat conducting element 110 has a length of about 5 millimetres. Each of the heat conducting elements 110 are evenly distributed in the longitudinal direction.

[0161] The heat conducting elements comprises aluminium.

[0162] The heater assembly 112 comprises a plurality of heating zones, not shown in Figure 1 , which may be activated independently such that different portions of an aerosol-generating article received within the recess 111 may be selectively heated by a corresponding heating zone. The plurality of heating zones are distributed along the longitudinal axis of the heater assembly 112.

[0163] The plurality of heating zones comprises a plurality of individually actuatable electrical resistive heating elements. Each of the individually actuatable electrical resistive heating elements comprises a sinusoidal resistive heating element.

[0164] Figures 2 to 5 show the arrangement of four different heater assemblies according to the present invention when viewed along plane A-A shown in Figure 1 .

[0165] In the example shown in Figure 2, the heater assembly 212 comprises a first heating zone 201 arranged at an upstream end 200 of the heater assembly 212, and a second heating zone 203 arranged at the downstream end 202 of the heater assembly 212. Each of the first heating zone 201 and the second heating zone 203 comprise an individually actuatable sinusoidal electrical resistive heating element 205. In the example shown in Figure 2, the first heating zone 201 and the second heating zone 203 have the same length.

[0166] In the example shown in Figure 3, the heater assembly 312 comprises a first heating zone 301 arranged at an upstream end 300 of the heater assembly 312, and a second heating zone 303 arranged at the downstream end 302 of the heater assembly 312. Each of the first heating zone 301 and the second heating zone 303 comprise an individually actuatable sinusoidal electrical resistive heating element 305. In the example shown in Figure 3, the first heating zone 301 has a first length and the second heating zone 303 has a second length. The second length is greater than the first length.

[0167] In the example shown in Figure 4, the heater assembly 412 comprises a first heating zone 401 arranged at an upstream end 400 of the heater assembly 412, and a second heating zone 403 arranged at the downstream end 402 of the heater assembly 412. Each of the first heating zone 401 and the second heating zone 403 comprise an individually actuatable sinusoidal electrical resistive heating element 405. In the example shown in Figure 4, the first heating zone 401 has a first length and the second heating zone 403 has a second length. The first length is greater than the second length.

[0168] In the example shown in Figure 5, the heater assembly 512 comprises a first heating zone 501 arranged at an upstream end 500 of the heater assembly 512, a second heating zone 503 arranged at the downstream end 502 of the heater assembly 512, and a third heating zone 506 arranged between the first heating zone 501 and the second heating zone 503. Each of the first heating zone 501 , the second heating zone 503, and the third heating zone 506 comprise an individually actuatable sinusoidal electrical resistive heating element 505. In the example shown in Figure 5, each of the first heating zone 501 , the second heating zone 503, and the third heating zone 506 have the same length. Each of the first heating zone 501 , the second heating zone 503, and the third heating zone 506 have a length of about 5 millimetres.

[0169] Referring again to Figure 1 , each heating zone 501 , 503, 506 has a corresponding heat conducting element 110 such that different portions of an aerosol-generating article received within the recess 111 may be selectively heated by the a corresponding heating zone 501 , 503, 506 and heat conducting element 510.

[0170] An aerosol-generating article 600 for use with an aerosol-generating device of the present invention is shown in Figure 6. The aerosol-generating article 600 comprises a container 610. The container 610 comprises a first wall 611 and a second wall 612 which together define a substrate compartment 613. An aerosol-generating substrate 614 is provided in the substrate compartment.

[0171] In the example shown in Figure 6, the first wall 611 is formed from a non-woven cotton material. The first wall 611 comprises between 85 weight percent and 90 weight percent cellulose, between 7 weight percent and 16 weight percent hemicellulose, and between 1 weight percent and 3 weight percent lignin. The first wall 611 is porous.

[0172] The second wall 612 comprises paper. The second wall 612 has a grammage of about 35 gsm. The second wall is non-porous.

[0173] The second wall 612 is substantially planar. The second wall 612 has a higher stiffness than the first wall 611. In this way, the first wall 611 may generally form a bag shape which is closed by the second wall 612.

[0174] An aerosol-generating substrate 614 is provided in the substrate compartment 613. The aerosol-generating substrate 614 comprises granules of homogenised tobacco material, and an aerosol-former. The aerosol-former comprises glycerine. The substrate compartment 613 contains about 150 milligrams of aerosol-generating substrate 614.

[0175] Referring again to Figure 1 , in use the heating wall 113 is moved into the open position to allow the aerosol-generating article 700 to be inserted into the recess 111 of the aerosolgenerating device 100. The heater assembly 112 is activated to heat the aerosol-generating article 700, particularly the portion directly adjacent the heater assembly 112 to generate an aerosol from the aerosol-generating substrate. The heat is also transferred by the heat conducting elements 110 away from the heater assembly 112 around the inner wall of the recess 111. Heat from the heat conducting elements 110 then heats a portion of the aerosol-generating article 700 which is spaced apart from the heating assembly 112 to generate an aerosol from the aerosol-generating substrate.

[0176] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". In this context, therefore, a number A is understood as A ± 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

Claims:

1. An aerosol-generating device for use with an aerosol-generating article, the aerosolgenerating device comprising: a housing, the housing comprising: a recess for receiving an aerosol-generating article, and a heater assembly configured to heat an aerosol-generating article when it is received in the recess, the heater assembly comprising a plurality of heating zones which may be activated independently such that different portions of an aerosol-generating article received within the recess may be selectively heated by a corresponding heating zone, and wherein the recess has a depth of at least 2 millimetres.

2. An aerosol-generating device according to claim 1, wherein the plurality of heating zones are distributed along the longitudinal axis of the heater assembly.

3. An aerosol-generating device according to claim 1 or claim 2, wherein the plurality of heating zones comprises no more than 10 heating zones.

4. An aerosol-generating device according to any preceding claim, wherein the plurality of heating zones comprises at least 3 heating zones.

5. An aerosol-generating device according to any preceding claim, wherein the plurality of heating zones comprises a plurality of individually actuatable electrical heating elements.

6. An aerosol-generating device according to claim 5, wherein the plurality individually actuatable electrical heating elements comprises at least one resistive heating element.

7. An aerosol-generating device according to claim 6, wherein the at least one resistive heating element is a planar sinusoidal heating element.

8. An aerosol-generating device according to claim 5, wherein the plurality of individually actuatable electrical heating elements comprises at least one inductive heating element.

9. An aerosol-generating device according to any preceding claim, wherein each of the plurality of heating zones have the same length.

10. An aerosol-generating device according to any one of claims 1 to 8, wherein the plurality of heating zones comprises a first heating zone having a first length, and a second heating zone having a second length, wherein the first length is greater than the second length.

11. An aerosol-generating device according to claim 10, wherein the first heating zone is upstream of the second heating zone.

12. An aerosol-generating device according to claim 10, wherein the first heating zone is downstream of the second heating zone.

13. An aerosol-generating device according to any preceding claim, wherein at least one heating zone of the plurality of heating zones has a length of at least 3 millimetres.

14. An aerosol-generating device according to any preceding claim, wherein the at least one heating zone of the plurality of heating zones has a length of no more than 20 millimetres.

15. An aerosol-generating system comprising: an aerosol-generating device according to any preceding claim; and an aerosol-generating article.

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