A device and method of releasing consistent aerosol in an aerosol-generating system

Abstract

The present invention discloses an aerosol-generating device for releasing consistent aerosol. The device comprises a resistive heater (104) which is cylindrical in shape with a tapered head, at one of its ends, configured to penetrate an aerosol-generating substrate (103-A), a resistive heating track, configured to generate heat for aerosolizing the aerosol-generating substrate and a temperature-measuring sensor track, embedded alongside the resistive heating track, configured to measure temperature variations during the heating cycle. Further, the device comprises a controller, configured to receive input from the temperature-measuring sensor track, implement a multiphase heating cycle, adjusting power distribution to maintain predefined temperature profiles, wherein the heating cycle comprises at least two distinct phases, and dynamically regulate power supplied to the resistive heating track to ensure consistent aerosol delivery while minimizing energy consumption.

Description

TITLE OF THE INVENTIONA DEVICE AND METHOD OF RELEASING CONSISTENT AEROSOL IN AN AEROSOL-GENERATING SYSTEMFIELD OF INVENTION

[0001] The present invention relates to an aerosol generating device and method. More particularly, the present invention relates to the aerosol generating device and method for releasing consistent aerosol in an aerosol-generating system.CROSS REFERENCE TO RELATED APPLICATIONS

[0002] Applicant claims priority and the benefit of Indian Provisional Patent application 202411027815, filed 04 April 2024 (04-04-2024), said application being hereby incorporated herein in its entirety by referenceBACKGROUND OF INVENTION

[0003] An aerosol-generating device are configured to heat an aerosol -generating substrate material. The device typically consists of a heater assembly with a control body. The heater assembly contains a cavity to accommodate an aerosol-generating article for aerosolization. The aerosol -generating article comprises an aerosol generating substrate and other segments. The aerosol-generating device heats the aerosol-generating substrate of the aerosol -generating article and releases the aerosol.

[0004] For a given aerosol-generating substrate, the release of aerosol substantially depends upon the heating temperature. It is essential for the heat to be distributed sufficiently throughout the aerosol-generating substrate segment to ensure that the optimum substrate temperature is achieved.

[0005] The key issues associated with current aerosol-generating devices available include prolonged preheating times, inconsistent aerosol distribution, overheating of the substrate, and unpleasant taste experiences for consumers.• Both high and low heating temperatures can result in uneven aerosol delivery.• At lower temperatures, the delay in reaching the necessary aerosol output can lead to suboptimal delivery.• Conversely, maintaining a higher temperature throughout operation may only produce heat without effectively delivering the required aerosols, resulting in increased power (battery) consumption and an unpleasant sensory experience for users.

[0006] To eliminate the above issues in an aerosol-generating device, various attempts were made. For example, the patent US9498000B2 outlines a method for controlling aerosol production in such devices. Similarly, US20230270178A1 describes a technique for operating an aerosol -generating device that produces aerosol from an aerosol-forming substrate during usage sessions. Another relevant patent, US20230320427A1, also focuses on methods for generating aerosol from an aerosol-forming substrate during usage.

[0007] Additionally, US11141548B2 introduces a method that involves heating the aerosol-generating substrate in a manner that creates distinct temperature profiles for different portions of the substrate during operation.

[0008] An ongoing need exists for aerosol-generating systems that deliver a superior sensory experience through precise temperature control of the heating element. This control aims to ensure consistent aerosol delivery throughout the heating cycle, while also minimizing the initial time required to achieve stable aerosol production.OBJECT OF INVENTION

[0009] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

[0010] It is an object of the present invention to ensure consistent aerosol delivery throughout the heating cycle of the aerosol-generating device.

[0011] It is another object of the present invention to reduce the preheating time required for the aerosol-generating device to reach optimal operating conditions.

[0012] It is yet another object of the present invention to optimize power consumption by efficiently managing the power supply to the heating element.

[0013] It is yet another object of the present invention to utilize a multi -phase heating profile to achieve specific temperature targets in different stages of the heating cycle.

[0014] It is yet another object of the present invention to prevent overheating of the aerosol-generating substrate and minimize the risk of aerosol -generating device malfunction or safety hazards.

[0015] It is yet another object of the present invention to enhance user experience.SUMMARY OF THE INVENTION

[0016] The present invention discloses an aerosol -generating device for releasing consistent aerosol in an aerosol-generating system. The aerosol -generating device comprises a heater / heating element which is cylindrical in shape with a tapered head, at one of its ends, facilitating efficient penetration into the aerosol -generating substrate. A temperature control mechanism divides the heating cycle into distinct phases, allowing for precise temperature adjustments during each phase. By providing power to the resistive heater / heating element and controlling its temperature profile, the aerosol-generating device ensures consistent aerosol delivery throughout the heating cycle. The aerosol -generating device aims to reduce preheating time, optimize power consumption, and enhance the overall user experience.

[0017] The present invention discloses a method for releasing consistent aerosol by controlling aerosol generation in an aerosol -generating device through precise temperature management. The method involves providing power to at least one heating element and controlling the power to achieve specific temperature transitions during distinct phases of the heating cycle. The method begins with aphase of maximum power to increase the temperature of the resistive heater / heating element from an initial temperature to a first temperature. Subsequent phases involve controlled power reduction to decrease the temperature to predefined levels. The method creates a controlled temperature profile with targeted temperatures for each phase. Optionally, a further phase may increase the temperature to the intended level. Specific durations and temperature ranges are defined for each phase to ensure consistent aerosol delivery and optimize energy consumption.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0018] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:

[0019] Figure 1 illustrates a schematic representation of an aerosol -generating device featuring a cylindrical heating element with a tapered head, according to one embodiment of the present invention.

[0020] Figure 2 is a schematic representation illustrating the heating cycle, according to an embodiment of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0021] The present invention may be embodied in several forms, and the details of embodiments of the present invention will be described in the following content with figures. The embodiments described below with reference to the drawings are merely illustrative of the technical solutions of the present disclosure but are not to be construed as limited to the technical solutions of the present disclosure.

[0022] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of the present invention is provided for illustration purposes only and not for the purpose of limiting the invention as defined by the appended claims. As used in the descriptionof the invention and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0023] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0024] In a preferred embodiment, the present invention discloses an aerosolgenerating device for releasing consistent aerosol. An aerosol-generating device includes a heater (104), configured to receive an aerosol -generating substrate (103- A). The at least one heating track on the said heater is configured to generate heat for aerosolizing the aerosol-generating substrate. A temperature-measuring sensor track is embedded alongside the heating track and configured to measure temperature variations during the heating cycle. A controller is configured to receive input from the temperature-measuring sensor track and implement a multiphase heating cycle, by adjusting power distribution to maintain predefined temperature profiles, wherein each phase corresponding to a specific temperature range and time duration and dynamically regulate power supplied to the heating track to ensure consistent aerosol delivery. The multi-phase heating cycle further comprises at least two phases, with temperature ranging from 335 to 395, operating between 0-340 seconds. The multi-phase heating cycle includes at least two phases selected from:Phase 1 : Applying maximum power to heat the resistive heater from an initial temperature (To) to a first temperature (Ti) within 0-10 seconds, within a range of 380°C - 395°C;Phase 2: Reducing power to maintain a temperature between 370°C - 390°C for 10-50 seconds;Phase 3 : Further reducing power to maintain a temperature between 360°C - 380°C for 50-100 seconds;Phase 4: Decreasing power further to maintain a temperature between 335°C - 355°C for 100-180 seconds;Phase 5: Increasing power to maintain a temperature between 345°C - 365°C for 180-260 seconds;Phase 6: Further increasing power to maintain a temperature between 355°C - 375°C for 260-340 seconds.

[0025] In a preferred embodiment, the present invention discloses an aerosolgenerating device for releasing consistent aerosol. The aerosol -generating device includes a resistive heater / heating element, a resistive heater having a cylindrical shape, a tapered head, a resistive heating track, a temperature-measuring sensor track, and a controller. An aerosol -generating article containing aerosol-generating substrate. The aerosol-generating article is put in the aerosol-generating device. The tapered head is configured to penetrate an aerosol-generating substrate. The resistive heater starts the heating cycle and serves as the primary component responsible for heating the aerosol-generating substrate. During phase 1 of the heating cycle, maximum power is applied to the resistive heater to increase the temperature from an initial level (TO) to a first temperature (Tl), typically lasting 4 to 15 seconds, preferably in the temperature range of 365°C to 395°C. Subsequent phases involve gradual power reduction to decrease the temperature, ensuring controlled heating, with Phase 2 lasting at max for 60 seconds, preferably in the temperature range of 355°C to 390°C, and Phase 3 lasting at max for 100 seconds, preferably in the temperature range of 345°C to 380°C. In Phase 4, which lasts for a max of 145 seconds, preferably in the temperature range of 320°C to 355°C, power is further decreased. Phase 5 entails increased power for max 135 seconds, preferably in the temperature range of 330°C to 365°C. Optionally, Phase 6 entailsfurther increased power for at max of 145 seconds, preferably in the temperature range of 340°C to 375°C, to reach the intended temperature. The resistive heating track is configured for generating heat within the aerosol -generating device, facilitating the release of aerosol from the aerosol-generating substrate. The resistive heating track is made up of at least one metal or its alloy and designed to create a uniform heating zone across the length of the aerosol -generating substrate of the aerosol-generating article. The resistive heating track material can include but not limited to Tungsten (Wolfram). The temperature-measuring sensor track is embedded alongside the resistive heating track. The temperature-measuring sensor track measures the temperature during the heating cycle. The controller receives input from the temperature sensor track and uses a pre-programmed multi-phase temperature profile. Based on predefined temperature profiles and heating phases, the controller adjusts power distribution to the heating element and the current temperature reading. The controller adjusts the power supplied to the resistive heating track, ensuring, and maintaining the target temperatures for each phase. The heating cycle parameters are customizable, allowing the user to select specific temperature settings.

[0026] In another embodiment of the present invention, the cylindrical shape ensures uniform distribution of heat, while the tapered head facilitates efficient penetration into the aerosol-generating substrate. By applying power to the resistive heater, heat is generated, causing the aerosol -generating substrate to be aerosolized.

[0027] In another embodiment of the present invention, the controller is configured to monitor temperature changes through integrated sensors within the heating element or aerosol-generating substrate, enabling accurate tracking of temperature variations. Utilizing predefined temperature profiles and heating phases, the controller adjusts power distribution to the heating element, initiating the heating cycle with maximum power to elevate the temperature to the intended range. Subsequent phases involve gradual power reduction to maintain optimal temperatures for aerosol production. The controller dynamically modulates power levels based on temperature feedback from sensors, ensuring consistent aerosoldelivery while minimizing energy consumption. Moreover, the controller incorporates safety protocols to prevent overheating and includes features like temperature limits or automatic shutoff mechanisms for user safety. The controller is configured to monitor temperature feedback in real time and adjust power to the heating track based on pre-programmed heating profiles and prevent overheating by incorporating temperature limits and automatic shutoff mechanisms.

[0028] In another embodiment of the present invention, the height of the tapered head is within the range of 1 mm to 5 mm.

[0029] In another embodiment of the present invention, the resistive heater is configured to be used alone or in combination with other heaters.

[0030] In another embodiment of the present invention, the resistive heater shape can be pin, blade, or tubular.

[0031] In another embodiment of the present invention, the present invention discloses a method for consistent aerosol delivery. A method for consistent aerosol delivery in an aerosol-generating device includes receive an aerosol-generating substrate (103A) using at least one heater (104), heating the aerosol -generating substrate using a heating track on the said heater, and measuring temperature variations in real time using a temperature-measuring sensor track embedded alongside the heating track while receiving temperature input from the temperaturemeasuring sensor track at a controller and implementing a multi -phase heating cycle via the controller, wherein the heating cycle comprises at least two distinct phases, each phase corresponding to a specific temperature range and time duration and dynamically regulating power supplied to the heating track on the said heater. The multi-phase heating cycle further comprises at least two phases, with temperature ranging from 335 to 395, operating between 0-340 seconds. The method further describes monitoring temperature feedback in real time by adjusting power to the heating track based on pre-programmed heating profiles, and preventing overheating by incorporating temperature limits and automatic shutoff mechanisms.

[0032] In another embodiment of the present invention, the heating element comprises a resistive heating track which is made up of at least one metal or its alloy.

[0033] In another embodiment of the present invention, the resistive heating track has a tapered head of not more than 3 mm.WORKING EXAMPLE

[0034] The present invention discloses a temperature profile specifically for the cylindrical resistive heater, allowing for consistent aerosol generation within the aerosol-generating substrate. The present invention is able to achieve this by dividing the duration of the aerosol generation-delivery cycle into at least two distinct phases based on the power provided to reach and maintain the predefined temperature.

[0035] Figure 1 discloses the aerosol generating device (100) consists of main body (101) and extractor (102) and aerosol generating article (103) comprising an aerosol generating substrate segment (103 -A). The heater assembly contains a cavity to accommodate an aerosol-generating article for aerosolization. The aerosolgenerating article comprises an aerosol -generating substrate and other segments. The device comprises a resistive heater (104) cylindrical in shape with a tapered head, at one of its ends, configured to penetrate an aerosol -generating substrate (103-A).

[0036] Figure 2 discloses the heating cycle of the present invention. In the first phase, maximum power is provided to the heater to quickly increase the temperature of the heater from the initial temperature (TO) to the first temperature (Tl). In the second phase, power is provided to decrease and maintain the temperature from the first temperature (Tl) to second temperature (T2) wherein T2 < Tl. In the third phase, power is provided to reduce and maintain the temperature from second temperature (T2) to third temperature (T3) wherein T3 < T2. In the fourth phase, power is further decreased to decrease and maintain the temperature from third temperature (T3) to fourth temperature (T4) wherein T4 < T3. In the fifth phase,power is provided to increase and maintain the temperature from fourth temperature (T4) to fifth temperature (T5) wherein T5 > T4. In the sixth phase, power is provided to increase and maintain the temperature from fifth temperature (T5) to sixth temperature (T6) wherein T6 > T5. The temperature (T1-T6) is the maximum temperature of the cylindrical heater.

[0037] The temperature of the heater is measured by the controller from the change in the resistance of the dedicated sensor tracks printed on the cylindrical heater.ADVANTAGES OF THE INVENTION

[0038] The present invention ensures consistent aerosol production by controlling the heating cycle, resulting in uniform aerosol output over time.

[0039] By employing a pre-programmed multi-phase temperature profile and adjusting power distribution to the heating element, the present invention minimizes energy consumption while maintaining optimal heating conditions.

[0040] The cylindrical shape and tapered head of the resistive heater allow for efficient penetration into the aerosol -generating substrate, ensuring thorough and effective heating throughout the aerosol-production process.

[0041] The present invention provides customizable temperature control options, allowing users to adjust temperature settings based on specific applications.

Claims

CLAIMS1. An aerosol-generating device comprising: at least one heater (104), configured to receive an aerosol -generating substrate (103 -A); at least one heating track on the said heater, configured to generate heat for aerosolizing the aerosol-generating substrate; a temperature-measuring sensor track, embedded alongside the heating track, configured to measure temperature variations during the heating cycle; a controller, configured to: receive input from the temperature-measuring sensor track; implement a multi-phase heating cycle, adjusting power distribution to maintain predefined temperature profiles, wherein each phase corresponding to a specific temperature range and time duration and dynamically regulate power supplied to the heating track to ensure consistent aerosol delivery.

2. The aerosol -generating device as claimed in claim 1, wherein the multiphase heating cycle further comprises at least two phases, with temperature(s) ranging from 335 to 395, operating between 0-340 seconds.

3. The aerosol -generating device as claimed in claim 1, wherein the said heater (104) is cylindrical in shape with a tapered head, at one of its ends.

4. The aerosol-generating device as claimed in claim 1, wherein the heating track is formed of at least one metal or its alloy thereof.

5. The aerosol -gen erating device as claimed in claim 1, wherein the controller is configured to: monitor temperature feedback in real time; adjust power to the heating track based on pre-programmed heating profiles; andprevent overheating by incorporating temperature limits and automatic shutoff mechanisms.

6. The aerosol -generating device as claimed in claim 1, wherein the temperature-measuring sensor track determines temperature variations on the said heating track.

7. The aerosol-generating device as claimed in claim 3, wherein the height of the tapered head is within 1 mm to 5 mm to facilitate efficient penetration into the aerosol-generating substrate.

8. The aerosol-generating device as claimed in claim 1, wherein the heater is configured to be used alone or in combination with other heaters.

9. The aerosol-generating device as claimed in claim 1, wherein the heating cycle parameters are customizable, allowing the user to select specific temperature settings.

10. A method for consistent aerosol delivery in an aerosol -generating device, comprising: receive an aerosol-generating substrate (103A) using at least one heater (104); heating the aerosol-generating substrate using a heating track on the said heater; measuring temperature variations in real time using a temperaturemeasuring sensor track embedded alongside the heating track; receiving temperature input from the temperature-measuring sensor track at a controller; implementing a multi-phase heating cycle via the controller, wherein the heating cycle comprises at least two distinct phases, each phase corresponding to a specific temperature range and time duration and dynamically regulating power supplied to the heating track on the said heater.

11. The method of Claim 10, wherein the multi-phase heating cycle further comprises at least two phases, with temperature(s) ranging from 335 to 395, operating between 0-340 seconds.

12. The method of Claim 10, further comprising: monitoring temperature feedback in real time; adjusting power to the heating track based on pre-programmed heating profiles; and13. preventing overheating by incorporating temperature limits and automatic shutoff mechanisms.

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