EP4623712A1

EP4623712A1 - Aerosol provision device

Info

Publication number: EP4623712A1
Application number: EP24167678.2A
Authority: EP
Inventors: Thomas WOODMAN; Mark Potter; Charanjit Nandra; Richard Hepworth; Marcus Hartley
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-28
Filing date: 2024-03-28
Publication date: 2025-10-01
Also published as: WO2025202305A1

Abstract

An aerosol provision device (100) is provided. The aerosol provision device (100) comprises a first member (130) and a second member (140). The first member (130) and the second member (140) define therebetween a heating zone (105) arranged to receive at least a portion of an article (300) comprising aerosol generating material (302). The first member (130) is movable relative to the second member (140) and the first and second members (130, 140) are arranged to grip the article (300) in the heating zone (105). The first member (130) is resilient. One or each of the first and second members (130, 140) comprises at least a portion of a magnetic field generator (119) for generating a varying magnetic field to be used in heating the aerosol generating material (302) when the portion of the article (300) is located in the heating zone (105).

Description

TECHNICAL FIELD

The present invention relates to an aerosol provision device for generating an aerosol from aerosol-generating material. The present invention also relates to an aerosol provision system.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles that burn tobacco by creating products that release compounds without burning. Examples of such products are heating devices which release compounds by heating, but not burning, the material. The material may be for example tobacco or other non-tobacco products, which may or may not contain nicotine.

SUMMARY

In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a first member and a second member defining therebetween a heating zone arranged to receive at least a portion of an article comprising aerosol generating material, wherein the first member is movable relative to the second member and the first and second members are arranged to grip the article in the heating zone; wherein the first member is resilient; and wherein one or each of the first and second members comprises at least a portion of a magnetic field generator for generating a varying magnetic field to be used in heating the aerosol generating material when the portion of the article is located in the heating zone.
In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a first member and a second member defining therebetween a heating zone arranged to receive at least a portion of an article comprising aerosol generating material, wherein the first member is movable relative to the second member and the first and second members are arranged to grip the article in the heating zone; wherein the first member is resilient, and comprising a flared section configured to cause deformation of the first member on insertion of the article into the heating zone.
In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a first member and a second member defining therebetween a heating zone arranged to receive a planar article comprising aerosol generating material, wherein the first member is movable relative to the second member; wherein the first and second members are arranged to grip the planar article in the heating zone and wherein the first member is resilient.
In an embodiment of any of the above, one or each of the first and second members may comprise at least a portion of a magnetic field generator for generating a varying magnetic field to be used in heating the aerosol generating material when the portion of the article is located in the heating zone.
In an embodiment of any of the above, the first member may comprise the at least a portion of a magnetic field generator. In an embodiment of any of the above, the second member may comprise the at least a portion of a magnetic field generator.
In an embodiment of any of the above, the at least a portion of a magnetic field generator may comprise an inductor coil. In an embodiment of any of the above, the inductor coil may be a two-dimensional coil. In an embodiment of any of the above, the inductor coil may be planar. In an embodiment of any of the above, the inductor coil may be flexible. In an embodiment of any of the above, the inductor coil may be printed. In an embodiment of any of the above, the inductor coil may be a spiral coil. In an embodiment of any of the above, the inductor coil may have a maximum width greater than a maximum height of the inductor coil. In an embodiment of any of the above, the inductor coil may comprise a flat spiral coil. In an embodiment of any of the above, the flat spiral coil may be arced.
In an embodiment of any of the above, the at least a portion of a magnetic field generator may comprise an array of inductor coils. In an embodiment of any of the above, the array of inductor coils may be aligned along an axis.
In an embodiment of any of the above, at least one of the first member and the second member may comprise a support member. In an embodiment of any of the above, the first member may comprise the support member. In an embodiment of any of the above, the second member may comprise the support member.
In an embodiment of any of the above, the support member may be resilient.
In an embodiment of any of the above, the inductor coil may be bonded to the support member. In an embodiment of any of the above, the inductor coil may be printed on the support member.
In an embodiment of any of the above, the inductor coil may be separated from the heating zone by the support member.
In an embodiment of any of the above, the support member may comprise thermal insulation. In an embodiment of any of the above, the support member may be a thermally insulating member.
In an embodiment of any of the above, the support member may comprise electrical insulation. In an embodiment of any of the above, the support member may be an electrically insulating member.
In an embodiment of any of the above, one or both of the first and second members may comprise a substantially planar portion configured to abut the article.
In an embodiment of any of the above, the heating zone may be configured to receive a planar article.
In an embodiment of any of the above, the aerosol provision device may comprise a flared section configured to cause deformation of the first member on insertion of the article into the heating zone.
In an embodiment of any of the above, the flared section may be comprised in the first member.
In an embodiment of any of the above, the flared section may be comprised in the second member.
In an embodiment of any of the above, the flared section may comprise a curved portion at least partly defining an opening of the heating zone.
In an embodiment of any of the above, the opening of the heating zone may be tapered.
In an embodiment of any of the above, the or each flared section may smoothly join the or each substantially planar portion.
In an embodiment of any of the above, the first and second members may be arranged to be urged away from each other by insertion of the article into the heating zone. In an embodiment of any of the above, the first and second members may be arranged to be forced apart by insertion of the article into the heating zone.
In an embodiment of any of the above, the first and second members may be arranged to compress at least a part of the article.
In an embodiment of any of the above, at least one of the first and second members may be biased towards the other of the first and second members.
In an embodiment of any of the above, the aerosol provision device may comprise an elastic member connecting the first member to the second member. The elastic member may be a spring.
In an embodiment of any of the above, at least one of the first member and the second member may comprise thermal insulation. In an embodiment of any of the above, at least one of the first member and the second member may be a thermally insulating member.
In an embodiment of any of the above, at least one of the first member and the second member may comprise electrical insulation. In an embodiment of any of the above, at least one of the first member and the second member may be an electrically insulating member.
In an embodiment of any of the above, the first and second members are arranged to compress the article in the heating zone.
In an embodiment of any of the above, the first and second members are arranged to compress the article in the heating zone to cause an increase in the pressure drop of airflow through the article relative to an uncompressed state of greater than 5%, greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 70% or greater than 100%.
In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a chamber configured to at least partially receive the article of any of the above, the chamber being configured as a heating chamber for heating the article, wherein the device is configured to direct air through the article.
In accordance with embodiments described herein, there is provided an aerosol provision system comprising the aerosol provision device of any of the above and an article comprising aerosol generating material.
In accordance with some embodiments described herein, there is provided an article for use with an aerosol provision device, the article comprising: an aerosol generating material, a first sheet material, a second sheet material, and a corrugated sheet material between the first and second sheet materials.
In accordance with some embodiments described herein, there is provided an article for use with an aerosol provision device, the article comprising: aerosol generating material, a first sheet material, a second sheet material, and a resilient member between the first and second sheet materials. The resilient member may be a corrugated sheet material. The resilient member may be a compressible member.
In an embodiment of any of the above, the first sheet material may be a planar sheet material. In an embodiment of any of the above, the second sheet material may be a planar sheet material.
In an embodiment of any of the above, the corrugated sheet material may be sandwiched between the first and second sheet materials.
In an embodiment of any of the above, the article may comprise a mouth end and a distal end.
In an embodiment of any of the above, an airflow path may be defined through the article between the mouth end and the distal end.
In an embodiment of any of the above, the corrugated sheet material may define at least part of the airflow path.
In an embodiment of any of the above, the corrugated sheet material may comprise a corrugation.
In an embodiment of any of the above, the corrugation may extend parallel to the airflow path. In an embodiment of any of the above, the corrugation may extend perpendicular to the airflow path.
In an embodiment of any of the above, the aerosol generating material may be between the first and second sheet materials. In an embodiment of any of the above, the aerosol generating material may be between at least one of the first and second sheet materials and the corrugated sheet material. In an embodiment of any of the above, the aerosol generating material may extend between at least one of the first and second sheet materials and the corrugated sheet material.
In an embodiment of any of the above, the aerosol generating material may be on the corrugated sheet material. In an embodiment of any of the above, the aerosol generating material may be on at least one of the first and second sheet materials.
In an embodiment of any of the above, the corrugated sheet material may contact at least one of the first and second sheet materials. In an embodiment of any of the above, the corrugated sheet material may be adhered to at least one of the first and second sheet materials. In an embodiment of any of the above, respective peaks of the corrugated sheet material may contact at least one of the first and second sheet materials. In an embodiment of any of the above, respective peaks of the corrugated sheet material may be adhered to at least one of the first and second sheet materials. In an embodiment of any of the above, at least one of the first and second sheet materials comprises a plurality of aerosol generating material free regions. In an embodiment of any of the above, respective peaks of the corrugated sheet material may contact respective aerosol generating material free regions of the first or second sheet material.
In an embodiment of any of the above, the corrugated sheet material may define a heating element. In an embodiment of any of the above, the corrugated sheet material may comprise a support. In an embodiment of any of the above, the support may comprise a heating material. In an embodiment of any of the above, the support may comprise a support layer and a heating material layer. In an embodiment of any of the above, the heating material layer may be on the support layer. In an embodiment of any of the above, the corrugated sheet material may be a bilaminate. In an embodiment of any of the above, the aerosol generating material may be on the corrugated sheet material.
In an embodiment of any of the above, the article may comprise a susceptor layer. In an embodiment of any of the above, the susceptor layer may comprise aluminium. In an embodiment of any of the above, the susceptor layer may comprise a foil. In an embodiment of any of the above, the heating material may be heatable by penetration with a varying magnetic field.
In an embodiment of any of the above, the first sheet material may define a heating element. In an embodiment of any of the above, the first sheet material may comprise a support. In an embodiment of any of the above, the support may comprise a heating material. In an embodiment of any of the above, the first sheet material may comprise a support layer and a heating material layer. In an embodiment of any of the above, the heating material layer may be on the support layer. In an embodiment of any of the above, the first sheet material may be a bilaminate. In an embodiment of any of the above, the aerosol generating material may be on the first sheet material.
In an embodiment of any of the above, the second sheet material may define a heating element. In an embodiment of any of the above, the second sheet material may comprise a support. In an embodiment of any of the above, the support may comprise a heating material. In an embodiment of any of the above, the second sheet material may comprise a support layer and a heating material layer. In an embodiment of any of the above, the heating material layer may be on the support layer. In an embodiment of any of the above, the second sheet material may be a bilaminate. In an embodiment of any of the above, the aerosol generating material may be on the second sheet material.
In an embodiment of any of the above, the corrugated sheet material may define a spacer.
In an embodiment of any of the above, the corrugated sheet material may be directly heated.
In an embodiment of any of the above, the corrugated sheet material may be indirectly heated.
In an embodiment of any of the above, the corrugated sheet material may be a first corrugated sheet material. In an embodiment of any of the above, the article may comprise a second corrugated sheet material.
In an embodiment of any of the above, the article may comprise an intermediate sheet material between the first and second corrugated sheet materials. In an embodiment of any of the above, the intermediate sheet material may define a heating element.
In an embodiment of any of the above, the article may be configured to be receivable in an aerosol provision device.
In an embodiment of any of the above, the corrugated sheet material may comprise a plurality of apertures in the airflow path.
In an embodiment of any of the above, the corrugated sheet material may comprise peaks and troughs.
In an embodiment of any of the above, each corrugated sheet material may be formed as a sine wave, a square wave, or a triangular wave.
In an embodiment of any of the above, the corrugated sheet material may define a resilient member. In an embodiment of any of the above, the corrugated sheet material may be resilient perpendicular to the longitudinal axis.
In an embodiment of any of the above, the article may be resilient between the first and the second sheet materials. In an embodiment of any of the above, the article may be compressible.
In an embodiment of any of the above, the corrugated sheet material may be compressible. In an embodiment of any of the above, the corrugated sheet material may be compressible to reduce a size of the airflow path relative to an uncompressed state. In an embodiment of any of the above, the corrugated sheet material may be compressible to increase an airflow resistance of the article relative to an uncompressed state. In an embodiment of any of the above, the corrugated sheet material may be compressible to increase an airflow resistance of the article relative to an uncompressed state by greater than 5%, greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 70% or greater than 100%.
In accordance with some embodiments described herein, there is provided an article for use with an aerosol provision device, the article comprising: an aerosol generating material, a first corrugated sheet material, a second corrugated sheet material, and an intermediate sheet material between the first and second corrugated sheet materials.
In an embodiment of any of the above, the intermediate sheet material may be planar.
In an embodiment of any of the above, the intermediate sheet material may be sandwiched between the first and second corrugated sheet materials.
In an embodiment of any of the above, the article may comprise a mouth end and a distal end. In an embodiment of any of the above, an airflow path may be defined through the article between the mouth end and the distal end. In an embodiment of any of the above, at least one of the first and second corrugated sheet materials may define at least part of the airflow path. In an embodiment of any of the above, each of the first and second corrugated sheet materials may define at least part of the airflow path.
In an embodiment of any of the above, the first corrugated sheet material may comprise a corrugation. In an embodiment of any of the above, the second corrugated sheet material may comprise a corrugation. In an embodiment of any of the above, the corrugation may extend parallel to the airflow path. In an embodiment of any of the above, the corrugation may extend perpendicular to the airflow path.
In an embodiment of any of the above, at least one of the first corrugated sheet material and the second corrugated sheet material may define a resilient member. In an embodiment of any of the above, each of the first corrugated sheet material and the second corrugated sheet material may define a resilient member. In an embodiment of any of the above, at least one of the first and second corrugated sheet materials may be resilient perpendicular to the longitudinal axis. In an embodiment of any of the above, each of the first and second corrugated sheet materials may be resilient perpendicular to the longitudinal axis.
In an embodiment of any of the above, the article may be compressible. In an embodiment of any of the above, at least one of the first corrugated sheet material and the second corrugated sheet material may be compressible. In an embodiment of any of the above, at least one of the first corrugated sheet material and the second corrugated sheet material may be compressible to reduce a size of the airflow path relative to an uncompressed state. In an embodiment of any of the above, at least one of the first corrugated sheet material and the second corrugated sheet material may be compressible to increase an airflow resistance of the article relative to an uncompressed state. In an embodiment of any of the above, at least one of the first corrugated sheet material and the second corrugated sheet material may be compressible to increase an airflow resistance of the article relative to an uncompressed state by greater than 5%, greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 70% or greater than 100%.
In an embodiment of any of the above, the aerosol generating material may be on at least one of the first and second corrugated sheet materials. In an embodiment of any of the above, the aerosol generating material may be on both the first and the second corrugated sheet material. In an embodiment of any of the above, the at least one of the first and second corrugated sheet materials may define a heating element.
In an embodiment of any of the above, the corrugated sheet material may comprise a support. In an embodiment of any of the above, the support may comprise a heating material. In an embodiment of any of the above, the support may comprise a support layer and a heating material layer. In an embodiment of any of the above, the heating material layer may be on the support layer.
In an embodiment of any of the above, the article may comprise a susceptor layer. In an embodiment of any of the above, the susceptor layer may comprise aluminium. In an embodiment of any of the above, the susceptor layer may comprise a foil. In an embodiment of any of the above, the heating material may be heatable by penetration with a varying magnetic field.
In an embodiment of any of the above, at least a portion of the article may be substantially planar. In an embodiment of any of the above, the entire article may be substantially planar. In an embodiment of any of the above, the article may be a flat strip. In an embodiment of any of the above, the article may be rectangular. In an embodiment of any of the above, the article may be oblong.
In an embodiment of any of the above, the article may comprise a heating element. In an embodiment of any of the above, the heating element may be a resistive heating element. In an embodiment of any of the above, the heating element may comprise a material heatable by penetration with a varying magnetic field.
In an embodiment of any of the above, the aerosol generating material may be a gel. In an embodiment of any of the above, the article may comprise a support. In an embodiment of any of the above, the aerosol generating material may be bonded to the support. In an embodiment of any of the above, the article may comprise a foil layer.
In an embodiment of any of the above, at least a portion of the article may be incompressible. In an embodiment of any of the above, the whole article may be incompressible.
In an embodiment of any of the above, the article may have a length, a width perpendicular to the length, and a depth perpendicular to each of the length and the width. In an embodiment of any of the above, the length may be greater than or equal to the width. In an embodiment of any of the above, the width may be greater than the depth.
In accordance with some embodiments described herein, there is provided an aerosol generating system comprising an aerosol provision device and the article of any of the above.
In accordance with some embodiments described herein, there is provided an aerosol generating system comprising the aerosol provision device of any of the above and the article of any of the above.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings, in which:

Figure 1 shows a schematic cross-sectional side view of an aerosol provision system;
Figure 2 shows a schematic cross-sectional side view of the aerosol provision device of Figure 1;
Figure 3 shows a schematic perspective view of part of an article comprising aerosol generating material for use with the device of Figure 2;
Figure 4 shows a schematic exploded view of an article of the aerosol provision system of Figure 1;
Figure 5 shows a schematic cross-sectional view of the article of Figure 4;
Figure 6 shows a schematic exploded view of another article of the aerosol provision system of Figure 1;
Figure 7 shows a schematic cross-sectional view of the article of Figure 6; and
Figure 8 shows a schematic exploded view of another article of the aerosol provision system of Figure 1.

DETAILED DESCRIPTION

As used herein, the term "delivery mechanism" is intended to encompass systems that deliver a substance to a user, and includes: non-combustible aerosol provision systems that release compounds from an aerosolisable material without combusting the aerosolisable material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosolisable materials; and articles comprising aerosolisable material and configured to be used in one of these non-combustible aerosol provision systems.
According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source.
In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
As used herein, the term "aerosol-generating material" (which is sometimes referred to herein as an aerosolisable material) is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.
In some embodiments, the substance to be delivered comprises an active substance (sometimes referred to herein as an active compound).
In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.
In some embodiments, the substance to be delivered comprises a flavour.
In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.
The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material.
The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.
In embodiments, the aerosol-generating material comprises a plurality of aerosol-generating films. In embodiments, the aerosol-generating film comprises a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and/or plurality of aerosol-generating film regions may have different properties, for example at least one of different compositions, thicknesses, density, active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.
The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.
The aerosol-generating material may be an "amorphous solid". In some embodiments, the amorphous solid is a "monolithic solid". The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol-generating material may be a dried gel. The aerosol-generating material may be a solid material that may retain some fluid, such as liquid, within it. In some embodiments the retained fluid may be water (such as water absorbed from the surroundings of the aerosol-generating material) or the retained fluid may be solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.
The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy.
An aerosol provision device can receive an article comprising aerosol generating material for heating. An "article" in this context is a component that includes or contains in use the aerosol generating material as described previously, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into or onto the aerosol provision device before it is heated to produce an aerosol, which the user subsequently inhales.
An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.
A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may comprise a conductor which can be heated by the passage of an electrical current through the conductor.
Non-combustible aerosol provision systems may comprise a modular assembly including both a reusable aerosol provision device and a replaceable aerosol generating article. In some implementations, the non-combustible aerosol provision device may comprise a power source and a controller (or control circuitry). The power source may, for example, comprise an electric power source, such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol provision device may also comprise an aerosol generating component. However, in other implementations the aerosol generating article may comprise partially, or entirely, the aerosol generating component. Various embodiments will now be described in more detail.
Figure 1 shows an aerosol provision system 10. The system 10 comprises an aerosol provision device 100 for generating aerosol from an aerosol generating material and an article 300 comprising aerosol generating material 302. In broad outline, the device 100 may be used to heat the article 300, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100.The article 300 and the device 100 together form an aerosol provision system 10. The system may comprise any of the articles described herein, such as the article 210 of Figures 4 and 5, the article 510 of Figures 6 and 7 and the article 410 of Figure 8.
The aerosol provision device 100 is an elongate structure, extending along a longitudinal axis. The aerosol provision device has a proximal end 104, which will be closest to the user (for example, the user's mouth) when in use by the user to inhale the aerosol generated by the aerosol provision device 100, as well as a distal end 106 which will be furthest from the user when in use. The proximal end 104 may also be referred to as the "mouth end". The aerosol provision device 100 also accordingly defines a proximal direction, which is directed towards the user when in use, i.e. in the direction from the distal end 106 to the proximal end 104. Further, the aerosol provision device 100 also likewise defines a distal direction, which is directed away from the user when in use, i.e. in the direction from the proximal end 104 to the distal end 106.
The aerosol provision device 100 comprises a main body 101. A housing 102 surrounds and houses various components of the main body 101. The device 100 also includes a button assembly 200, acting as a user interface, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the button assembly 200. The button assembly 200 includes button 107, as shown in Figure 2. The button assembly 200 may be assembled as part of the other assemblies of the aerosol provision device 100.
Figure 3 shows a perspective view of the article 300. The article 300 comprises a support 306. The support defines a sheet material. The sheet material may comprise a single layer or a plurality of layers as described below. The aerosol generating material 302 is on the support 306, configured as a sheet material. The aerosol generating material 302 is bonded to the support 306. The support 306 provides structural support to the aerosol generating material 302. In embodiments, the support 306 may be omitted. The aerosol generating material 302 in embodiments is a gel. The aerosol generating material 302 is formed as an aerosol generating material layer 302.
The article 300 comprises heating material 304. The heating material 304 is a heating element 304. The heating material 304 is comprised in the support 306. The heating material 304 forms the support 306. In embodiments, the heating material 304 is a heating layer 304. In embodiments, the support 306 comprises a support layer and the heating layer is a separate layer to the support layer, provided on the support layer. In embodiments, the heating material 304 is omitted, for example when the heating element is in the device 100.
The aerosol generating material 302 is on the heating material 304. The support 306 forms a substrate. In embodiments, the support layer, heating layer 304 and aerosol generating material layer 302 form a laminate. In embodiments, the heating material 304 is separate from the support 306. In embodiments, the support 306 is free from a heating material. In embodiments, the support 306 comprises one or more of paper, card, foil and a laminate thereof. In embodiments, the heating material 304 may be omitted from the article 300. The heating material may be provided in the aerosol provision device 100.
The heating element 304 comprises a material heatable by penetration with a varying magnetic field. The heating element 304 is a susceptor. In embodiments, the heating element 304 is a resistive heating element. In such embodiments, at least part of an electrical path comprising the heating element 304 is exposed to an exterior of article 300. The electrical path comprises exposed electrical contacts. The exposed electrical contacts are configured to electrically connect to a device connector. The device connector, in embodiments, is comprised in the aerosol provision device 100. This allows contact between the exposed electrical contacts and the device connector, to pass current through the resistive heating element 304.
The aerosol generating material 302 and the support 306 together form a sheet. The sheet comprises a plurality of layers. The layers are formed as a laminate.
The article 300 is planar. The article 300 is a flat strip. As used herein, the term planar refers to a component which has a depth significantly smaller than its length and width. The exterior of the article 300 has a length L, a width W and a depth D. The width W is perpendicular to the length L and the depth D is perpendicular to each of the length L and the width W. In this embodiment, the length L is greater than the width W, and the width W is greater than the depth D. The depth D is less than 30%, less than 20% or less than 10% of the width W. The depth D is less than 30%, less than 20% or less than 10% of the length L.
In this embodiment, the exterior of the article 300 is a rectangular cuboid, so that the article 300 is elongate with a substantially rectangular cross-section. However, in other embodiments, the length L may be equal or substantially equal to the width W, so that the article 300 is not elongate as such. In some such embodiments, the exterior of the article 300 may be a square cuboid. In some embodiments, the exterior of the article 300 may be other than cuboid. For example, in some embodiments, some or all of the edges of the exterior of the article 300 may be bevelled or rounded. In some embodiments, the article 300 may have other than a substantially rectangular cross-section, such as an elliptical cross-section. In embodiments, the article 300 is a rod. In embodiments, the article 300 is substantially cylindrical.
The article 300 may also comprise other components such as at least one of a filter, wrapping materials and a cooling structure.
Figure 2 shows a schematic cross-sectional view of the aerosol provision device 100. The aerosol provision device 100 comprises a heating zone 105.The aerosol provision device 100 comprises an opening 103 leading into the heating zone 105. The opening 103 is at a proximal end 104 of the device. The article 300 may be inserted through the opening 103 to be retained within the heating zone 105. The article 300 is heated so that an inhalable medium is generated which may then be inhaled by a user of the aerosol provision device 100.
The aerosol provision device 100 comprises a first receptacle wall arrangement 130 and an opposing second receptacle wall arrangement 140. The first receptacle wall arrangement 130 acts as a first member 130 and the second receptacle wall arrangement 140 acts as a second member 140. The heating zone 105 is defined between the first member 130 and the second member 140. Further members may define the heating zone in embodiments.
The first member 130 is movable relative to the second member 140. Such movement need only be relative. The first member 130 is movable relative to the main body 101. The second member 140 is fixed relative to the main body 101. In embodiments, the first member 130 is fixed relative to the main body 101 and the second member is movable relative to the main body 101. In embodiments, both the first member 130 and the second member 140 are movable relative to the main body 101. In embodiments, neither the first member 130 nor the second member 140 is movable. In embodiments, the first member 130 and the second member 140 are fixed relative to one another.
The first member 130 is elongate. The first member 130 comprises a first wall portion 130a. The first wall portion 130a is a majority of the axial extent of first member 130. The first wall portion 130a extends in an axial direction of the aerosol provision device 100. The first wall portion 130a has a constant profile along its axial extent. At least part of the profile of the first wall portion 130a conforms to an exterior profile of the article 300. This allows the article 300 to be inserted in the axial direction into the heating zone 105, sliding over the first wall portion 130a. The first wall portion 130a is substantially planar. In embodiments, the first wall portion 130a is not planar. In embodiments, the first wall portion 130a is curved. In embodiments, the first wall portion 130a has a concave profile. In embodiments, the first wall portion 130a has a part-circular profile, such as a semi-circular profile, for example to conform to a rod-shaped consumable.
The first member 130 is resilient. That is, the first member tends towards a neutral position and is movable away from that neutral position. The first member 130 may deflect or deform without breaking. In embodiments, only a part of the first member 130 is resilient. A part of the first member 130 may be rigid. The second member 140 is rigid. In embodiments, the second member 140 is resilient.
The second member 140 is elongate. The second member 140 comprises a second wall portion 140a. The second wall portion 140a is a majority of the axial extent of second member 140. In this embodiment, the second wall portion 140a is the entirety of the second member 140. The second wall portion 140a extends in an axial direction of the aerosol provision device 100. The second wall portion 140a has a constant profile along its axial extent. The profile of the second wall portion 140a conforms to an exterior profile of the article 300. This allows the article 300 to be inserted in the axial direction into the heating zone 105, sliding over the second wall portion 140a. The second wall portion 140a is substantially planar. In embodiments, the second wall portion 140a is not planar. In embodiments, the second wall portion 140a is curved. In embodiments, the second wall portion 140a has a concave profile. In embodiments, the second wall portion 140a has a part-circular profile, such as a semi-circular profile, for example to conform to a rod-shaped consumable.
The first wall portion 130a of the first member 130 is substantially parallel to the second wall portion 140a of the second member 140. A distance between the wall portions 130a 140a of the first and second members 130 140 defines a width of the heating zone 105 in a neutral condition. The width of the heating zone 105 in the neutral condition is substantially constant along most of a length or axial extent of the heating zone 105. The width of the heating zone 105 may vary due to relative movement between first and second members 130, 140, such as deformation or deflection of the first member 130.
The aerosol provision device 100 comprises a flared section 150. The flared section 150 is at proximal end of the heating zone 105. The flared section 150 partly defines the opening 103. The width of the heating zone 105 is therefore wider at the opening 103 and subsequently narrows in the distal direction. The flared section 150 comprises a curved portion. In embodiments, the flared section 150 is not curved. The flared section 150 provides a taper. The flared section 150 is comprised in the first member 130. The first member 130 therefore comprises the flared section 150 and the first wall portion 130a. There is a smooth join between the flared section 150 and the first wall portion 130a. The flared section 150 may be omitted.
The flared section 150 aids insertion of the article 300 in the heating zone 105. In embodiments, insertion of the article 300 in the heating zone 105 causes relative movement between the first member 130 and the second member 140. As the article 300 is inserted into the opening 103, a distal end of the article 300 will initially contact the flared section 150. As the article 300 is pushed into the heating zone 105, the distal end of the article 300 engages the flared section 150, causing relative movement between the first member 130 and the second member 140. This increases the width of the heating zone 105 until it matches the depth of the article 300.
The first member 130 is a unitary component. The first member 130 is a one-piece component. In embodiments, the first member 130 is a composite component. The flared section 150 is resilient. In embodiments, the flared section 150 may be comprised in the second member 140. In embodiments, both the first member 130 and the second member 140 comprise a flared section.
The distance between the first wall portions 130a, 140a when the heating zone 105 is free of the article 300, that is in the neutral condition, is less than a thickness of article 300. In embodiments, the first wall portions 130a, 140a are free from contact with each other.
Inserting the article 300 in the heating zone 105 causes relative movement between the first and second members 130 140. Inserting the article 300 in the heating zone 105 causes deflection or deformation of the first member 130 to accommodate the article 300. The first member 130 and the second member 140 are arranged to grip the article 300 when the article 300 is at least partially inserted in the heating zone 105. Because the first member 130 is resilient, on deformation or deflection, it exerts a reaction force on the article 300. This helps to retain the article 300 in the heating zone 105.
The first member 130 and the second member 140 are arranged to compress at least a portion of the article 300 when the article 300 is at least partially inserted in the heating zone 105. This may occur both in embodiments in which one or both of the first member 130 and the second member 140 are movable and in embodiments in which both are fixed.
Such compression of the article 300 may compress the aerosol generating material 302, so as to increase the thermal conductivity of the aerosol generating material 302. Compression of the aerosol generating material 302 may provide for higher heat transfer through the article 300. Such compression should not be so great as to break the article 300 or to prevent a user to be able to draw volatilised material from the article 300. In embodiments, the article 300 is not significantly compressed on insertion into the heating zone 105. In embodiments, the article is incompressible or substantially incompressible.
Compression of the article 300 may increase a pressure drop of airflow through the article 300 relative to an uncompressed state. The dimensions of the heating zone 105, such as a neutral distance (in the absence of the article 300) between the first and second members 130, 140, and the compressibility of the article 300 may be selected to provide a desired pressure drop through the article 300 in use. In embodiments, the pressure drop through the article when inserted in the heating zone 105 and compressed may increase relative to a pressure drop through the article when not compressed (such as when outside the heating zone 105) by greater than 5%, greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 70% or greater than 100%.
In embodiments, one or both of the first and second members 130, 140 are biased towards the other member 130, 140. In embodiments, an elastic member such as a spring provides the biasing. The elastic member may extend between the first and second members 130, 140. The elastic member may extend between the first or second member 130, 140 and another feature of the aerosol provision device 100, such as the main body 101. The biasing may be a result of the resilience of the first member 130. In embodiments, the elastic member may be omitted. In embodiments, the first and or second member 130, 140 themselves may comprise the elastic member, acting as a biasing member.
As discussed above, the heating element 304 is comprised in the article 300. In embodiments, the heating element 304 is comprised in the aerosol provision device 100. In embodiments, the article 300 is free from a heating element 304.
The aerosol provision system 10 comprises an induction-type heating system. The induction-type heating system includes a magnetic field generator 119 and the heating element 304. The magnetic field generator 119 comprises an inductor coil assembly. The inductor assembly forms a portion of the magnetic field generator 119. The inductor coil assembly is comprised in the aerosol provision device 100.
The inductor coil assembly comprises an inductor coil 121. In embodiments, the number of inductor coils differs. In embodiments, two or more inductor coils are used. In embodiments, the inductor coil assembly comprises an array of inductor coils. In embodiments, the array of inductor coils is aligned along an axis. The axis in embodiments is the longitudinal axis. In embodiments, the inductor coil assembly also comprises a coil support. The coil support may be omitted.
The inductor coil 121 is a two-dimensional coil. The inductor coil 121 is planar. In embodiments, the inductor coil 121 may be a three-dimensional coil, such as a helical coil, for example a circular helix. The inductor coil 121 is flexible. The inductor coil 121 is able to flex without breaking. In embodiments, the inductor coil 121 is rigid. The inductor coil 121 defines a spiral. The inductor coil 121 defines a two-dimensional spiral.
The inductor coil 121 has a maximum width and a maximum height. The maximum width is greater than the maximum height. In embodiments, the inductor coil 121 comprises a flat spiral coil.
The inductor coil 121 is comprised in the first member 130. A portion of the magnetic field generator 119 is therefore comprised in the first member 130. In embodiments, the inductor coil 121 is comprised in the second member 140.In embodiments, inductor coils 121 are comprised in each of the first member 130 and the second member 140.
The first member 130 comprises a support member 132 and the inductor coil 121. The inductor coil 121 is bonded to the support member 132. In embodiments, the inductor coil 121 is printed on the support member 132. In embodiments, the inductor coil 121 is embedded in the support member. In embodiments, the inductor coil 121 forms part of the support member 132.
The inductor coil 121 is separated from the heating zone 105 by at least a portion of the support member 132. The inductor coil 121 is provided on an opposite side of the support member 132 to the heating zone 105. The support member 132 comprises thermal insulation. The support member 132 is a thermally insulating member. The support member 132 comprises electrical insulation. The support member 132 is an electrically insulating member. The support member 132 separates the inductor coil 121 from the heating zone 105. The first member 130 comprises thermal insulation. The first member 130 is a thermally insulating member. The first member 130 comprises electrical insulation. The first member 130 is an electrically insulating member. In embodiments, the inductor coil 121 is exposed to the heating zone. In embodiments, the support member 132 may be omitted.
Provision of a two-dimensional inductor coil 121 in at least one of the first and second members 130, 140 allows the inductor coil 121 to be biased toward the article 300. This helps to provide for a consistent spacing between the inductor coil or coils and the heating element 304. Accordingly, consistent heating may be achieved given that the effectiveness of inductive heating is dependent on the distance between the inductor source, for example the coil 121 and the susceptor, for example the heating element 304. For embodiments with an array of coils, such an arrangement aids in providing a consistent spacing between each coil and the heating element 304. Accordingly, this may lead to more efficient heating and may avoid hot spots and/or cold spots due to variable spacing between the inductor coil 121 and the heating element 304. Pressure exerted on the article 300 due to the resilience of the first member 130 may lead to improved proximity between the inductor coil 121 and the heating element 304. This may also reduce or eliminate the presence of air gaps between the article 300 and the first or second member 130, 140, which may further increase heating efficiency.
A similar effect may be obtained where the article 300 is compressible, for example where the first and second members 130, 140 are fixed. This may be the case with any of the articles 300, 210, 410, 510 disclosed herein. In the case of articles 210, 410, 510 comprising one or more corrugated sheet materials, the article 210, 410, 510 may be relatively more resilient, owing to the inherent compressibility of the corrugated sheet material. Further, use of a resilient or compressible article 300, 210, 410, 510 in an aerosol provision device 100 in which one or more of the first and second members 130, 140 is movable, as described above, may provide more efficient heating still.
Biasing between the first and second members 130, 140 and/or compression of a compressible article 300 may reduce or prevent relative movement between the inductor source or heating element and the article 300. This may improve user experience when using the device 100 during walking or jogging.
The aerosol provision system 10 may include other types of heating systems in addition or in alternative to the induction heating system. In embodiments, the aerosol provision system 10 comprises a resistive heating system.
As described above, in embodiments, the article 300 may comprise a resistive heating element 304. The aerosol provision device 100 may comprise device contacts for electrical connection with the heating element 304 for electrically activating the heating element 304 by passing a flow of electrical energy through the heating element 304. In embodiments, the article 300 may provide electrical tracks or contacts joined to the heating element 304, such that the device contacts need not contact the heating element 304 directly. The device contacts may be disposed in the heating zone 105. The device contacts may be provided on or form part of the first member 130. The device contacts may be flexible. The device contacts may be resilient. Electrical contact between the device contacts and the heating element 304 or article 300 electrical contacts may be improved by the biasing of the first and second members 130, 140 as described below, or by the resilience or compressibility of the article 300, latterly even in the case where the first and second members 130, 140 are fixed.
In embodiments, the aerosol provision device 100 may comprise a resistive heating element. Other types of heating element are envisaged. In embodiments, the number of heating elements may differ. In embodiments, the aerosol provision device 100 comprises two or more heating elements. The heating element may be two-dimensional. The heating element may be planar. The heating element may be flexible. The heating element may be resilient. The heating element may be able to flex without breaking. The heating element may be a resistive heating track. The track may follow a tortuous path.
The heating element may be provided on the first member 130. The heating element may be bonded to the first member 130. In embodiments, the heating element is printed on the first member 130. In embodiments, the heating element forms part of the first member 130. In embodiments, the heating element is provided on the second member 140. In embodiments, the heating element is bonded to the second member 140. In embodiments, the heating element is printed on the second member 140. In embodiments, the heating element forms part of the second member 140.In embodiments, each of the first and the second member 130, 140 include a heating element. In embodiments, the heating element is embedded in at least one of the first member 130 and the second member 140.
The heating element may be separated from the heating zone 105 by the first member 130. The heating element may be provided on an opposite side of the first member 130 to the heating zone 105. In embodiments, the heating element is exposed to the heating zone. In embodiments, the heating element is separated from the heating zone by the second member.
Provision of a two-dimensional heating element on the first or second member 130, 140 allows the heating element to be positioned close to the aerosol generating material 302, which may lead to more efficient heating. Biasing exerted on the article 300 due to the resilience of the first member 130 may lead to improved proximity between the heating element and the aerosol generating material 302.
The aerosol provision device 100 comprises an electrical component connector 160, which can receive a cable to charge the device 100. For example, the connector 160 may be a charging port, such as a USB charging port. In embodiments, the connector 160 may be used additionally or alternatively to transfer data between the device 100 and another device, such as a computing device.
The aerosol provision device 100 comprises a power source 170, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the magnetic field generator 119 to supply electrical power when required and under control of a controller to heat the aerosol generating material.
The aerosol provision device 100 comprises an electronics module 112. The electronics module 112 may comprise, for example, a printed circuit board (PCB). The PCB may support at least one controller, such as a processor, and memory. The PCB may also comprise one or more electrical tracks to electrically connect together various electronic components of the device 100. For example, the battery terminals may be electrically connected to the PCB so that power can be distributed throughout the device 100. The coil or coils may be disposed on a PCB. The coil or coils may comprise litz wire.
As used herein, the term one-piece component refers to a component of the device 100 which is not separable into two or more components following assembly of the device 100. As used herein, the term integrally formed refers to two or more features that are formed into a one-piece component during a manufacturing stage of the component.
The aerosol provision device 100 comprises an air passage 180. The air passage 180 extends from an air inlet 190 to the heating zone 105. The air passage 180 extends through the main body 101. The air passage 180 is arranged to direct airflow from an exterior of the aerosol provision device 100 to the heating zone 105, where the airflow may enter the article 300 and entrain the generated aerosol for inhalation by a user. The air inlet 190 is in the distal end 106 of the main body 101. The air passage 180 is defined by a flow path member 182. The flow path member 182 extends between the heating zone 105 and the air inlet 190. The flow path member 182 is tubular. The flow path member 182 defines a bore. The flow path member 182 extends in an axial direction along its length. In embodiments, the flow path member 182 follows a tortuous path. Other airflow arrangements are envisaged. For example, airflow may be provided between a receptacle defining the heating zone 105 and the article 300. One or more of the air passage 180, air inlet 190 and flow path member 182 may be omitted.
With reference to Figures 4 to 8, the structure of an embodiment of the aerosol forming article 210 is described in detail. The aerosol forming article 210 may be referred to as an article 210 comprising aerosol generating material. The aerosol forming article 210 may be used with the aerosol provision device 100 of Figures 1 and 2. The article 210 is a flat article. The article 210 is a planar article. The article 210 has a stacked structure. The stacked structure comprises a plurality of sheets 212. Each sheet of the plurality of sheets 212 is adjacent another sheet in the stacked structure. Each sheet of the plurality of sheets 212 is arranged in the stacked structure such that the plane of each sheet is generally parallel to adjacent sheets.
The stacked structure shown in Figures 4 and 5 comprises sheets that are generally planar. Planar sheets are considered to be sheets that extend generally in a flat plane. A planar sheet may comprise minor surface undulations, deformities, corrugations or other such features whilst still being considered a planar sheet. The sheets are formed from a sheet material.
The stacked structure comprises a first sheet material 214 and a second sheet material 216. The first and second sheet materials 214, 216 are planar sheet materials. The first and second sheet materials 214, 216 are generally flat. The sheet materials 214, 216 comprise a generally flat outer surface. The outer surface of the sheet materials 214, 216 extends in the plane of the sheet material.
The article 210 further comprises a corrugated sheet material 218. The stacked structure of Figure 4 comprises the corrugated sheet material 218 sandwiched between the first sheet material 214 and the second sheet material 216. The corrugated sheet material 218 is formed from a panel. The corrugated sheet material 218 is sandwiched between the first and second sheet materials 214, 216. The first and second sheet materials 214, 216 are separated by the corrugated sheet material 218. The first and second sheet materials 214, 216 are adjacent to the corrugated sheet material 218, but are spaced from each other. The corrugated sheet material 218 defines a spacer. The corrugated sheet material 218 spaces the first and second sheet materials 214, 216. The corrugated sheet material 218 provides structural resilience to the article 210. The corrugated sheet material 218 may bias the first sheet material 214 and the second sheet material 216 outwardly so that the article 210 is able to retain its dimensions.
The corrugated sheet material 218 comprises corrugations. The corrugated sheet material 218 comprises at least one corrugation. Corrugations may also be referred to as undulations, channels, ribs, crimps, ripples, grooves or any other configuration that is considered to comprise a rise and fall. The cross section of the corrugated sheet material 218 resembles a wave-like structure. The corrugations comprise peaks 220 and troughs 222. Each of the peaks 220 and troughs 222 comprise an inner surface 224 and an outer surface 226. The inner surface 224 is the shorter surface of the respective peak 220 or trough 222, and the outer surface 226 is the longer surface. The cross section of the corrugated sheet material 218 is the same along the length of the corrugated sheet material 218. The cross section of the corrugated sheet material 218 traces a meandering or serpentine path. The cross section of the corrugated sheet material 218 is formed as a sine wave. In other embodiments, the configuration of the corrugated sheet material 218 may differ. In embodiments, the corrugations of the corrugated sheet material 218 may be formed as a square wave or a triangular wave. In other embodiments, the cross section of the corrugated sheet material 218 may differ along the length of the corrugated sheet material 218.
As shown in Figure 4, the plurality of sheet materials 212 are arranged in the aerosol-forming article 210 in a stacked configuration, such that the aerosol forming article 210 is generally planar. The article 210 has a length L and a width W. The length L of the article 210 is greater than the width W. The article 210 extends along a longitudinal axis A. The article 210 comprises a proximal end 228 and a distal end 230. The proximal end 228 of the article 210 is also known as the mouth end.
The article 210 defines an airflow path 232. The airflow path 232 is defined through the article 210 between the mouth end 228 and the distal end 230. The airflow path 232 extends from the distal end 230 to the proximal mouth end 228. The airflow path 232 is defined between the first and the second sheet materials 214, 216. The corrugated sheet material 218 defines at least part of the airflow path 232. The airflow path 232 extends though the corrugated sheet material 218. The corrugations extend parallel to the airflow path 232. The corrugated sheet material 218 comprises a plurality of channels 234. The plurality of channels 234 each form a portion of the airflow path 232. Each of the plurality of channels 234 extends along the longitudinal axis A. In other embodiments, the corrugation may extend perpendicular to the airflow path 232. In this embodiment, the corrugated sheet material 218 may comprise a plurality of apertures in the airflow path 232. The plurality of apertures provide a fluid pathway along the airflow path through the corrugated sheet 218.
On insertion into the aerosol provision device 100, the article 210 may be compressed. The corrugated sheet material 218 provides structural resilience to the article 210 and may allow the article 210 to be compressed. The compression may be in a direction substantially perpendicular to the plane of the corrugated sheet material 218. Compression of the article 210 results in a reduction of the size of the airflow path 232 which may increase the resistance to airflow in the article 210, resulting in an increased pressure drop of the airflow through the article 210 relative to an uncompressed state.
The dimensions of the heating zone 105, such as a neutral distance (in the absence of the article 210) between the first and second members 130, 140, and the compressibility of the article 210 may be selected to provide a desired pressure drop through the article 210 in use. In embodiments, the pressure drop through the article 210 when inserted in the heating zone 105 and compressed may increase relative to a pressure drop through the article 210 when not compressed (such as when outside the heating zone 105) by greater than 5%, greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 70% or greater than 100%.
The article 210 comprises aerosol generating material. The aerosol generating material is on the corrugated sheet material 218. The aerosol generating material is an aerosol generating layer. In such an embodiment the aerosol generating material defines a discontinuous layer on the corrugated sheet material 218. The corrugated sheet material 218 acts as a support for the aerosol generating material. In embodiments, the aerosol generating material is a continuous layer. In embodiments, the aerosol generating material may be provided on one or more of the first and second sheet materials 214, 216 or omitted.
The aerosol generating material is arranged in the troughs 222 of the corrugations. The aerosol generating material extends along the length of the corrugated sheet material 218. In other embodiments, the aerosol generating material may cover the corrugated sheet material 218. The aerosol generating material may be a gel layer. The aerosol generating layer may be a solid material layer, such as reconstituted tobacco. The aerosol generating layer may be on one side of the corrugated sheet material 218. The aerosol generating layer may be on both sides of the corrugated sheet material 218.
In embodiments, the aerosol generating material is on one or each of the first and second sheet materials 214, 216 between which the corrugated sheet material 218 is disposed. The aerosol generating material may be discontinuous layer. The aerosol generating material in embodiments is an inner layer on one or each of the first and second sheet materials 214, 216. In embodiments, the corrugated sheet material 218 is free from aerosol generating material. In embodiments, the aerosol generating material is on each of the first and second sheet materials 214, 216 and the corrugated sheet material 218.
The article 210 comprises a heating arrangement. The heating arrangement comprises a heating element 236. The heating element 236 comprises a heating material. The heating element 236 is configured to heat the aerosol generating material to generate aerosol. In embodiments, the heating element 236 is a heating layer. In embodiments, the article 210 may be free from a heating arrangement and the heating arrangement may be provided in the aerosol provision device 100.
The heating element 236 is comprised in the corrugated sheet material 218. The corrugated sheet material 218 defines the heating element 236. The corrugated sheet material 218 comprises a support layer 238 and a heating layer 240. The support layer 238 may be omitted, such that the heating material forms the support. In embodiments, the heating element 236 may additionally or alternatively be comprised in one or more of the first sheet material 214 and the second sheet material 216.
In embodiments, the heating element 236 is a susceptor. The article 210 comprises a susceptor layer 236. The heating material 240 is heatable by penetration with a varying magnetic field. The susceptor layer 236 comprises a foil. The susceptor layer comprises aluminium.
In embodiments, the heating element 236 may be a resistive heating element. The heating element 236 may be heatable upon receiving electrical power from a power source of an aerosol provision device when in situ in the device, for example from the device connector described above.
In embodiments, the article 210 may be free from a heating arrangement. The article 210 may be heated when in situ in the device 100. The device 100 may comprise the heating element to heat the article 210. The article 210 may be indirectly heated by the heating element.
In embodiments, the heating arrangement of the article may have a different configuration. In embodiments, the heating material is on one or each of the first and second sheet materials 214, 216 between which the corrugated sheet material 218 is disposed. The aerosol generating material in such embodiments may be a layer on one or each of the first and second sheet materials 214, 216.
Providing the aerosol generating material on or adjacent to the heating element 236 may increase the efficiency or rate of heating and aerosol generation. Providing the aerosol generating material on the corrugated sheet material may provide a relatively large surface area of aerosol generating material, which may increase spatial efficiency. Providing the heating element 236 in the corrugated sheet material 218 rather than in the first or second sheet materials 214, 216 may reduce the temperature at the outer surfaces of the article 210 after heating, which may allow a user to handle a spent article 210 shortly after heating with lower or no discomfort.
In embodiments, the corrugated sheet material 218 is free from heating material. In such embodiments, the corrugated sheet material comprises a spacer. The corrugated sheet material may be formed from a thermally conductive heating material. The corrugated sheet material may be indirectly heated by the first and second sheet materials 214, 216 and so act as a heating member heated by the first and second sheet materials 214, 216 acting as heating elements. In embodiments, each of the first and second sheet materials 214, 216 and the corrugated sheet material 218 comprise heating material. In embodiments, the corrugated sheet material 218 is free from aerosol generating material. In embodiments, each of the first and second sheet materials 214, 216 and the corrugated sheet material 218 has aerosol generating material. In embodiments, each of the first and second sheet materials 214, 216 are free from aerosol generating material.
The first sheet material 214 may define a heating element. The first sheet material 214 may comprise a first support layer and a first heating layer. The first heating layer may be a susceptor. The first support layer provides support to the heating layer. The heating material layer may adjacent to the corrugated layer 218. The heating layer may define the airflow path.
In embodiments, the second sheet material 216 may define a heating element. The second sheet material 216 may define a heating element. The second sheet material 216 may be substantially the same as the first sheet material 214 with a heating element.
In embodiments, the first and the second sheet material 214, 216 may each comprise a heating element. The heating element of the first sheet material 214 may be a first heating element. The heating element of the second sheet material may be a second heating element. The first and second heating elements are separated by the corrugated layer 218. Aerosol generating material may be on the first sheet material 214. Aerosol generating material may be on the second sheet material.
The support layer 238 of the corrugated sheet material 218 may form an inner panel. The support layers of the first and second sheet materials may form first and second outer panels. In embodiments, the article 210 may comprise any configuration of heating elements. The aerosol generating material may comprise any sheet material that defines the airflow path. The aerosol generating material may be on the inner panel. The aerosol generating material may be on the first and second outer panels. The aerosol generating material may be on the inner panel and the outer panels.
With reference to Figure 6 and Figure 7, another embodiment of the article 510 is described. The arrangement is generally the same as described above for Figures 4 and 5, and so a detailed description will be omitted. In this embodiment, the arrangement of the stacked structure differs, and is formed from a differing number of planar and corrugated sheet materials. The combinations of configurations of each of the planar and corrugated sheet materials described above may be relevant here. Figure 6 shows an exploded view of the article 510. Figure 7 shows a cross sectional view of the article 510. The article 510 comprises a first corrugated sheet material 518 and a second corrugated sheet material 519. The first and second corrugated sheet materials 518, 519 each comprise a plurality of corrugations. The number of corrugations may differ.
A first airflow path 546 is defined by the first corrugated sheet 518. A second airflow path 548 is defined by the second corrugated sheet material 519. The corrugations of the first corrugated sheet material 518 extend parallel to the first airflow path 546. The corrugations of the second corrugated sheet material 519 extend parallel to the second airflow path 548. The first corrugated sheet material 518 defines a heating element 536. The first corrugated sheet material 518 may comprise a support layer and a heating material layer on the support layer.
In embodiments, the corrugations of the first corrugated sheet material 518 may extend perpendicular to the first airflow path 546. The first and second corrugated sheet materials 518, 519 may comprise a plurality of apertures. The first airflow path 546 may extend through the plurality of apertures. The second corrugated sheet material 519 may be the same configuration as the first corrugated sheet material 518. In other embodiments, the first and second corrugated sheet materials 518, 519 may have different configurations.
On insertion into the aerosol provision device 100, the article 510 may be compressed. At least one of the first and second corrugated sheet materials 518, 519 provides structural resilience to the article 510 and may allow the article 510 to be compressed. The compression may be in a direction substantially perpendicular to the plane of the corrugated sheet materials 518, 519. Compression of the article 510 can result in a reduction of the size of at least one of the first airflow path 546 and the second airflow path 548 which may increase the resistance to airflow in the article 510, resulting in an increased pressure drop of the airflow through the article 510 relative to an uncompressed state.
The dimensions of the heating zone 105, such as a neutral distance (in the absence of the article 510) between the first and second members 130, 140, and the compressibility of the article 510 may be selected to provide a desired pressure drop through the article 510 in use. In embodiments, the pressure drop through the article 510 when inserted in the heating zone 105 and compressed may increase relative to a pressure drop through the article 510 when not compressed (such as when outside the heating zone 105) by greater than 5%, greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 70% or greater than 100%.
The article 510 comprises an intermediate sheet material 542 sandwiched between the first and second corrugated sheet materials 518, 519. A first outer planar sheet material 514 is adjacent the first corrugated sheet material 518. A second outer planar sheet material 516 is adjacent the second corrugated sheet material 519. The first corrugated sheet material 518 is between the first outer planar sheet material 514 and the intermediate sheet material 542. The second corrugated sheet material 519 is between the second outer planar sheet material 516 and the intermediate sheet material 542. The first and second outer planar sheet materials 514, 516 are substantially the same as the embodiment of Figure 4. In the embodiment of Figure 6, the intermediate sheet material 542 defines a heating element 544. The heating element 544 of the intermediate sheet material 542 may be similar to any of the heating elements previously described.
The intermediate sheet material 542 is planar. The intermediate sheet material 542 is sandwiched between the first and second corrugated sheet materials 518, 519. The intermediate sheet material 542 separates the first corrugated sheet material 518 and the second corrugated sheet material 519. The first airflow path 546 is at least partially defined by the first outer planar sheet material 514. The first airflow path 546 is at least partially defined by the intermediate sheet material 542. The second airflow path 548 is at least partially defined by the second outer planar sheet material 516. The second airflow path 548 is at least partially defined by the intermediate sheet material 542. A first aerosol generating material is provided on the first corrugated sheet material 518. A second aerosol generating material is provided on the second corrugated sheet material 519. In embodiments, the first and second aerosol generating materials may be formed of the same material. In embodiments, the first and second aerosol generating materials may be formed of different materials. The first and second aerosol generating materials may provide different experiences to the user, for example different flavours. In embodiments, the first and second airflow paths 546, 548 may be a single fluid passageway. The first and second corrugated sheet materials 518, 519 may define at least part of the single fluid passageway.
With reference to Figure 8, another embodiment of the article 410 is described. The aerosol forming article 410 may be used with the aerosol provision device 100 of Figures 1 and 2.
The article 410 comprises a first and second sheet material 414, 416 arranged as planar sheet materials, and a corrugated sheet material 418, similar to the embodiment described with reference to Figure 2. The article 410 comprises an airflow path 432. The article 410 further comprises a first susceptor layer 450 and a second susceptor layer 452. The first susceptor layer 450 is adjacent to the first sheet material 414. The first susceptor layer 450 comprises a first edge 454 and a second edge 456. The first and the second edge 454, 456 are on opposite sides of the first susceptor layer 450. The first and the second edges 454, 456 extend parallel to the airflow path 432. The first and the second edge 454, 456 are deformed edges. The deformed edges contact the first sheet material 414. The deformed edges act as a spacer.
The airflow path 432 is a first airflow path and the article 410 further comprises a second airflow path 458. At least a part of the second airflow path 458 is external to the first sheet material 414. The first susceptor layer 450 defines at least a part of the second airflow path 458. The first sheet material 414 defines the second airflow path 458. The second airflow path 458 extends between the first sheet material 414 and the first susceptor layer 450.
The first susceptor layer 450 comprises aluminium. The first susceptor layer 450 comprises a foil. The first susceptor layer 450 comprises a heating material. The heating material is heatable by penetration with a varying magnetic field.
The second susceptor layer 452 is adjacent to the second sheet material 416. The second susceptor layer 452 comprises a first edge 468 and a second edge 470. The first and the second edge 468, 470 are on opposite sides of the first susceptor layer 450. The first and the second edges 468, 470 extend parallel to the airflow path 432. The first and the second edge 468, 470 are deformed edges. The deformed edges contact the second sheet material 416. The deformed edges act as a spacer. The configuration of the second susceptor layer 452 is substantially the same as the first susceptor layer 450.
The article 410 further comprises a third airflow path 460. The second susceptor layer 452 defines at least a part of the third airflow path 460. The second sheet material 416 defines at least a part of the third airflow path 460. The third airflow path 460 extends between the second sheet material 416 and the second susceptor layer 452. The first and the second sheet materials 414, 416 comprise a plurality of perforations 462. The plurality of perforations 462 provide a fluid pathway between the first airflow path 432 and the second and third airflow paths 458, 460. In embodiments, the article 410 may comprise any number of susceptor layers, including just one. In embodiments, the article 410 may comprise any number of perforations 462, including just one.
On insertion into the aerosol provision device 100, the article 410 may be compressed. The corrugated sheet material 418 provides structural resilience to the article 410 and may allow the article 410 to be compressed. The compression may be in a direction substantially perpendicular to the plane of the corrugated sheet material 418. Compression of the article 410 can result in a reduction of the size of at least one of the first airflow path 432, the second airflow path 458 and the third airflow path 460 which may increase the resistance to airflow in the article 410, resulting in an increased pressure drop of the airflow through the article 410 relative to an uncompressed state.
The dimensions of the heating zone 105, such as a neutral distance (in the absence of the article 410) between the first and second members 130, 140, and the compressibility of the article 410 may be selected to provide a desired pressure drop through the article 410 in use. In embodiments, the pressure drop through the article 410 when inserted in the heating zone 105 and compressed may increase relative to a pressure drop through the article 410 when not compressed (such as when outside the heating zone 105) by greater than 5%, greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 70% or greater than 100%.
In examples, the article 300, 210, 510, 410 comprises a mouthpiece at its proximal end. In an aerosol provision system 10 comprising an aerosol forming article 300, 210, 510, 410 and an aerosol provision device 100, the mouthpiece may be provided in the article 300, 210, 510, 410 or the device 100.
The article 300, 210, 510, 410 may be symmetrical about a midpoint along its longitudinal length. This means that the article 300, 210, 510, 410 may be smaller and more compact. Additionally, the article 300, 210, 510, 410 may be insertable into an aerosol provision device 100 in more than one orientation, which may be easier for a user.
In embodiments, the configuration of the article 300, 210, 510, 410 may differ. The article 300, 210, 510, 410 may be a curved article. The article 300, 210, 510, 410 may be curved along the longitudinal axis. The article 300, 210, 510, 410 may be curved in a direction perpendicular to the longitudinal axis. The article 300, 210, 510, 410 may be a tubular article. The layers of the article 300, 210, 510, 410 may not be planar. Layers of the article 300, 210, 510, 410 may be curved. Layers of the article 300, 210, 510, 410 may be tubular. The article 300, 210, 510, 410 may form a cylindrical shape. The stacked structure may form a cylindrical shape.
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

An aerosol provision device comprising:
a first member and a second member defining therebetween a heating zone arranged to receive at least a portion of an article comprising aerosol generating material,

wherein the first member is movable relative to the second member and the first and second members are arranged to grip the article in the heating zone;

wherein the first member is resilient; and

wherein one or each of the first and second members comprises at least a portion of a magnetic field generator for generating a varying magnetic field to be used in heating the aerosol generating material when the portion of the article is located in the heating zone.
The aerosol provision device of claim 1, wherein the first member comprises the at least a portion of a magnetic field generator.
The aerosol provision device of claim 1 or 2, wherein the at least a portion of a magnetic field generator comprises an inductor coil.
The aerosol provision device of claim 3, wherein the inductor coil is planar.
The aerosol provision device of claim 3 or 4, wherein the inductor coil is flexible.
The aerosol provision device of any of claims 3 to 5, wherein at least one of the first member and the second member comprises a support member and wherein the inductor coil is bonded to the support member.
The aerosol provision device of any of claims 1 to 6, wherein the first and second members are arranged to be urged away from each other by insertion of the article into the heating zone.
The aerosol provision device of any of claims 1 to 7, wherein the first and second members are arranged to compress at least a part of the article.
An aerosol provision device comprising:
a first member and a second member defining therebetween a heating zone arranged to receive a planar article comprising aerosol generating material, wherein the first member is movable relative to the second member; the first and second members are arranged to grip the planar article in the heating zone and the first member is resilient.
The aerosol provision device of claim 9, comprising a flared section configured to cause deformation of the first member on insertion of the article into the heating zone.
An aerosol provision system comprising the aerosol provision device of any of claims 1 to 10, and an article comprising aerosol generating material.
The aerosol provision system of claim 11, wherein the article is substantially planar.
The aerosol provision system of claim 11 or 12, wherein the article comprises a heating element.
The aerosol provision system of claim any of 11 to 13, wherein the article comprises a corrugated sheet material.
The aerosol provision system of any of claims 11 to 14, comprising a first sheet material; a second sheet material; and a corrugated sheet material between the first and second sheet materials.