EP4681559A1

EP4681559A1 - Aerosol provision device

Info

Publication number: EP4681559A1
Application number: EP24189871.7A
Authority: EP
Inventors: James Sheridan
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-07-19
Filing date: 2024-07-19
Publication date: 2026-01-21
Also published as: WO2026017736A1

Abstract

An aerosol provision device (100) for generating aerosol from aerosol generating material, the aerosol provision device (100) comprising: a receptacle (104; 204) defining a heating zone (202) configured to receive at least a portion of an article (110) comprising aerosol generating material, wherein the receptacle (104; 204) comprises material which is heatable by penetration with a varying magnetic field; an insulating member (244) wrapped around the receptacle (104; 204); and a flexible inductor coil arrangement (212) wrapped around the insulating member (244), wherein the insulating member (244) supports the flexible inductor coil arrangement (212) to space the flexible inductor coil arrangement (212) from the receptacle (104; 204).

Description

Technical Field

The present invention relates to an aerosol provision device. The present invention also relates to an aerosol provision system and a method of forming an aerosol provision device.

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 by creating products that release compounds without combusting. Examples of such products are so-called "heat not burn" products or tobacco heating devices or products, which release compounds by heating, but not burning, material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.
Aerosol provision devices are known. Common devices use heaters to create an aerosol from a suitable medium which is then inhaled by a user. Often the medium used needs to be replaced or changed to provide a different aerosol for inhalation.

Summary

In accordance with some embodiments described herein, there is provided an aerosol provision device for generating aerosol from aerosol generating material, the aerosol provision device comprising: a receptacle defining a heating zone configured to receive at least a portion of an article comprising aerosol generating material, wherein the receptacle comprises material which is heatable by penetration with a varying magnetic field; an insulating member wrapped around a receptacle; and a flexible inductor coil arrangement wrapped around the insulating member, wherein the insulating member supports the flexible inductor coil arrangement to space the flexible inductor coil arrangement from the receptacle.
The flexible inductor coil arrangement may comprise a flexible support and an inductor coil formed on the flexible support layer.
The flexible inductor coil arrangement may be wrapped around the insulating member.
The flexible support and the inductor coil may be wrapped around the insulating member.
The flexible inductor coil arrangement may comprise an inductor coil film comprising the flexible support layer and the inductor coil formed on the flexible support layer.
The inductor coil film may be wrapped around the insulating member.
The insulating member may be a first insulating member and the device may comprise a second insulating member, wherein the second insulating member may be wrapped around the flexible inductor coil arrangement.
The flexible inductor coil arrangement may be sandwiched between the first insulating member and the second insulating member.
The receptacle may comprise a tubular member.
The receptacle may comprise a tubular heating member.
The tubular member may be the tubular heating member
The tubular heating member may extend around the tubular member.
The receptacle may comprise a sealing film.
The sealing film may extend around the tubular member.
The receptacle may comprise a first end member at a first end of the tubular member.
The receptacle may comprise a second end member at a second end of the tubular member.
A sealing film may be wrapped around the tubular member and may overlap the first end member and the second end member to form a fluid seal between the tubular member and each of the first end member and the second end member.
The flexible inductor coil arrangement may comprise a helical inductor coil.
The flexible inductor coil arrangement may comprise a flexible printed circuit.
The flexible inductor coil arrangement may comprise an electrically conductive path formed on the flexible support extending between a first type of connection and a second type of connection.
The electrically conductive path may comprise a plurality of electrically parallel conductive tracks.
The plurality of parallel conductive tracks may be electrically insulated from each other along at least part of their length.
The electrically conductive path may be printed on the flexible support.
Each conductive track may be a width of between 100µm and 250µm.
The electrically conductive path may be formed on both sides of the flexible support.
The plurality of parallel conductive tracks may comprise a first series of parallel conductive tracks formed on a first side of the flexible support.
A second series of parallel conductive tracks may be formed on a second, opposite side of the flexible support.
The flexible support may be a film. The film may be a polyamide film. The film thickness may be in the range of between 25µm and 150 µm.
The electrically conductive path may be formed on the flexible support as a plurality of electrically conductive portions discontinuously formed on the flexible support. Each electrically conductive portion discontinuously formed on the flexible support may be spaced apart from adjacent portions of the plurality of electrically conductive portion discontinuously formed on the flexible support.
The plurality of electrically conductive portions discontinuously formed on the flexible support may be connected together via a plurality of connections.
Each connection may be formed by a cut-out in the flexible support, for example an aperture, an array of apertures, a via or a plurality of vias.
Each connection may connect two adjacent electrically conductive portions discontinuously formed on the flexible support. The two adjacent electrically conductive portions discontinuously formed on the flexible support may be electrically connected together via the connection.
The two adjacent electrically conductive portions discontinuously formed on the flexible support may be soldered together via the connection. The two adjacent electrically conductive portions discontinuously formed on the flexible support may be welded together via the connection.
The first insulating member may comprise a flexible material.
The first insulating member may comprise aerogel.
The second insulating member may comprise a flexible material.
The second insulating member may comprise aerogel.
The second insulating member may comprise a vacuum insulation member.
The vacuum insulation member may have a vacuum gap of less than 1.5 mm, and optionally less than 0.7 mm.
The vacuum insulation may have a vacuum gap of between 0.3 mm and 0.7 mm, and optionally about 0.5mm.
The vacuum insulation member may be tubular.
The device may comprise a housing.
The second insulating member may extend between the inductor coil film and the housing.
The housing may comprise a conductive material.
The conductive material may be aluminium.
The conductive material may be copper.
The conductive material may be a steel, for example stainless steel.
The conductive material may be a thermally conductive plastic.
The device may be free from an air gap between the inductor coil film and the tubular heating member.
The device may be free from an air gap between the housing and the tubular heating member.
The flexible inductor coil arrangement may have a thickness from 25 µm to 50 µm.
The heater film may be a flexible printed circuit heater.
The aerogel may be a silica aerogel.
The aerogel may be SKOGAR^™ Aerogel.
The aerogel may comprise an intrinsic thermal conductivity of less than 0.020 W/(m.K), optionally less than 0.018 W/(m.K), optionally less than 0.014 W/(m.K), and optionally about 0.012 W/(m.K).
The device may further comprise a ferrite shield extending around the flexible inductor coil arrangement and between the first and second insulating member.
The flexible inductor coil arrangement may be connected to the PEEK material portion via laser welding.
The device may comprise a support member at the distal end of the device.
The flexible inductor coil arrangement may be retained in position by the first and second insulating members.
The vacuum insulation member may comprise an inner wall and the outer wall.
The inner wall may be spaced from the outer wall to provide the vacuum gap.
The vacuum insulation member may extend beyond an end of the receptacle in a longitudinal direction of the receptacle.
The vacuum insulation member may extend beyond an end of the receptacle in a longitudinal direction of the receptacle by greater than 5 mm. The vacuum insulation member may extend beyond an end of the receptacle in a longitudinal direction of the receptacle by between 5 mm and 25 mm.
The vacuum insulation member may comprise a connector wall portion between the inner wall and the outer wall. The connector wall portion may be integrally formed with at least one of the inner wall and the outer wall. The connector wall portion may be a proximal connector wall portion. The vacuum insulation member may comprise a distal connector wall portion. The proximal wall portion may be offset from the end of the receptacle in a longitudinal direction of the receptacle by greater than 5 mm. The proximal wall portion may extend beyond an end of the receptacle in a longitudinal direction of the receptacle by between 5 mm and 25 mm.
Each wall may be approximately about 150 µm.
The housing may be cylindrical.
The housing may comprise a maximum width, for example a diameter, of between 8mm to 25mm, optionally 12mm to 20mm, and optionally about 16mm. The maximum width may be less than 25mm.
In accordance with some embodiments described herein, there is provided an aerosol provision device, comprising: a tubular member configured to receive at least a portion of an article comprising aerosol generating material, wherein the tubular member comprises material which is heatable by penetration with a varying magnetic field; a first end member at a first end of the tubular member; a second end member at a second end of the tubular member; and a sealing film wrapped around the tubular member and overlapping the first end member and the second end member to form a fluid seal between the tubular member and each of the first end member and the second end member.
The sealing film may be PEEK.
The sealing film may be affixed to the tubular member. The sealing film may be bonded to the tubular member. The sealing film may be shrunk wrapped to the tubular member.
The sealing film may be affixed to the first end member and the second end member. The sealing film may be bonded to the first end member and the second end member. The sealing film may be shrunk wrapped to the first end member and the second end member.
In accordance with some embodiments described herein, there is provided an aerosol provision device, comprising: a tubular heating member defining a heating zone configured to receive at least a portion of an article comprising aerosol generating material, wherein the tubular heating member comprises material which is heatable by penetration with a varying magnetic field; a housing comprising an opening providing access to the heating zone; and a vacuum insulation member extending beyond an end of the tubular member towards the opening.
The vacuum insulation member may be a vacuum tube member.
The vacuum insulation member may comprise an inner wall and the outer wall.
The inner wall may be spaced from the outer wall to provide the vacuum gap.
The vacuum insulation member may extend beyond an end of the receptacle in a longitudinal direction of the receptacle.
The vacuum insulation member may extend beyond an end of the receptacle in a longitudinal direction of the receptacle by greater than 5 mm. The vacuum insulation member may extend beyond an end of the receptacle in a longitudinal direction of the receptacle by between 5 mm and 25 mm.
The vacuum insulation member may comprise a connector wall portion between the inner wall and the outer wall. The connector wall portion may be integrally formed with at least one of the inner wall and the outer wall. The connector wall portion may be a proximal connector wall portion. The vacuum insulation member may comprise a distal connector wall portion. The proximal wall portion may be offset from the end of the receptacle in a longitudinal direction of the receptacle by greater than 5 mm. The proximal wall portion may extend beyond an end of the receptacle in a longitudinal direction of the receptacle by between 5 mm and 25 mm.
The receptacle may comprise a susceptor which is heatable by penetration with a varying magnetic field.
In accordance with some embodiments described herein, there is provided an aerosol provision system comprising: an aerosol provision device according to any of the above embodiments; and an article comprising aerosol generating material. The article may be dimensioned to be at least partially received within the receptacle.
In accordance with some embodiments described herein, there is provided a method of forming an aerosol provision device, the method comprising: forming a receptacle defining a heating zone configured to receive at least a portion of an article comprising aerosol generating material, wherein the receptacle comprises material which is heatable by penetration with a varying magnetic field; wrapping an insulating member around the receptacle; and wrapping a flexible inductor coil arrangement around the insulating member such that the insulating member supports the flexible inductor coil arrangement to space the flexible inductor coil arrangement from the receptacle.

Brief Description of the Drawings

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

Figure 1 shows a schematic perspective view of an aerosol provision system comprising an aerosol provision device and an article comprising aerosol generating material received by the aerosol provision device;
Figure 2 shows a schematic cross-sectional view of a portion of the aerosol provision system of Figure 1;
Figure 3 shows a schematic cross-sectional view of a portion of another aerosol provision system, for example of the aerosol provision system of Figure 1;
Figure 4 shows a schematic cross-sectional view of a portion of another aerosol provision device, for example of the aerosol provision system of Figure 1; and
Figure 5 shows a schematic perspective view of an inductor coil arrangement; and
Figure 6 shows a schematic perspective view of a blank of the inductor coil arrangement of Figure 5.

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 or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic 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.
The aerosol generating material may be a gel layer. The aerosol generating layer may be a solid material layer, such as reconstituted tobacco. In some embodiments, the substance to be delivered comprises an active substance (sometimes referred to herein as an active compound). 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 generating 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, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article.
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.
With reference to Figure 1, an aerosol provision system 10 is provided comprising an aerosol provision device 100 for generating aerosol from an aerosol generating material. The aerosol provision system 10 further comprises an article 110 comprising aerosol generating material. The article 110 may be replaceable. In broad outline, the aerosol generating device 100 may be used to heat the article 110 to generate an aerosol or other inhalable medium, which is inhaled by a user of the device 100. In use, the article is inserted into the device for heating. The article 110 is dimensioned to be at least partially received within a receptacle 204 (refer to Figure 2) of the device 100.
The aerosol provision device 100 comprises a body 102. A housing arrangement 106, also referred to as a housing, surrounds and houses various components of the body 102. An aperture 104, also referred to as an opening, is formed at one end of the body 102, through which the article 110 may be inserted for heating by a heating arrangement. The aperture 104 is an opening at an end of the receptacle 204 for receiving the article. The receptacle 204 is defined by a tubular member. The receptacle defines a heating zone in which the article is heated to produce aerosol.
The device 100 may also include a user-operable control element 150, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 150.
The aerosol generator defines a longitudinal axis 111, which aligns with an axis of the article 110.
In use, the article 110 may be fully or partially inserted into the aerosol generator where it may be heated by one or more components of the aerosol generator.
The device 100 includes an apparatus for heating aerosol-generating material. The apparatus includes an aerosol generating assembly, a controller (control circuit) 160, and a power source 170. The apparatus forms part of the body 102. The aerosol generating assembly is configured to enable heating of the aerosol-generating material of the article 110 inserted through the article aperture 104, such that an aerosol is generated from the aerosol generating material. The power source supplies electrical power to the aerosol generating assembly, and the aerosol generating assembly converts the supplied electrical energy into heat energy for heating the aerosol-generating material. The power source may be, 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 power source 170 may be electrically coupled to the aerosol generating assembly to supply electrical power when required and under control of the controller 160 to heat the aerosol generating material. The control circuit may be configured to activate and deactivate the aerosol generating assembly based on a user input. The user input may be via a button press or opening a door of the device (for example, a door covering a article receiving receptacle). The control circuit may be configured to activate and deactivate automatically, for example on insertion of an article.
The aerosol generating assembly may comprise various components to heat the aerosol generating material via an inductive heating process. Induction heating is a process of heating an electrically conducting heating element (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor (heating element) suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive element and the susceptor, allowing for enhanced freedom in construction and application.
With reference to Figures 2, 3 and 4, the aerosol provision device 100 comprises an aerosol generator. Figure 2 shows an insulation stack or configuration comprising multiple solid insulation members. Figures 3 and 4 show an insulation stack or configuration comprising a combination of solid insulation and vacuum insulation members.
A receptacle 204 is provided for receiving the article 110 in the device 100. The receptacle 204 defines a heating zone 202. A heating arrangement 210 is provided for heating the article 110 inserted into the device 100. The heating arrangement 210 is arranged to heat the heating zone 202. The heating arrangement 210 comprises an inductive heating arrangement 210. The receptacle 204 comprises a tubular heating member 214.
The inductive heating arrangement 210 comprises an inductor coil arrangement 212 and the tubular heating member 214. The tubular heating member 214 is a susceptor heatable by penetration with a varying magnetic field. The receptacle 204 comprises the susceptor 214.
In embodiments, the heating member does not form part of the receptacle. The receptacle 204 may comprise a tubular member and a heating member, for example in the form of a pin or a blade, may upstand in the receptacle 204. A tubular member 200, which in the present embodiment is the tubular heating member 202, extends around the heating zone. In embodiments, the tubular member 200 is a wall of the receptacle 204.
The tubular member 200 comprises a first end 206 and a second end 208. The receptacle 204 comprises a first end member 222 at a first end 206 of the tubular member 200 and a second end member 224 at a second end 208 of the tubular member 200. The first end member 222 is disposed at a proximal, mouth end of the tubular member 200. The first end member 222 defines the opening 206 to the receptacle 204. The first end member 222 is tubular.
The second end member 224 is disposed at a distal end of the tubular member 200. The second end member 224 defines a base of the receptacle 204. The base defines the longitudinal extent of insertion of the article 110. The first and second end members 222, 224 are configured to support the tubular member 200. The first and second end members 222, 224 are end supports.
The first and second end members 222, 224 space the tubular member 200 from the housing 106. By spacing the tubular member 200 from the housing 106, the first and second end members 222, 224 help to insulate the housing 106 from heat generated by the heating arrangement 210 during use of the device 100. The first and second end members 222, 224 comprise an insulative material. The first and second end members 222, 224 may comprise a PEEK material. The first end member 222 defines a portion of the receptacle 204. The first end member 222 comprises a PEEK material portion arranged at a mouth end of the device 100. In embodiments not shown, the PEEK material portion of the receptacle 204 is arranged to support the inductor coil arrangement 212. In embodiments, the first and second end members 222, 224 may comprise a different thermally insulating material.
The receptacle 204 comprises a film layer 230. The film layer 230 is a sealing film. The film layer 230 extends annularly and longitudinally. The sealing film extends around the tubular member 200. The film layer 230 is wrapped around the susceptor 214. The film layer 230 extends longitudinally beyond the length of the tubular member 200. The film layer overlaps a portion of the first end member 222. The film layer overlaps a portion of the second end member 224. The film layer 230 is wrapped around the first end member 222. The film layer 230 is wrapped around the second end member 224. The sealing film 230 is wrapped around the tubular member 200 and overlapping the first end member 222 and the second end member 224 to form a fluid seal between the tubular member 200 and each of the first end member 222 and the second end member 224.
The film layer 230 is a single unitary layer. The film layer 230, as a sealing layer, helps to minimises fluid leakage, such as air, condensate or aerosol from the flow path defined through the device.
The film layer 230 in embodiments is affixed to the first end member 222 and the second end member 224. The film layer 230 is sealable bonded to the first end member 222 and the second end member 224. The film layer 230 in the present embodiment is shrunk wrapped to the first end member 222 and the second end member 224. Other sealing configurations are envisaged.
The film layer 230 may act as an insulating layer. The film layer 230 is arranged to reduce the transmission of heat generated by the heating arrangement 210 during use of the device 100 to the housing 106 of the device 100. The film layer 230 is a sheet layer. The film layer 230 comprises an insulative material, for example PEEK material. In embodiments, the material may have special properties, such as that of the APTIV^™ series of materials. The film layer 230 comprises a thickness from 20 µm (micron) to 50 µm (micron). The film layer 230 is connected to the first end support 222 and the second end support 224. The film layer 230 in embodiments is affixed to the tubular member 200. The film layer 230 is sealable bonded to the tubular member 200. The connection comprises welding, via laser welding, the film layer 230 to the first end support 222 and the second end support 224. Other sealing configurations are envisaged. The film layer 230 in embodiments is shrunk wrapped to the tubular member 200.
The device 100 comprises an insulating arrangement 240. The insulating arrangement 240 is configured to reduce the transmission of the heat generated by the susceptor 214 during operation of the device 100 away from the receptacle 204. The insulating arrangement 240 is configured to retain the heat generated by the susceptor 214 during operation of the device 100 within the receptacle 204. The insulating arrangement 240 is configured to reduce the transmission of the heat generated by the susceptor 214 during operation of the device 100 to the housing 106 of the device 100.
In embodiments, the insulating arrangement 240 comprises a plurality of layers 242 comprising insulating materials. The insulating arrangement 240 may comprise a plurality of wrapped layers. Each layer of the plurality of layers 242 has a different configuration. The configuration of each layer of the plurality of layers 242 may vary in that each layer may comprise a different material, may have different properties, may be flexible or rigid, may comprise different dimensions, may comprise different shapes and may comprise different thicknesses. In embodiments, the insulating arrangement 240 may comprise a combination of rigid annular layers and flexible wrapped layers. In embodiments, the insulating arrangement 240 comprises a combination of aerogel and PEEK material layers. In other embodiments the insulating arrangement 240 comprises a combination of an aerogel layer and a vacuum insulation layer. In embodiments, the insulating arrangement 240 comprises a combination of aerogel. In embodiments, the insulating arrangement 240 comprises a combination of aerogel and PEEK material layers and a vacuum insulation layer. In the shown embodiments, each layer of the plurality of layers 242 comprises a different thickness. In embodiments not shown, the plurality of layers 242 may have the same thickness.
The insulating arrangement 240 comprises an insulating member 244, referred to as the first insulating member. The first insulating member 244 extends around the receptacle 204. The first insulating member 244 is wrapped around the receptacle 204. The first insulating member 244 extends longitudinally at least the longitudinal extent of the tubular member 200. The first insulating member 244 extends annularly around the tubular member 200. The insulating member 244 is wrapped around the receptacle 204. The inductor coil arrangement 212 is insulated from the susceptor 214 by the first insulating member 244. The insulating member 244 is a layer of insulating material. The first insulating member 244 is a flexible material. In embodiments, the first insulating member is an inner insulating member. The insulating member 244 may comprise a silica material. The first insulating member 244 comprises aerogel. In embodiments, the aerogel may comprise Skogar^™ aerogel. The insulating member has a low thermal conductivity. The insulating member is a non-flammable insulation material. In embodiments, the insulating member may comprise an intrinsic thermal conductivity of less than 0.020 W/(m.K), optionally less than 0.018 W/(m.K), optionally less than 0.014 W/(m.K), and optionally about 0.012 W/(m.K).
A member that is wrapped around another component in accordance with this specification is intended to mean the application of a flexible member around a component by winding such that the flexible member surrounds the component and is in continual contact with a surrounding outer surface of the component. Wrapping is considered to be the act of winding the flexible member around the component such that the component is wrapped as defined above.
The first insulating member 244 is wrapped around the receptacle 204. The inductor coil arrangement 212 is spaced from the receptacle 204 by the insulating member 244. The device 100 is free from an air gap between the inductor coil arrangement 212 and the tubular heating member 214. The insulating member 244 is wrapped around the receptacle 204 such that the insulating member 244 spaces the inductor coil arrangement 212 from the receptacle 204. In embodiments comprising the film layer 230, the first insulating member 244 is wrapped around the film layer 230.
The insulating arrangement 240 comprises a second insulating member 246. The second insulating member 246 extends annularly around the first insulating layer 244. The second insulating layer 246 extends around the first insulating layer 244. The second insulating layer 246 extends longitudinally beyond the length of the first insulating layer 244. The second insulating layer 246 extends longitudinally from the mouth end of the device 100.
In embodiments, such as those shown in Figures 2 and 3, the second insulating member 246 is an outer insulating layer of the insulating arrangement 240. The housing 106 of the device 100 is adjacent the second insulating member 246. The second insulating member 246 extends between the inductor coil arrangement 212 and the housing 106. The device 100 is free from an air gap between the housing 106 and the inductor coil arrangement 212. The device 100 is free from an air gap between the housing 106 and the tubular heating member 214. In embodiments, the second insulating member 246 is a flexible material. In embodiments, the second insulating member is an outer insulating member. The second insulating member contacts an inner surface of the housing.
The omission of an air gap between the housing 106 and the tubular heating member 214, such that insulation members and other components extend therebetween without a break, has been identified with aiding thermal insulation and distribution across the device. The arrangements described herein have been identified with minimising any hot spots, that is areas of higher temperature, on the device housing.
In embodiments, such as shown in Figure 2, the second insulating layer 246 is wrapped around the first insulating layer 244. The second insulating member 246 comprises aerogel. In other embodiments, such as shown in Figures 3 and 4, the second insulating member 246 is a rigid member. The second insulating member 246 in such embodiments comprises a vacuum insulation member.
In embodiments, the vacuum insulation member comprises an inner wall 260 and an outer wall 262, which are connected together by longitudinally spaced connecting walls 263, 265. Between the inner, outer and connecting walls 260, 262, 263, 265 is disposed an evacuated space 264. The evacuated space 264 acts as an insulating region. In embodiments, the walls of the vacuum insulation 246 may define a thermally conductive path along which heat is distributed. As shown in Figures 3 and 4, the vacuum insulation member 246 extends longitudinally beyond the tubular member 200. This helps to increase the thermally conductive path along which heat may be transferred. The thermally conductive path defined by the connecting walls 263, 265 of the vacuum insulation member 246 are spaced from the tubular heating member and the heat transfer along this path is therefore reduced. The radial transmission of the heat energy produced by the tubular heating member is minimised by the presence of an evacuated space 264 that may significantly reduce transmission of heat by conduction or convection. The transmission of heat energy in a radial direction by the connecting walls 263, 265 is minimised. The radial transmission of heat via the walls of the vacuum insulation 246 is thereby delayed and reduced.
In various embodiments, the aerosol provision device 100 further comprises a third insulating member 248, also identified as a proximal insulating member, extending from an end of the tubular member 200 towards the opening 104. The third insulating member 248 extends at least 14mm mm from the end of the tubular member 200. In embodiments, the third insulating member 248 extends from 5mm to 25mm from the end of the tubular member 200. The third insulating member 248 is arranged to extend around the receptacle 204. The third insulating member 248 spaces the tubular member 200 from the opening 104. The third insulating member 248 extends around the first end member 222. The third insulating member 248 extends around the PEEK material. The first end member 222 defines the mouth end of the receptacle 204. The third insulating member 248 reduces the transmission of heat from the heating arrangement 210 to the mouth end of the device 100. The third insulating member 248 accommodates the different dimensions of the tubular member 200 and the first end member 222. In embodiments, the first and third insulating members are integrally formed.
In embodiments, the various insulating members and/or components of the device and/or the insulating arrangement are not limited by the numbering of these components. For example, the first, second and third insulating members described above may be renumbered while still referring to the same components.
In embodiments, the inductor coil arrangement 212 is a flexible inductor coil arrangement, also referred to as a flexible coil arrangement. The flexible coil arrangement 212 comprises an inductor coil film 250. The inductor coil film 250 is wrapped around the first insulating member 244. The first insulating member 244 supports the inductor coil arrangement 212. The second insulating member 246 is wrapped around the inductor coil arrangement 212. The inductor coil film 250 is sandwiched between the first insulating member 244 and the second insulating member 246. The inductor coil film 250 is supported by the first and second insulating members 244, 246. The flexible inductor coil arrangement 212 is retained in position by the first and second insulating members 244, 246. The inductor coil 254 is a helical inductor coil. In embodiments, the flexible inductor coil arrangement 212 may be connected to the PEEK material portion via laser welding.
In various embodiments, the housing 106 is cylindrical. The housing 106 comprises a conductive material. The housing 106 comprises a material that is thermally conductive, such as a metallic material. The insulating arrangement 240 is configured to reduce the transmission of heat from the heating arrangement 210 to the thermally conductive housing 106. Further, the various configurations of the insulating arrangement 240 dissipate the heat energy. By dissipating the energy throughout the insulating arrangement 240, regions of significantly higher temperatures, known as hot-spots, are minimised. The housing 106 also helps with heat energy distribution. The housing 106 is configured to restrict the formation of hot-spots. As such, a user holding the device may not be surprised by an unexpectedly hot region of the device. Rather, the device 100 is configured to help protect the user, and provide them with a tactile sense of whether the device 100 was active, and perhaps how long the device 100 had been active, by the temperature of the housing 106.
Metallic materials, such as Copper and Aluminium, are light and durable materials, and are advantageous materials from which to form the housing 106 of an aerosol provision device 100. Other thermally conductive materials may be used. The conductive material may be a steel, for example stainless steel. The conductive material may be a non-metallic material, such as a thermally conductive plastic.
The insulating arrangement 240 is configured such that a device 100 can be designed to take advantage of the beneficial properties of materials that are otherwise thermally conductive, and would therefore normally be unsuitable. The durability of metallic materials provides a device housing 106 that is aesthetically pleasing, and is able to protect the internal components of the device 100 due to being less susceptible to shocks or damage. In examples, the housing 106 comprises a diameter of 60mm. In examples, the housing 106 may have a diameter from 30mm to 80mm.
In embodiments, the device 100 comprises a magnetic shield 260. The magnetic shield 260 extends around the inductor coil arrangement 212. The magnetic shield 260 directs the magnetic field generated by the inductor coil arrangement 212. The magnetic shield 260 directs the magnetic field such that the magnetic field does not extend to the housing 106. The magnetic shield 260 is a ferrite magnetic shield. The ferrite shield 260 extends around the flexible inductor coil arrangement 212 and between the first and second insulating member 244, 246. The magnetic shield 260 helps to minimise heat generation in the housing 106. This further helps with taking advantage of beneficial properties of materials that would otherwise interact with magnetic fields in a manner that would render them unsuitable for an induction heating device housing 106.
With reference to each of Figures 2, 3 and 4, specific example configurations are provided.
With reference to Figure 2, the insulating arrangement 240 comprises the first insulating member 244, the second insulating member 246 and the third insulating member 248. The first, second and third insulating members 244, 246, 248 comprise the same material. The first, second and third insulating members 244, 246, 248 comprise an aerogel material. The device 100 is free from air gaps between the tubular member 200 and the housing 106. The device 100 is free from air gaps between the first end member 222 and the housing 106.
With reference to Figure 3, in the shown embodiment, the insulating arrangement 240 comprises the first insulating member 244, the second insulating member 246 and the third insulating member 248. The second insulating member 246 comprises the vacuum insulation member 246. The vacuum insulation 246 comprises an inner wall 260 and an outer wall 262. The inner wall 260 and the outer wall 262 are connected by the first connecting wall 263 and the second connecting wall 265. The first and second connecting walls 263, 265 are longitudinally spaced. The first connecting wall 263 connects the first and second inner walls 260, 262 at the proximal end. The second connecting wall 265 connects the first and second inner walls 260, 262 at the distal end. Each of the inner and outer wall 260, 262 have a thickness of approximately 150 µm. In examples, the thickness of each of the inner and outer walls 260, 262 is from 100 µm to 200 µm. The inner and outer walls comprise stainless steel material, however the walls of the vacuum insulation 246 may comprise any suitable material. Between the inner and outer wall 260, 262 is an evacuated space 264. The evacuated space 264 is a space containing near-vacuum. The near vacuum reduces the transmission of heat by conduction and convection.
The walls 260, 262, 263, 265 of the vacuum insulation 246 may act as a thermally conductive path. As shown in Figures 3 and 4, the vacuum insulation 246 member extends longitudinally beyond the tubular member. The vacuum insulation member 246 extends longitudinally substantially beyond the tubular member at the proximal end. The vacuum insulation 246 extends longitudinally such that the first connecting wall 263 is proximal the inside surface of the proximal end of the housing of the device. This helps to space a conductive path provided by the first connecting wall 263 at the proximal end from the heat source. Heat energy produced by the tubular heating member will, in use, tend to be transmitted towards the proximal end of the device 100 as the user will hold the device near vertical or at an inclined angle. The provision of the insulation arrangement discussed herein helps minimise or delay the transmission of heat energy at the proximal end of the device that will have a greater effect in insulating the device.
The vacuum insulation is supported at either end of the tube by a cushion 266. The cushions 266 support the vacuum insulation. The vacuum insulation has a thickness of less than 1.5mm. In examples, the vacuum insulation layer may be from 0.5mm to 1.4mm. The vacuum insulation is tubular. The first and third insulating member 244, 248 comprise aerogel. Further, at least one of the connecting walls 263, 265 of the vacuum insulation are longitudinally spaced from the tubular heating member. The small thickness of the evacuated space 264, otherwise known as a vacuum gap, may be offset by the increase in the length of the thermally conductive path due to the longitudinally extending walls of the vacuum insulation. As a result, the thickness of the evacuated space 264, can be minimised without detriment to the insulative properties of the vacuum insulation. The dimensions of the device can therefore be minimised. In addition, or alternatively, an increased thickness of solid insulation may therefore be provided to the insulation stack, due to a reduction in the overall thickness of the vacuum insulation member, in dependence on the required thermal performance.
With reference to Figure 4, the arrangement is generally the same as the embodiment of Figure 3. However, the insulating arrangement 240 comprises the first insulating member 244, the second insulating member 246, the third insulating member 248 and the fourth insulating member 270. The fourth insulating member 270 extends between the housing 106 and the second insulating layer 246. The housing 106 is spaced from the second insulating layer 246 by the fourth insulating layer 270. The housing 106 is adjacent the fourth insulating layer 270. The first, third and fourth insulating members 244, 248, 270 comprise an insulating material. The first, third and fourth insulating layers 244, 248, 270 comprise aerogel. The second insulating member 246 comprises vacuum insulation. The thickness of the second insulating member 246 is from 0.4mm to 0.6mm, and optionally about 0.5mm. The thickness of the fourth insulating member 270 is from about 0.5mm to 3mm, optionally about 0.5mm to 1.5mm, and optionally about 1mm. In this embodiment, a cushion 266 at either end of the vacuum insulation support the second and fourth insulating members 246, 270.
With reference to Figure 5, the inductor coil film 250 is shown. The inductor coil film 250 comprises a flexible support 252 and an inductor coil 254 formed on the flexible support 252. The flexible support 252 is also referred to as a flexible support layer. The flexible coil arrangement 212 comprises a flexible support 252 and an electrically conductive path 256. The flexible coil arrangement 212 may be a flexible printed circuit heater. The flexible support 252 comprises a flexible substrate. The flexible support 252 can be formed into a desired shape by bending, rolling or otherwise flexing the flexible support 252. The flexible support 252 is formed into a tubular member when wrapped around the first insulating member 244. The flexible support 252 may have a longitudinal axis 259. The longitudinal axis 259 of the flexible support 252 may be concentric with the longitudinal axis 111 of the aerosol provision device 100. In embodiments, the flexible support 252 comprises a thin, flexible sheet of material. The flexible substrate 252 is a film. The film is made of polyamide. The flexible support 252 has a thickness of about 50µm. In examples, the flexible support 252 may have a thickness in the range of 25µm and 150 µm. In other examples, the flexible inductor coil arrangement 212 has a thickness from 25 µm to 50µm.
The flexible support 252 is made of electrically insulating material. The electrically conductive path 256 is formed on the flexible support 252. The electrically conductive path 256 may be deposited on or inscribed into the flexible support 252. The electrically conductive path 256 is made of an electrically conductive material, such as copper. The electrically conductive path 256 extends between a first type of connection 257 and a second type of connection 258. The first type of connection 257 and the second type of connection 258 are configured to electrically connect the flexible coil arrangement 212 to other components of the aerosol provision device 100. The flexible coil arrangement 212 is connectable to the controller 160 and power source 170 of the aerosol provision device 100 via the first type of connection 257 and the second type of connection 258.
With reference to Figure 6, a blank 280 may be formed into the flexible coil configuration 212 by forming the blank 280 into a tubular member. The blank 280 may be formed into a tubular member by rolling it along a forming axis 282. The forming axis 282 defines the longitudinal axis 259 of the flexible coil configuration 212 once formed. The plurality of discontinuous electrically conductive portion 256 may be arranged on and spaced apart from one another in the direction of the forming axis 282.
The electrically conductive path 256 comprises a plurality of electrically conductive portions discontinuously formed on the flexible support 252, also identified as discontinuous electrically conductive portions 256a-e. The electrically conductive path may be formed on the flexible support 252 as a plurality of discontinuous electrically conductive portions 256, each discontinuous portion 256a-e spaced apart from adjacent portions of the plurality discontinuous electrically conductive portions 256. The discontinuous portions are connected together via a plurality of connections 284. The discontinuous portions 256a-e may be soldered together to form the electrically conductive path 256 once the flexible support 252 is formed into a tubular member.
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 for generating aerosol from aerosol generating material, the aerosol provision device comprising:
a receptacle defining a heating zone configured to receive at least a portion of an article comprising aerosol generating material, wherein the receptacle comprises material which is heatable by penetration with a varying magnetic field;

an insulating member wrapped around the receptacle; and

a flexible inductor coil arrangement wrapped around the insulating member, wherein the insulating member supports the flexible inductor coil arrangement to space the flexible inductor coil arrangement from the receptacle.
The aerosol provision device of claim 1, wherein the flexible inductor coil arrangement comprises a flexible support layer and an inductor coil formed on the flexible support layer, and wherein the flexible support layer and the inductor coil are wrapped around the insulating member.
The aerosol provision device of claim 1 or claim 2, wherein the receptacle comprises a tubular heating member.
The aerosol provision device of claim 3, wherein the receptacle comprises a first end member at a first end of the tubular member; a second end member at a second end of the tubular heating member, and a sealing film wrapped around the tubular member and overlapping the first end member and the second end member to form a fluid seal between the tubular member and each of the first end member and the second end member.
The aerosol provision device of any preceding claim, wherein the insulating member comprises aerogel.
The aerosol provision device of any of claims 2 to 5, wherein the insulating member is a first insulating member and the device comprises a second insulating member, wherein the second insulating member extends around the flexible inductor coil arrangement.
The aerosol provision device of claim 6, wherein the flexible inductor coil arrangement is sandwiched between the first insulating member and the second insulating member.
The aerosol provision device of claim 6 or 7, wherein the second insulating member comprises aerogel.
The aerosol provision device of any of claims 6 to 8, wherein the second insulating member comprises a vacuum insulation member.
The aerosol provision device of claim 9, wherein the vacuum insulation member extends beyond an end of the receptacle in a longitudinal direction of the receptacle.
The aerosol provision device of any of claims 6 to 10, wherein the second insulating member extends between the flexible inductor coil arrangement and the housing.
An aerosol provision device for generating aerosol from aerosol generating material, the aerosol provision device, comprising:
a tubular member configured to receive at least a portion of an article comprising aerosol generating material, wherein the tubular member comprises material which is heatable by penetration with a varying magnetic field;

a first end member at a first end of the tubular member;

a second end member at a second end of the tubular member; and

a sealing film wrapped around the tubular member and overlapping the first end member and the second end member to form a fluid seal between the tubular member and each of the first end member and the second end member.
An aerosol provision device for generating aerosol from aerosol generating material, the aerosol provision device, comprising:
a tubular heating member defining a heating zone configured to receive at least a portion of an article comprising aerosol generating material, wherein the tubular heating member comprises material which is heatable by penetration with a varying magnetic field;

a housing comprising an opening providing access to the heating zone; and

a vacuum insulation member extending beyond an end of the tubular heating member towards the opening.
An aerosol provision system comprising:
an aerosol provision device according to any of claims 1 to 14; and

an article comprising aerosol generating material.
A method of forming an aerosol provision device, the method comprising:
forming a receptacle defining a heating zone configured to receive at least a portion of an article comprising aerosol generating material, wherein the receptacle comprises material which is heatable by penetration with a varying magnetic field;

wrapping an insulating member around the receptacle; and

wrapping a flexible inductor coil arrangement around the insulating member such that the insulating member supports the flexible inductor coil arrangement to space the flexible inductor coil arrangement from the receptacle.