EP4681560A1

EP4681560A1 - Aerosol provision device

Info

Publication number: EP4681560A1
Application number: EP24189885.7A
Authority: EP
Inventors: James Sheridan; Lewis CONNER; Matthew Hodgson
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: WO2026017749A1

Abstract

There is discloses an aerosol provision device (100) for generating an aerosol from aerosol generating material. The device (100) comprises a receptacle (116) defining a heating zone (120) for receiving at least a portion of an article (104) comprising aerosol generating material; and a flexible coil configuration (130). The flexible coil configuration (130) comprises comprising a flexible support (132) and an electrically conductive path (134) formed on the flexible support (132) extending between a first type of connection (136a) and a second type of connection (136b). The electrically conductive path (134) comprises a plurality of electrically parallel conductive tracks (150).

Description

Technical Field

The present invention relates to an aerosol provision device and to an aerosol provision system. The present invention further relates to a blank configured to form a flexible coil configuration for an aerosol provision device and to a method of forming a flexible coil configuration for 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. It is known to use resistive heating systems as heaters to create an aerosol from a suitable medium.

Summary

According to an aspect, there is provided an aerosol provision device for generating an aerosol from aerosol generating material, the device comprising: a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol generating material; and a flexible coil configuration comprising: a flexible support; and an electrically conductive path formed on the flexible support extending between a first type of connection and a second type of connection, wherein the electrically conductive path comprises a plurality of electrically parallel conductive tracks.
The flexible coil configuration may comprise a flexible printed circuit.
The flexible printed circuit may comprise the flexible support and the electrically conductive path.
The flexible coil configuration may at least partially extend around the heating zone.
The electrically conductive path may define a helical coil.
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 define a coil.
The coil may be an inductive coil. The aerosol provision device may comprise a magnetic field generating assembly comprising the coil.
The aerosol provision device may comprise a resistive heating assembly comprising the coil. The coil may be a resistive heating coil.
The flexible coil configuration may at least partially extend around the receptacle.
The aerosol provision device may comprise a heater element. The receptacle may comprise the heater element. The heater element and the coil may extend along concentric longitudinal axes.
The coil may extend around the heater element. The coil may be formed around the heater element. The flexible support may be rolled around the heater element.
The coil may comprise 2 to 10 turns.
The electrically conductive path may be deposited on the flexible support. The electrically conductive path may be bonded to the flexible support. The depositing may comprise printing or adhering.
The electrically conductive path may be printed on the flexible support.
Each electrically parallel conductive track may have a width of between 100µm and 250µm.
The plurality electrically parallel conductive tracks may define an active width of the electrically conductive path, and the active width may be between 1 mm and 4mm.
The electrically parallel conductive path may comprise between 7 and 25 parallel conductive tracks. The electrically parallel conductive tracks may comprise between 7 and 25 parallel conductive tracks on each side of the flexible support. The electrically parallel conductive tracks may comprise between 14 and 50 parallel conductive tracks.
The electrically conductive path may be formed on both sides of the flexible support. The electrically conductive path may be formed on a single side 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 and a second series of parallel conductive tracks formed on a second, opposite side of the flexible support. The first series of parallel conductive tracks may overlap the second series of parallel conductive tracks.
The plurality of conductive tracks may comprise a first conductive track formed on a first side of the flexible support and a second conductive track formed on a second, opposite side of the flexible support. The first conductive track formed on the first side of the flexible may overlap the second conductive track formed on the second side of the flexible support. The first conductive track may be a single track. The second conductive track may be a single track. The first conductive track may be electrically parallel to the second conductive part along at least part of their length.
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.
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.
Each electrically conductive portion discontinuously formed on the flexible support may be arranged to define a turn of the coil.
Each discontinuous portion may be arranged to partially define two adjacent turns of the coil.
According to an aspect, there is provided an aerosol provision system, comprising an article comprising aerosol generating material; and the aerosol provision device of any of the above.
According to an aspect, there is provided a blank configured to form a flexible coil configuration for an aerosol provision device, the blank comprising a flexible support; and an electrically conductive path formed on the flexible support, extending between a first type of connection and a second type of connection, wherein the electrically conductive path comprises a plurality of electrically parallel conductive tracks.
The blank may be configured to form a flexible coil configuration when the flexible support is formed into a tubular member. The blank may be configured to form a coil. The blank may be configured to form a coil when the flexible coil configuration is formed from the blank. The flexible coil configuration defines the coil when formed.
The electrically conductive path may be configured to define a helical coil when the flexible support is formed into a tubular member.
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 define a coil when the flexible support is formed into a tubular member. The coil may be an inductive coil. The coil may be a resistive heating coil.
The flexible coil configuration may be configured to at least partially extend around a heating zone of an aerosol provision device when the flexible support is formed into a tubular member.
The flexible coil configuration may be configured to at least partially extends around the receptacle of an aerosol provision device when the flexible support is formed into a tubular member.
The coil may be configured to comprise between 2 and 10 turns when the flexible support is formed into a tubular member.
The electrically conductive path may be printed on the flexible support
Each electrically parallel conductive track may have a width of between 100µm and 250µm.
The plurality electrically parallel conductive tracks may define an active width of the electrically conductive path, and the active width may be between 1 mm and 4mm.
The electrically parallel conductive path may comprise between 7 and 25 parallel conductive tracks. The electrically parallel conductive tracks may comprise between 7 and 25 parallel conductive tracks on each side of the flexible support. The electrically parallel conductive tracks may comprise between 14 and 50 parallel conductive tracks.
The electrically conductive path may be formed on both sides of the flexible support. The electrically conductive path may be formed on a single side 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 and a second series of parallel conductive tracks formed on a second, opposite side of the flexible support. The first series of parallel conductive tracks may overlap the second series of parallel conductive tracks.
The plurality of conductive tracks may comprise a first conductive track formed on a first side of the flexible support and a second conductive track formed on a second, opposite side of the flexible support. The first conductive track formed on the first side of the flexible may overlap the second conductive track formed on the second side of the flexible support. The first conductive track may be a single track. The second conductive track may be a single track. The first conductive track may be electrically parallel to the second conductive part along at least part of their length.
The flexible support may be a film. The film may be a polyamide film. The film thickness may be between 25µm (micron) and 150 µm (micron).
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 portions discontinuously formed on the flexible.
The electrically conductive portions discontinuously formed on the flexible support may be connected together via a plurality of connections when the flexible support is formed into a tubular member.
Each connection may be formed by a cut-out in the flexible support.
Each connection may be configured to connect two adjacent electrically conductive portions discontinuously formed on the flexible support when the flexible support is formed into a tubular member. 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 configured to be soldered together via the connection when the flexible support is formed into a tubular member.
The blank may comprise a plurality of connections configured to connect adjacent electrically conductive portions discontinuously formed on the flexible support when the flexible support is formed into a tubular member such as to form the electrically conductive path.
The electrically conductive portions discontinuously formed on the flexible support may be configured to be soldered together to form the electrically conductive path when the flexible support is formed into a tubular member.
Each electrically conductive portion discontinuously formed on the flexible support may be arranged to define a turn of the coil.
Each electrically conductive portion discontinuously formed on the flexible support may be arranged to partially define two adjacent turns of the coil.
The flexible coil configuration may define a longitudinal axis. The electrically conductive path may comprise a plurality of turns, wherein at least one turn comprises a portion extending perpendicular to the longitudinal axis
According to an aspect, there is provided a method of forming a flexible coil configuration for an aerosol provision device, method comprises: providing a flexible support; and forming an electrically conductive path on the flexible support, the electrically conductive path comprises a plurality of electrically parallel conductive tracks.
The method may further comprise forming the flexible support into a tubular member.
According to an aspect, there is provided an aerosol provision device for generating an aerosol from aerosol generating material, the device comprising: a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol generating material; and a flexible coil configuration. The flexible coil configuration comprises: a flexible support formed into a tubular member; and an electrically conductive path on the flexible support. The an electrically conductive path comprises: a plurality of discontinuous electrically conductive portions on the flexible support, each of the plurality of discontinuous electrically conductive portions being spaced from adjacent portions of the plurality of discontinuous portions on the flexible support; and a plurality of connections, each connection connecting two adjacent discontinuous portions so as to form the electrically conductive path.
According to an aspect, there is provided an aerosol provision device for generating an aerosol from aerosol generating material, the device comprising: a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol generating material; and a flexible coil configuration; wherein the flexible coil configuration comprises: a flexible support formed into a tubular member; and an electrically conductive path on the flexible support comprising: a plurality of electrically conductive portions discontinuously formed on the flexible support; and a plurality of connections, each of the plurality of connections connecting at least two of the plurality of electrically conductive portions so as to form the electrically conductive path.
Each of the plurality of connections may connect two adjacent portions of the plurality of electrically conductive portions. The flexible coil configuration may comprise a flexible printed circuit.
The flexible printed circuit may comprise the flexible support and the electrically conductive path.
The flexible coil configuration may at least partially extend around the heating zone.
The electrically conductive path may define a coil.
The coil may be an inductive coil.
The aerosol provision device may comprise a magnetic field generating assembly comprising the coil.
The aerosol provision device may comprise a resistive heating assembly comprising the coil. The coil may be a resistive heating coil.
The coil may be a helical coil.
The magnetic field generating assembly may comprise the controller.
The resistive heating assembly may comprise the controller.
The flexible coil configuration may extend at least partially around the receptacle. The flexible coil configuration may at least partially extend around the receptacle.
The aerosol provision device may comprise a heater element. The receptacle may comprise the heater element. The heater element and the coil may extend along concentric longitudinal axes.
The coil may extend around the heater element. The coil may be formed around the heater element. The flexible support may be rolled around the heater element.
The coil may comprise between 2 and 10 turns.
The electrically conductive path may be deposited on the flexible support. The electrically conductive path may be bonded to the flexible support. The depositing may comprise printing or adhering.
Each connection may be formed by a cut-out in the flexible support.
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.
Each electrically conductive portion discontinuously formed on the flexible support may be arranged to define a turn of the coil.
Each electrically conductive portion discontinuously formed on the flexible support may be arranged to partially define two adjacent turns of the coil.
The electrically conductive portions discontinuously formed on the flexible support may be soldered together to close the electrically conductive path. Adjacent electrically conductive portions discontinuously formed on the flexible support may be soldered together at the connections.
Each electrically conductive portion discontinuously formed on the flexible support may comprise a plurality of electrically parallel conductive tracks.
Each electrically parallel conductive track may have a width of between 100µm and 250µm.
The plurality electrically parallel conductive tracks may define an active width of the electrically conductive path, and the active width may be between 1 mm and 4mm.
The electrically parallel conductive path may comprise between 7 and 25 parallel conductive tracks. The electrically parallel conductive path may comprise between 7 and 25 parallel conductive tracks on each side of the flexible support. The electrically parallel conductive path may comprise between 14 and 50 parallel conductive tracks.
The electrically conductive path may be formed on both sides of the flexible support. The electrically conductive path may be formed on a single side 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 and a second series of parallel conductive tracks formed on a second, opposite side of the flexible support. The first series of parallel conductive tracks may overlap the second series of parallel conductive tracks.
The plurality of conductive tracks may comprise a first conductive track formed on a first side of the flexible support and a second conductive track formed on a second, opposite side of the flexible support. The first conductive track formed on the first side of the flexible may overlap the second conductive track formed on the second side of the flexible support. The first conductive track may be a single track. The second conductive track may be a single track. The first conductive track may be electrically parallel to the second conductive part along at least part of their length.
The flexible support may be a film. The film may be a polyamide film. The film thickness may be between 25µm and 150 µm.
According to an aspect, there is provided an aerosol provision system, comprising: an article comprising aerosol generating material; and the aerosol provision device of any of the above.
According to an aspect, there is provided a blank configured to form a flexible coil configuration for an aerosol provision device, the blank comprising: a flexible support configured to be formed into a tubular member; and an electrically conductive path on the flexible support, wherein the electrically conductive path comprises: a plurality of discontinuous electrically conductive portions on the flexible support, each of the plurality of discontinuous electrically conductive portions being spaced from adjacent portions of the plurality of discontinuous portions on the flexible support; and a plurality of connections, each connection configured to connect two adjacent discontinuous portions so as to form the electrically conductive path when the flexible support is formed into a tubular member.
The blank may be configured to form a flexible coil configuration when the flexible support is formed into a tubular member. The blank may be configured to form a coil. The blank may be configured to form a coil when the flexible coil configuration is formed from the blank. The flexible coil configuration defines the coil when formed.
The electrically conductive path may define a coil when the flexible support is formed into a tubular member. The coil may be an inductive coil. The coil may be a resistive heating coil. The coil may be a helical coil.
The flexible coil configuration may at least partially extend around a heating zone of an aerosol provision device.
The flexible coil configuration may extend at least partially extends around a receptacle of an aerosol provision device when the flexible support is formed into a tubular member. The flexible coil configuration may at least partially extend around the receptacle.
The coil may comprise between 2 and 10 turns.
Each connection may be formed by a cut-out in the flexible support. The cut-out in the flexible support may be 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 when the flexible support is formed into a tubular member. The two adjacent electrically conductive portions discontinuously formed on the flexible support may be soldered together via the connection when the flexible support is formed into a tubular member.
Each electrically conductive portions discontinuously formed on the flexible support may be arranged to partially define two adjacent turns of the coil when the flexible support is formed into a tubular member.
The electrically conductive portions discontinuously formed on the flexible support may be soldered together to close the electrically conductive path when the flexible support is formed into a tubular member. Adjacent electrically conductive portions discontinuously formed on the flexible support may be soldered together at the connections when the flexible support is formed into a tubular member.
Each electrically conductive portions discontinuously formed on the flexible support may comprise a plurality of electrically parallel conductive tracks.
Each electrically parallel conductive track may have a width of between 100µm and 250µm.
The plurality electrically parallel conductive tracks may define an active width of the electrically conductive path, and the active width may be between 1mm and 4mm.
The electrically parallel conductive tracks may comprise between 7 and 25 parallel conductive tracks. The electrically parallel conductive tracks may comprise between 7 and 25 parallel conductive tracks on each side of the flexible support. The electrically parallel conductive tracks may comprise between 14 and 50 parallel conductive tracks.
The electrically conductive path may be formed on both sides of the flexible support. The electrically conductive path may be formed on a single side 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 and a second series of parallel conductive tracks formed on a second, opposite side of the flexible support. The first series of parallel conductive tracks may overlap the second series of parallel conductive tracks.
The plurality of conductive tracks may comprise a first conductive track formed on a first side of the flexible support and a second conductive track formed on a second, opposite side of the flexible support. The first conductive track formed on the first side of the flexible may overlap the second conductive track formed on the second side of the flexible support. The first conductive track may be a single track. The second conductive track may be a single track. The first conductive track may be electrically parallel to the second conductive part along at least part of their length.
The flexible support may be a film. The film may be a polyamide film. The film thickness may be between 25µm and 150 µm.
According to an aspect, there is provided a method of forming a coil for an aerosol provision device, the method comprising: providing a flexible support; forming a plurality of discontinuous electrically conductive portions on the flexible support, wherein each portion is spaced from adjacent portions of the plurality of discontinuous portions on the flexible support; forming the flexible support into a tubular member; and forming an electrically conductive path on the flexible support by connecting the discontinuous electrically conductive portions via a plurality of connections.
The method may comprise forming the plurality of connections as cut-out in the flexible support. The cut-out in the flexible support may be an aperture, an array of apertures, a via or a plurality of vias.
The method may comprise soldering adjacent discontinuous portions together at the plurality of connections.
The method may comprise forming the flexible support around a heater element of an aerosol provision device.
Forming the flexible support may close the electrically conductive path so as to form a helical coil arrangement.
According to an aspect, there is provided an aerosol provision device for generating an aerosol from aerosol generating material, the aerosol provision device comprising: a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol generating material; and a coil configuration, wherein the coil configuration comprises: a helical coil extending around the heating zone defining a longitudinal axis, wherein the helical coil comprises a plurality of turns, and wherein at least one turn comprises a portion extending perpendicular to the longitudinal axis.
Each turn may extend perpendicular to the longitudinal axis along at least a portion of the length of the turn.
The helical coil may comprise a transition section between each turn.
Each transition section may extend at an acute angle to each adjacent turn.
The coil configuration may be a flexible coil configuration. The flexible coil configuration may comprise a flexible support and an electrically conductive path formed on the flexible support extending between a first type of connection and a second type of connection.
According to an aspect, there is provided an aerosol provision system, comprising: an article comprising aerosol generating material; and the aerosol provision device of any of the above.

Brief Description of the Drawings

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

FIG. 1 schematically shows an aerosol provision system comprising an aerosol provision device and an article comprising aerosol generating material;
FIG. 2 schematically shows a flexible coil arrangement for an aerosol provision device, for example of FIG. 1;
FIG. 3 schematically shows a blank configured to form the flexible coil configuration of FIG. 2;
FIG. 4 schematically shows a flexible coil arrangement for an aerosol provision device, for example of FIG. 1;
FIG. 5 schematically shows a blank configured to form the flexible coil configuration of FIG. 4;
FIG. 6 shows a flowchart illustrating a method of forming a flexible coil configuration for an aerosol provision device, for example of FIG. 1; and
FIG. 7 shows a flowchart illustrating a further method of forming a flexible coil configuration for an aerosol provision device, for example of FIG. 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.
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 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.
Fig. 1 shows an aerosol provision device 100 for generating aerosol from an aerosol generating material. In broad outline, the device 100 may be used to heat a replaceable article 104 comprising aerosol generating material, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The article 104 and the device 100 together form an aerosol provision system 102.
The aerosol provision system 102 comprises the aerosol provision device 100 and the article 104 comprising aerosol generating material. The article 104 is received into the device 100 for heating. The article 104 may be fully or partially received by the device 100 for heating by the device 100. In the arrangement shown in FIG.1, the article 104 protrudes from the device 100.
The configuration of the aerosol provision device 100 may vary. For example, the aerosol provision device 100 may be configured to resistively or inductively heat the aerosol generating material comprised in the article 104. In other words, the aerosol provision device 100 may comprise a resistive or an inductive heating arrangement. In the arrangement shown in FIG.1, aerosol provision device 100 comprises an inductive heating arrangement.
In the example shown, the aerosol provision device 100 is elongate, extending along a longitudinal axis 103. The aerosol provision device 100 has a proximal end 106, which will be closest to the user (e.g. the user's mouth) when the device is in use, and a distal end 108, which will be furthest from the user when in use. The user inhales aerosol generated by the aerosol provision device 100 by drawing the generated aerosol towards the proximal end 106.
The proximal end may also be referred to as the "mouth end". The aerosol provision device 100 accordingly defines a proximal direction, which is directed towards the user when in use. Further, the aerosol provision device 100 likewise defines a distal direction, which is directed away from the user when in use. The terms 'proximal' and 'distal' as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along a longitudinal axis.
The device 101 comprises a body 105. The body 105 comprises a housing, which surrounds and houses various components of the device 100. The housing is elongate.
The 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 aerosol provision device 100 comprises a heating assembly 110. The heating assembly is housed within the body 105.The heater assembly 110 is configured to heat at least a portion of an aerosol generating material received by the device 100. The heater assembly 110 is configured to heat at least a portion of an aerosol generating material received by a heating chamber of the device 100. The heating chamber is formed by a receptacle 116. The receptacle 116 acts as a support member. The receptacle 116 comprises a generally tubular member. The receptacle 116 extends along and around and is substantially coaxial with the longitudinal axis 103 of the device 100. The receptacle 116 is open at its proximal end such that an article 110 can be received by the heating chamber 116 therethrough.
The aerosol provision device 100 includes a power source 114. The power source 114 is disposed within the housing. The power source 114 is 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 heating assembly 110 to supply electrical power when required and under control of a controller 115 to heat the aerosol generating material. The aerosol provision device 100 may comprise a device electrical connector, wherein the power source 114 is releasably connected to the device electrical connector. The power source 114 is electrically connected to the heating assembly 110. The controller 115 may also be referred to as a control unit. The controller 115 may comprise processor and a memory. The controller 115 is disposed within the body 105. 112. The controller 115 may be form part of the heating assembly 110.
The heating assembly 110 comprises a heater element 112 for generating aerosol from aerosol generating material. As shown, the heater element 112 is configured to receive aerosol generating material. As such, the heater element 112 defines at least a portion of the receptacle 116. The heater element 112 is tubular. The heater element 112 is configured to heat aerosol generating material of the article 104 from external of the article, and for this reason may be referred to as an outer heater element. However, in other embodiments, the configuration of the heater element 112 may vary. In embodiments, the heater element 112 may have a blade-like profile and in use an aerosol generating article may be forced onto the heater element 112 so that the blade-like profile of the heater element 112 inserts into a distal end of the aerosol generating article.
The heating assembly 110 defines a heating zone 120 in which the portion of the article 104 received by the heating assembly 110 is heated. The heater element 112 is configured to heat the heating zone 120. The heater element 112 defines the heating zone 120.
The heater assembly 110 comprises a flexible coil configuration 130. The flexible coil configuration 130 comprises a helical coil. The flexible coil configuration 130 surrounds the heater element 112. The flexible coil configuration 130 is configured to heat the heater element 112. The flexible coil configuration 130 at least partially extend around the heating zone 120.The flexible coil configuration 130 at least partially extend around the receptacle 116. The heater element 112 and the flexible coil configuration 130 may extend along concentric longitudinal axes.
In this example, the flexible coil configuration 130 comprises an inductor coil and the heater element 112 comprises a susceptor. The flexible coil configuration 130 comprises a magnetic field generating assembly. The flexible coil configuration 130 is configured to generate a varying magnetic field. The varying magnetic field generated by the flexible coil configuration 130 penetrates the susceptor suitably positioned with respect to flexible coil configuration 130, 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.
In other examples, not shown, the flexible coil configuration 130 may comprise a resistive heating circuit. The resistive heating circuit may be configured as a resistive heating coil. The resistive heating coil may be in contact with the heater element 112. The resistive heating coil may heat the heater element 112 by conduction heating. The resistive heating coil may act as the heater element 112.
In the example shown, the flexible coil arrangement 130 comprises a helical coil surrounding the heater element 112. However, other embodiments are envisaged. By way of example, the flexible coil arrangement 130 may form a flat coil. The flat coil may comprise a spiral. The flat coil may be planar.
FIG. 2 shows the flexible coil arrangement 130. The flexible coil configuration 130 comprises a flexible support 132 and an electrically conductive path 134. The flexible coil configuration 130 may be a flexible printed circuit.
The flexible support 132 comprises a flexible substrate. The flexible support 132 can be formed into a desired shape by bending, rolling or otherwise flexing the flexible support 132. In the example of FIG, 2, the flexible support 132 is formed into a tubular member. The tubular member may have a longitudinal axis 133. The longitudinal axis 133 of the tubular member may be concentric with the longitudinal axis 103 of the aerosol provision device 103.
In this example, the flexible support 132 comprises a thin, flexible sheet of material. The flexible substrate 132 is a film. The film is made of polyamide. The flexible support 132 has a thickness of about 50µm. In examples, the flexible support 132 may have a thickness in the range of 25µm and 150 µm. The flexible support may comprise a flexible support layer.
The flexible support 132 is made of electrically insulating material. The electrically conductive path 134 is formed on the flexible support 132. The electrically conductive path 134 may be deposited on or inscribed into the flexible support 132. The electrically conductive path 134 is made of an electrically conductive material, such as copper. The electrically conductive path 134 extends between a first type of connection 136a and a second type of connection 136b. The first type of connection 136a and the second type of connection 136b are configured to electrically connect the flexible coil configuration 130 to other components of the aerosol provision device 100. The flexible coil configuration 130 is connectable to the controller 115 and power source 114 of the aerosol provision device 100 via the first type of connection 136a and the second type of connection 136b.
FIG. 3 shows an embodiment of a blank 200 of a flexible coil configuration, such as the flexible coil configuration 130 described above, for use in an aerosol provision device, such as the aerosol provision device 100. The blank 200 comprises the flexible support 132 and the electrically conductive path 134 prior to the forming of the flexible support 132 in its desired shape. A coil for an aerosol provision device 100 may be manufactured from the blank 200 by forming the flexible support 130 from the blank.
When the flexible configuration 130 in the form of the blank 200, the flexible support 132 takes a generally flat shape. This helps to provide ease of manufacture when forming the electrically conductive path 134 on the flexible support 132.
The flexible coil configuration 130 may comprise an electrically conductive layer defining the electrically conductive path. The electrically conductive layer may be a film. The electrically conductive layer and the support layer may define a laminate.
The electrically conductive path 134 comprises a plurality of electrically conductive portions discontinuously formed on the flexible support 138, also identified as discontinuous electrically conductive portions 138. The electrically conductive portions discontinuously formed on the flexible support 138 are discontinuously formed on the blank 200 of the flexible coil configuration 130 and together form one or more continuous paths comprising at least two of the plurality of electrically conductive portions discontinuously formed on the flexible support when arranged into the assembled flexible coil configuration.
The blank 200 comprises four discontinuous electrically conductive portions- a first discontinuous electrically conductive portion 138a; a second discontinuous electrically conductive portion 138b; a third discontinuous electrically conductive portion 138c and a fourth discontinuous electrically conductive portion 138d. However, the plurality of discontinuous electrically conductive portions 138 may comprise different number of portions. In examples, plurality of discontinuous electrically conductive portions 138 may comprises between 2 to 10 portions.
The plurality of discontinuous electrically conductive portions 138 is formed on the flexible support 132. The plurality of discontinuous electrically conductive portions 138 is printed onto the flexible support 132. In examples, the plurality of discontinuous electrically conductive portions 138 may be deposited on or engraved into the flexible support 132. Each portion of the plurality of discontinuous electrically conductive portions 138 is spaced from other portions of the plurality of discontinuous electrically conductive portions 138 on the flexible support 132 when formed on the flexible support 132. Prior to forming the flexible coil configuration 130 into the desired shape, the plurality of discontinuous electrically conductive portions 138 may not form a single conductive path due to these being separated by the electrically insulative flexible support 132.
In the example show, the electrically conductive path 134 comprises a plurality of connections 140. The blank 200 comprises four connections- a first connection 140a; a second connection 140b; a third connection 140c; and a fourth connection 140d. However, the plurality of conenction portions 138 may comprise a different number of connections.
Each connection of the plurality of connections 140 is configured to connect two adjacent discontinuous electrically conductive portions so as to form the electrically conductive path 134 when the flexible support 132 is formed into a tubular member. In other words, the plurality of connections 140 are configured to close the electrically conductive path 134 such that a single conductive path is formed between the first type of connection 136a and the second type of connection 136b.
In the example shown, the first connection 140a is configured to connect the first discontinuous electrically conductive portion 138a to the second first discontinuous electrically conductive portion 138b. The second connection 140b is configured to connect the second discontinuous electrically conductive portion 138b to the third first discontinuous electrically conductive portion 138c.The third connection is configured to connect the third discontinuous electrically conductive portion 138c to the fourth first discontinuous electrically conductive portion 138d. The fourth connection 140d is configured to connect the fourth discontinuous electrically conductive portion 138d to the first type of connection 136a.
As shown, each discontinuous electrically conductive portion has a first end and a second end. Each connection of the plurality of connection 140 is configured to connect the first end of one of the discontinuous electrically conductive portions with the second end of an adjacent discontinuous electrically conductive portion. For example, the connection 140a is configured to connect a first end of the first discontinuous electrically conductive portion 138a with a second end of the discontinuous electrically conductive portion 138b. The first ends of the plurality of discontinuous electrically conductive portion may be aligned. The second end of the plurality of discontinuous electrically conductive portion may be aligned.
As shown, the plurality of connection 140 may be provided at an end of a discontinuous electrically conductive portion from the plurality of discontinuous electrically conductive portion 140. Each of the plurality of connections 140 may be configured so as to allow the first end of one of the discontinuous electrically conductive portions to overlap with the second end of an adjacent discontinuous electrically conductive portion when the blank 200 is formed into the flexible coil configuration 130. It will be appreciated that one or more connections of the plurality of connections may not be formed at an end of a discontinuous electrically conductive portion from the plurality of discontinuous electrically conductive portion 140. By a way of example, the connection 140d is provided on the first type of connection 136a instead.
The blank 200 may be formed into the flexible coil configuration 130 by forming the blank 200 into a tubular member. The blank 200 may be formed into a tubular member by rolling it along a forming axis 135. The forming axis 135 defines the longitudinal axis 133 of the flexible coil configuration 130 once formed. The plurality of discontinuous electrically conductive portion 138 may be arranged on and spaced apart from one another in the direction of the forming axis 135.
In the example shown, each connection of the plurality of connections 140 is formed by a cut-out in the flexible support 132. In this regard, the blank 200 comprises a plurality of cut-outs. The cut-out in the flexible support may be an aperture, an array of apertures, a via or a plurality of vias. The plurality of cut-outs are configured such that when the blank if formed into a tubular member, one end of each discontinuous electrically conductive portions overlaps the end of another, adjacent discontinuous electrically conductive portions. Adjacent discontinuous electrically conductive portions can be electrically connected, for example by soldering together, at the respective connection. Other electrical connections are envisaged, for example welding. This arrangement retains the flexible coil configuration 130 in a tubular condition.
In embodiments, each connection of the plurality of connections 140 is formed by a connector. The connector is made of conductive material. The connector may extend through the flexible support 132. In examples, the connector may be provided as an extension of one or more of the discontinuous electrically conductive portions 138. Adjacent discontinuous electrically conductive portions can be electrically connected, for example by soldering one of the adjacent discontinuous electrically conductive portions to the connector, the connector being provided on the other of the adjacent discontinuous electrically conductive portions 138.
With reference to FIG. 2, each of discontinuous electrically conductive portion 138 is arranged to partially define two adjacent turns of the coil when the blank 200 is formed into the flexible coil configuration 130. The flexible coil configuration 130 of FIG. 2 comprises a coil having four turns, though other configurations are envisaged. In examples, the flexible coil configuration 130 may comprise a coil having 2 to 10 turns.
In the example shown, the electrically conductive path 134 is formed on both sides of the flexible support 132. A first series 141 of the plurality of discontinuous electrically conductive portions 140 is formed on the first side 146 of the flexible support 132 and a second series 142 of the plurality of discontinuous electrically conductive portions 140 is formed on the second, opposite side 148 of the flexible support 132. The first series 141 of the plurality of discontinuous electrically conductive portions 140 overlaps the second series 142 of the plurality of discontinuous electrically conductive portions 140. In embodiments the electrically conductive path 134 is on a single side of the flexible support 132.
Each connection of the plurality of connections 140 is configured to connect two adjacent discontinuous electrically conductive portions of the first series 141 and two adjacent discontinuous electrically conductive portions of the second series 142 so as to form the electrically conductive path 134 when the flexible support 132 is formed into a tubular member. The plurality of connections 140 is configured to electrically connect the first series 141 of discontinuous electrically conductive portions to the second series 142 of discontinuous electrically conductive portions. The first and the second series 141, 142 of discontinuous electrically conductive portions define a single electrically conductive path (i.e. the electrically conductive path 134). The second series 142 of the plurality of discontinuous electrically conductive portions 140 may be identical in configuration to the first series of the plurality of discontinuous electrically conductive portions 140.
In the example of FIG. 2, the electrically conductive path 134 comprises a plurality of electrically parallel conductive tracks 150. In other words, the electrically conductive path 134 is split into a plurality of electrically parallel conductive paths, each path defined by a single track of the plurality of electrically parallel conductive tracks 150. The electrically conductive tracks 150 are arranged to be electrically parallel to one another. The electrically conductive tracks 150 are electrically insulated from each other along at least a portion of their length. The electrically conductive tracks 150 are electrically insulated from each other by the flexible support 132.
In the example of FIG.2 each of the plurality of discontinuous electrically conductive portions 140 is defined by the plurality of electrically parallel conductive tracks 150. In this regard, each of the plurality of discontinuous electrically conductive portions 140 is formed on the flexible support 132 as a plurality of plurality of electrically parallel conductive tracks 150. The plurality of electrically parallel conductive tracks 150 of a discontinuous electrically conductive portion are configured to be connected to the plurality of electrically parallel conductive tracks 150 of an adjacent discontinuous electrically conductive portion at a respective connection of the plurality of connections 140. In examples, the plurality of electrically parallel conductive tracks 150 of a discontinuous electrically conductive portion are configured to be soldered to the plurality of electrically parallel conductive tracks 150 of an adjacent discontinuous electrically conductive portion at a respective connection of the plurality of connections 140 when the flexible coil configuration 130 is formed from the blank 200. In other examples, the blank 200 may not comprise a plurality of discontinuous electrically conductive portions 140 and the plurality of electrically conductive parallel tracks may be formed to extend continuously from the first type of connection 136a to the second type of connection 136b.
The plurality of electrically conductive parallel tracks 150 define an active width W of the electrically conductive path 134. The active width of the electrically conductive path 134 is defined as the width of each of the plurality of electrically conductive parallel tracks 150 comprising the electrically conductive path 134 in addition to any spacing (for example, insulation) between the plurality of electrically conductive parallel tracks 150. In examples, the plurality of electrically conductive tracks 150 define a width of each of the plurality of discontinuous electrically conductive portion 138. The plurality of electrically conductive tracks 150 provide a decreased resistance of the electrically conductive path 134 in comparison to a single track of equivalent active width. The plurality of electrically conductive tracks 150 may further allow for more power to be drawn from the power source 114 resulting in a faster ramp-up time to operational temperatures.
In embodiments, the active width W of the electrically conductive path 134 is in the range of 1mm to 4mm. In an example, the active width W of the electrically conductive path 134 is 2mm.
In embodiments, the width of each of the electrically conductive tracks 150 is in the range of 100µm and 250 µm. In an example, the width of each of the electrically conductive tracks 150 is 150µm. In examples, the spacing between track is 150µm.
In embodiments, the plurality of parallel conductive tracks 150 may comprise between 7 and 25 tracks on each side of the flexible support 132. The plurality of parallel conductive tracks 150 may comprise between 14 and 50 tracks in total. In an embodiment, the plurality of parallel conductive tracks 150 comprises 16 tracks on each side of the flexible support 132. In embodiments where the electrically conductive path 134 is formed on a single side of the flexible support 132, the electrically parallel conductive tracks may comprise between 7 and 25 parallel conductive tracks. It will be appreciated that FIG. 2 and FIG. 3 illustratively shows the plurality of parallel conductive tracks 150 comprising 5 tracks on each of the first side 146 and the second side 148 of the flexible support 132 for clarity purposes.
FIG. 4 shows a further embodiment of a flexible coil configuration 130b. The flexible coil configuration 130b is substantially similar to flexible coil configuration of FIG. 2 and a detailed description is omitted with the same reference numbers being used to refer to the same or similar elements.
The flexible coil configuration 130b differs from the embodiment of FIG. 2 in that the electrically conductive path 134 is formed by first single conductive track 152 and a second single conductive track 154. The first single conductive track 152 is formed on the first side 146 of the flexible support 132 and the second single conductive track 154 is formed on the second side 148 of the flexible support 132. The first single conductive track 152 and the second single conductive track 154 are electrically parallel to one another. The first single conductive track 152 and the second single conductive track 154 define the same electrically conductive path (i.e. the electrically conductive path 134). The first single conductive track 152 is electrically connected to the second single conductive track 154 via the plurality of connections 140. The first single conductive track 152 is soldered to the second single conductive track 154. In a further embodiment, the electrically conductive path 134 may be formed by the first single conductive track 152 only and the second single conductive track 154 may be omitted.
The flexible coil configuration 130b further differs from the embodiment of FIG. 2 in the number of turns formed by the flexible coil configuration. As shown, the electrically conductive path 134 of the flexible coil configuration 130b defines a helical coil having five turns.
FIG. 5 shows an embodiment of a blank 200b of a flexible coil configuration, such as the flexible coil configuration 130b described above, for use in an aerosol provision device, such as the aerosol provision device 100. The blank 200b is substantially similar to blank 200 of FIG. 3 and a detailed description is omitted with the same reference numbers being used to refer to the same or similar elements.
In the embodiments of FIG. 3 and FIG. 5, the blanks 200a, 200b are respectively shown as configured to form a flexible coil configuration comprising a single coil. In other embodiments, the blanks 200a, 200b may be configured to form a flexible coil configuration comprising a plurality of coils. For example, the blanks 200a, 200b may be configured to form a first helical coil and a second helical coil, wherein the first and second helical coil extend along the longitudinal axis 133 and are spaced from one another in the direction along the longitudinal axis 133. In embodiments, the plurality of coils comprised in the flexible coil configuration formed may be controlled by the controller 115 individually to heat the aerosol generating material received in the aerosol provision device 100.
FIG. 6 illustrates a method 300 of forming a coil for an aerosol provision device from a blank configured to form a flexible coil configuration, such as the blank 200 of FIG. 3. In step 402, the flexible support 132 is provided. In step 304, an electrically the electrically conductive path 134 is formed on the flexible support 132. Forming the electrically the electrically conductive path 134 comprises forming the plurality of electrically parallel conductive tracks 150 on the flexible support 134. In examples, forming the electrically the electrically conductive path 134 further comprises forming the first type of connection 136a and the second type of connection 136b.
FIG. 7 illustrates a method 400 of forming a coil for an aerosol provision device from a blank configured to form a flexible coil configuration, such as the blank 200b of FIG. 5. In step 402, the flexible support 132 is provided. In step 404, a plurality of discontinuous electrically conductive portions 138 is formed on the flexible support 132, wherein each portion is spaced from adjacent portions of the plurality of discontinuous electrically conductive portions 138 on the flexible support 132. The method 400 may further comprise, forming the plurality of connections 140 as cut-outs in the flexible support 132. In step 406, the flexible support 132 is formed into a tubular member. In step 408, the electrically conductive path 134 is formed on the flexible support 132 by connecting plurality of discontinuous electrically conductive portions 138 to one another via the plurality of connections 140. Connecting the plurality of discontinuous electrically conductive portions 138 via the plurality of connections 140 may include soldering adjacent discontinuous electrically conductive portions together at the plurality of connections 140. Forming the flexible support 132 into the tubular member closes the electrically conductive path 134 so as to define a helical coil. In examples, the flexible support 132 may be formed into the tubular member by wrapping it around the heater element 112 of the aerosol provision device 100. Forming the electrically the electrically conductive path 134 may comprise forming the plurality of electrically parallel conductive tracks 150 on the flexible support 134.
The present application further relates a helical coil comprising a plurality of turns, wherein at least one turn comprises a portion extending perpendicular to a longitudinal axis of the helical coil. By a way of example, the flexible coil configuration 130 of FIG. 2 defines a helical coil having four turns wherein each turn comprises a portion extending perpendicular to a longitudinal axis 133 of the flexible coil configuration 130. In other examples, the helical coil may not comprise a flexible coil configuration. In examples, the helical coil may be formed from wire, for example Litz wire or a single strand wire.
With reference to FIG. 2, each turn of the coil of the flexible coil configuration 130 extends perpendicular to the longitudinal axis 133 along at least a portion of the length of the turn. As shown, each turn of the coil may extend perpendicular to the longitudinal axis 133 along a majority of the length of the turn. As shown, a transition section 160 is provided between each turn. Each transition section connects two portions extending perpendicular to the longitudinal axis. The transition section 160 may extend at an acute angle to each adjacent turn, for example each transition section may extends at 45° angle. The transition section reduces the risk of hot spot areas from forming.
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 an aerosol from aerosol generating material, the device comprising:
a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol generating material; and

a flexible coil configuration comprising:
a flexible support;

an electrically conductive path formed on the flexible support extending between a first type of connection and a second type of connection;

wherein the electrically conductive path comprises a plurality of electrically parallel conductive tracks.
An aerosol provision device according to claim 1, wherein the flexible coil configuration at least partially extends around the heating zone.
An aerosol provision device according to claim 1 or 2, wherein the electrically conductive path defines a helical coil.
An aerosol provision device according to claim 1 or 3, wherein each electrically parallel conductive track has a width of between 100µm and 250µm.
An aerosol provision device according to any of claims 1 to 4, wherein the plurality electrically parallel conductive tracks define an active width of the electrically conductive path, and wherein the active width is between 1mm and 4mm.
An aerosol provision device according to any of claims 1 to 5, wherein the flexible support comprises a first side and a second side, and wherein the electrically conductive path is formed on each of the first side and the second side of the flexible support.
An aerosol provision device according to any of claims 1 to 6, wherein the electrically conductive path is formed on the flexible support as a plurality of electrically conductive portions discontinuously formed on the flexible support.
An aerosol provision device according to claim 7, wherein the plurality of electrically conductive portions discontinuously formed on the flexible support are connected together via a plurality of connections.
An aerosol provision device according to claim 8, each connection of plurality of connections is formed by a cut-out in the flexible support.
An aerosol provision device according to any of claims 1 to 9, wherein the flexible coil configuration defines a longitudinal axis; and wherein the electrically conductive path comprises a plurality of turns, wherein at least one turn comprises a portion extending perpendicular to the longitudinal axis.
An aerosol provision system, comprising:
an article comprising aerosol generating material; and

the aerosol provision device of any of claims 1 to 10.
A blank configured to form a flexible coil configuration for an aerosol provision device, the blank comprising:
a flexible support;

an electrically conductive path formed on the flexible support; extending between a first type of connection and a second type of connection, wherein the electrically conductive path comprises a plurality of electrically parallel conductive tracks.
A method of forming a flexible coil configuration for an aerosol provision device, the method comprising:
providing a flexible support;

forming an electrically conductive path on the flexible support, the electrically conductive path comprising a plurality of electrically parallel conductive tracks.
An aerosol provision device for generating an aerosol from aerosol generating material, the device comprising:
a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol generating material; and

a flexible coil configuration;

wherein the flexible coil configuration comprises:
a flexible support formed into a tubular member; and

an electrically conductive path on the flexible support comprising:
a plurality of electrically conductive portions discontinuously formed on the flexible support; and

a plurality of connections, each of the plurality of connections connecting at least two of the plurality of electrically conductive portions so as to form the electrically conductive path.
An aerosol provision device for generating an aerosol from aerosol generating material, the device comprising:
a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol generating material; and

a coil configuration comprising a helical coil extending around the heating zone defining a longitudinal axis;

wherein the helical coil comprises a plurality of turns, wherein at least one turn comprises a portion extending perpendicular to the longitudinal axis.