RU2815805C1 - Method of making package containing consumable material for use in aerosol production device - Google Patents

Abstract

FIELD: packing.

SUBSTANCE: invention relates to a method of producing a package containing a consumable material for use in an aerosol production device. Method of making a package includes: combining a current collector with a consumable to form a unit containing the consumable; coating the block containing the consumable; heating of coating for hardening of shell around block containing consumable material. Shell is porous, as a result of which a package containing consumable material is obtained.

EFFECT: providing tight packing of consumable material.

5 cl, 88 dwg

Description

TECHNICAL FIELD

The present invention relates to methods, compositions and devices for aerosolizing drugs using a high-temperature non-flammable induction heating method and their applications. The present invention further relates to methods and apparatus for producing an aerosol from tobacco and/or other non-medicinal substances using similar methods.

BACKGROUND ART

When faced with a condition causing physical discomfort, such as a painful condition, disorder, ailment, disruption of the normal functioning of the body and the like, most people use medicinal remedies such as drugs, supplements, herbs, etc. to immediately relieve the symptoms experienced as a result of the underlying disease. There are certain legal and widely available over-the-counter (OTC) medications and supplements that provide benefits for a variety of common conditions. There are also certain controlled drugs and pharmaceuticals prescribed by doctors for a variety of more serious conditions.

One of the most common routes of administration of these OTC and prescription drugs is oral administration. However, as with any oral drug delivery, it must pass through the digestive tract. There are a number of disadvantages to oral administration. For example, because a drug must pass through the digestive system, the onset of drug activation occurs slowly. In addition, in the digestive tract, the drug may be inactivated or destroyed and therefore may lose its activity or effectiveness. The drug itself may also cause digestive tract problems or side effects such as loss of appetite, diarrhea, acidity, etc. Additionally, patients may be reluctant or unable to swallow oral medications in tablet form.

Certain medications are designed to affect the brain or its actions or activities, but given the common route of ingestion—gastrointestinal, intravenous, or intramuscular—these medications can also have a variety of unpleasant side effects due to the nature of ingestion or injection. These include, but are not limited to, gastrointestinal complications, digestive disorders, high blood pressure and/or headaches, and reluctance of users to self-administer medications by injection.

There are other delivery methods such as intradermal injections, patches, inhalation, etc. Each of them has its own advantages and disadvantages. Therefore, there is still room for improvement in drug administration methods.

For example, there are types of drugs that are safer, more effective, and more effective in terms of both safety and effectiveness when ingested by inhalation of an aerosol such as gas, steam, spray, or any other inhalant containing drug or its active ingredient and not by gastrointestinal, intravenous or intramuscular delivery.

Additionally, certain methods of aerosolization and delivery of these drugs also have disadvantages, particularly those that aerosolize the drug itself, changing the molecular or chemical structure of the drug, or those that can be aerosolized at high temperatures - increasing the duration of heating and increasing the risk of changes in the molecular or chemical structure of the active ingredient. Other disadvantages of current aerosolization techniques include transporting, storing and selling some of these drugs in cartridges that are susceptible to leaking and, in many cases, are designed and manufactured from cartridge materials that are not environmentally friendly, contain plastics and other materials that are not biodegradable .

To ensure that the drug product is delivered unchanged by the high-temperature, non-flammable induction method, it is preferable that the aerosolization method does not alter the chemical or fundamental molecular structure of the drug product or other materials of which the drug product is composed, or, if such changes occur, that they do not affected the effectiveness of the drug and/or did not improve it.

Therefore, there is still a need to improve methods of drug administration. In particular, there is still a need for improved methods of aerosolizing inhaled drugs that would also provide the added benefit of dispensing, controlling and metering precise doses into inhalers without destroying the active ingredient or adding other chemicals to the aerosol resulting in energy inefficiencies or increased duration heating There is also a need for consumable embodiments that are biodegradable and do not contain materials that are not suitable for environmentally safe disposal.

In addition to medical delivery systems, heated non-burn (HNB) devices are a type of device typically used to heat tobacco at temperatures below those that cause combustion to create an aerosol containing nicotine and other tobacco components, which is then made available to the user of the device . In some embodiments, a heated element or pantograph is placed within a solid tobacco product with a coil wrapped around the tobacco product and pantograph to cause the pantograph to be heated through an inductive mechanism. Unlike traditional cigarettes, the goal is not to burn the tobacco, but to heat the tobacco enough to release the nicotine and other constituents by creating an aerosol. Lighting and burning a cigarette creates unwanted toxins that can be avoided by using an HNB device. However, there is a delicate balance between providing sufficient heat to effectively release the tobacco constituents in aerosol form and preventing the tobacco from burning or igniting. Current HNB devices on the market have not found this balance, either heating the tobacco at temperatures that produce insufficient aerosol, or overheating the tobacco and creating an unpleasant or "burnt" flavor profile. Additionally, current methodology leaves the internal components of traditional HNB devices contaminated with tobacco combustion byproducts and accidental combustion byproducts.

In addition, to provide rapid and energy efficient solid or liquid to aerosol transition using high temperature, non-flammable induction heating, the composition must be designed to eliminate air flow between the composition and the current collector of the inductive system.

For the above reasons, there is a need for a device, method and composition that provides the user with the ability to control the power of the device, which will influence the temperature at which the tobacco will be heated using the induction method to reduce the risk of burning - even at temperatures that would otherwise be sufficient for ignition - while increasing the efficiency and flavor characteristics of the produced aerosol.

SHORT DESCRIPTION

The present invention is directed to devices, methods and composition for delivering a consumable material in an aerosol state for inhalation administration and ingestion using a high-temperature non-flammable induction aerosolization method of an embodiment of the composition development and configuration.

In particular, the present invention is directed to further improvements to non-combustion heating devices such as those described in US Provisional Application No. 63/000456, filed March 26, 2020, the contents of which are incorporated herein by reference in their entirety. In general, a non-combustion heating device is a device for converting a consumable material into an aerosol that contains certain of its constituents but limits the byproducts most commonly associated with combustion, such as smoke, ash, tar, and some other potentially harmful chemicals. This is accomplished by using high temperature without burning the consumables by packaging the consumables containing an internal pantograph inside the shell. This invention may include positioning and gradually advancing heat along a consumable tobacco component using an induction heating element wrapped around a package containing the consumable to heat the susceptor using a magnetic field generated by the induction heating element.

An object of the present invention is an apparatus in which an induction heating source is provided for use for heating a consumable tobacco component.

Another object of the present invention is to provide a consumable tobacco component consisting of a plurality of sealed, individual, airtight, coated casings containing the consumable tobacco preparation and an induction heating source. The shell may be an aluminum cover layer with pre-installed holes. The shells can be coated with a gel, which seals the holes until an induction heating process melts the gel, clearing the holes. In some embodiments, the gel may include a flavoring agent that can add or enhance flavor to the tobacco aerosol.

In some embodiments, multiple casings are stacked inside a paper tube with spaces between them formed by excess aluminum wrapping at the lower end of each casing and channels on either side to allow the resulting aerosol to pass through. When the induction heating source is activated, the preset holes are cleaned and the taste and aroma are mixed into the aerosol that passes through the tube and is made available to the user of the device.

By using these methods and fixtures, the device has to heat less mass, can heat up instantly, cool down quickly, and save energy, allowing you to use it more between recharging sessions. This is in contrast to well known, currently used, commercially available non-combustion heating devices.

Another object of the present invention is a tobacco-containing consumable component consisting of a plurality of sealed, individual, airtight coated casings and an induction heating source. The shells are then coated with a gel, which seals them until the induction heating process melts the gel, clearing the holes. In some embodiments, the gel may include a flavoring agent that may add or enhance flavor to the consumable tobacco component.

Another object of the present invention is to provide a package containing consumables that is easy to replace and that minimizes contamination of the interior of the housing during use so as to reduce the effort of cleaning the housing.

Another object of the present invention is to move a heating element relative to a susceptor or consumable to heat segments of the consumable independently of other segments.

Another object of the present invention is to maximize the energy efficiency of an aerosol generating apparatus.

Another object of the present invention is to aerosolize a consumable that can be compressed around a pantograph so as to eliminate any air flow between the consumable and the pantograph. For example, the block containing the consumable may contain inert, non-reactive compounds that are mixed with the consumable shape and then compressed tightly around the pantograph. The composition can be aerosolized using a portable high temperature induction heating device configured in accordance with the consumable embodiment.

The present invention further improves the non-combustion heating device by using a paper-thin susceptor made of steel wool, which heats efficiently and is easy to manufacture, thereby saving costs.

In some embodiments, efficiency is enhanced by an easy-to-apply coating.

In some embodiments, efficiency is improved by using a valve to regulate the pressure differential created within the package containing the consumable.

In some embodiments, the effectiveness of the device is enhanced by a unique seal configuration for sealing the space between the package containing the consumable and the receptacle through a high-temperature, non-flammable induction process designed to aerosolize the contained consumables and configured in the consumable embodiment without causing combustion.

In some embodiments, the effectiveness of the device is enhanced by a recognition system. The recognition system can identify specific characteristics and features of a consumable and interface with a system controller to control the manner in which the consumable is introduced based on the profile of the consumable. For example, a consumable may be treated with a marker, such as ink or dye (visible or invisible), which can be read by a sensor in the device. The characteristics of the marker, once determined by the sensor, can allow the device to recognize the various characteristics that the device has been programmed to recognize and adjust the temperature, heat duration and number of doses to best heat the consumable according to its taste and improve the consumer experience. Additionally, the recognition system can cause the consumable to change color after it has been used for a specifically programmed number of puffs, indicating when the consumable has been completely used up. Such an indication will then make the consumable material unsuitable for further use in the device. Finally, the recognition system can be used to initiate a shutdown response to render the consumable unusable. For example, there may be a surge in power that causes a hole to appear in the consumable, making it no longer usable.

Accordingly, the device, method and composition of the present invention can be used to aerosolize various consumables, preferably drugs. For example, these drugs include, but are not limited to, drugs designed to enhance bronchial efficiency, support tobacco and nicotine cessation, aid in relaxation, reduce anxiety, suppress disruptive thoughts, manage pain, increase alertness, promote restful sleep, aid in sexual activity, increasing energy and alertness, and counteracting the harmful effects of overdose of certain other drugs. In addition, these consumables may include tobacco, hemp, or other substances that can be inhaled by consumers.

BRIEF DESCRIPTION OF GRAPHIC MATERIALS

In fig. 1 is a side view of the interior of an embodiment of the present invention.

In fig. 2A is a perspective view of an embodiment of the present invention with parts removed to show the interior of the embodiment.

In fig. 2B is a perspective view of the embodiment shown in FIG. 2A, with portions cut and/or removed to show internal components.

In fig. 2C is a cross-sectional view of the embodiment shown in FIG. 2A, cut along the line 2C-2C.

In fig. 2D is an exploded view of the embodiment shown in FIG. 2A.

In fig. 2E is a perspective view of another embodiment of the present invention with portions cut off and/or removed to show internal components.

In fig. 2F is a perspective view of another embodiment of the present invention with portions cut off and/or removed to show internal components.

In fig. 3A is a perspective view of another embodiment of the present invention.

In fig. 3B is a partially exploded view of the embodiment shown in FIG. 3A.

In fig. 3C is a perspective view of the embodiment shown in FIG. 3A, with portions cut and/or removed to show internal components.

In fig. 3D is a close-up perspective view of the consumable containing unit shown in FIG. 3A.

In fig. 4A and 4B show exploded views of embodiments of a package containing a consumable.

In fig. 4C is a perspective view of another embodiment of a package containing a consumable, with portions cut or removed to show internal components.

In fig. 4D is a cross-sectional view of an embodiment of a package containing a consumable.

In fig. 4E is a perspective view of another embodiment of a package containing a consumable, with portions cut or removed to show internal components.

In fig. 5A is a perspective view of another embodiment of the present invention.

In fig. 5B is a cross-sectional view of the embodiment shown in FIG. 5A, viewed along line 5B-5B.

In fig. 5C is a perspective view of a package containing a consumable of the embodiment shown in FIG. 5A.

In fig. 6A is a perspective view of another embodiment of the present invention.

In fig. 6B is an exploded view of the embodiment shown in FIG. 6A.

In fig. 7A and 7B are perspective views of other embodiments of the present invention.

In fig. 7C shows another embodiment of a package containing a consumable.

In fig. 7D is an exploded view of the embodiment shown in FIG. 7C.

In fig. 8A is a side view of an embodiment of a heating element.

In fig. 8B is a front view of the heating element shown in FIG. 8A.

In fig. 9A is a side view of an embodiment of an aerosol generating apparatus.

In fig. 9B is a top view of the aerosol generating apparatus.

In fig. 9C shows a block diagram of an embodiment of a controller and its connection to other components of the present invention.

In fig. 10A-10B show block diagrams of embodiments of the controller and its connections to other components of the present invention.

In fig. 11A is a perspective view of an embodiment of a movable heating element with a recognition system.

In fig. 11B-11E show another embodiment of a recognition system.

In fig. 12A through 12D are exploded views, sectional views, and perspective views of an embodiment of the present invention using an alignment magnet.

In fig. 12E is a perspective view of another embodiment of the alignment mechanism.

In fig. 13A-13B are perspective views of a pantograph with multiple pointed elements.

In fig. 13C-D show cross-sectional side views of the embodiments of FIGS. 13A and 13B, respectively, sectioned along the longitudinal axis, showing the removal and insertion of a pantograph with several pointed elements into a package containing a consumable.

In fig. 14A through 14C show end views of an embodiment of a package containing a consumable with a heating element rotating about the package containing the consumable.

In fig. 15A through 15C show end views of an embodiment of a package containing a consumable, having another pantograph with three pointed elements, with a heating element rotating about the package containing the consumable.

In fig. 16A through 16D are end views of an embodiment of a package containing a consumable, having a susceptor with four pointed elements, with a heating element rotating about the package containing the consumable.

In fig. 17A through 17B are perspective views of an embodiment of a mechanism for rotating a heating element in an eccentric path around a package containing a consumable.

In fig. 18A through 18B are end views of the embodiment of FIG. 17A-17B of a mechanism for rotating the heating element in an eccentric path around a package containing a consumable.

In fig. 19 is a perspective view of an embodiment of a mechanism for rotating a heating element along an eccentric path and moving the heating element along a package containing a consumable.

In fig. 20 is a perspective view of an embodiment of a mechanism for moving a heating element relative to a package containing a consumable.

In fig. 21 is a block diagram of an embodiment of a controller and its connection to other components of the present invention.

In fig. 22 shows an embodiment of a heat sink attached to a heating element, with portions of the heat sink removed to reveal the heating element.

In fig. 23A is a cross-sectional view of an air flow controller attached to a package containing a consumable.

In fig. 23B shows another embodiment of an airflow controller attached to a receiver.

In fig. 23C-23J show various sealing embodiments.

In fig. 24A is an exploded perspective view of another embodiment of the present invention.

In fig. 24B is an end view of the embodiment of FIG. 24A.

In fig. 24C is a sectional view taken along line 24C-24C shown in FIG. 24V.

In fig. 25A-B are partial cut-away perspective views of a package containing a consumable with the pantograph removed to show a configuration within the package containing a consumable that utilizes a pantograph with hollow pointed elements.

In fig. 25C-D are partial cutaway views of the embodiments of FIGS. 25A-B, respectively, with a pantograph with hollow pointed elements built into the package containing the consumables.

In fig. 25E is a cross-sectional view of the embodiment shown in FIG. 25A-D, cut along its longitudinal axis to show air flow during use.

In fig. 26A is a perspective view of another embodiment of a package containing a consumable before inserting a pantograph.

In fig. 26B-C are partial cutaway views of the embodiment shown in FIG. 26A to show the relationship of the internal components before inserting the pantograph.

In fig. 26D is a cross-sectional view of an embodiment of the consumable-containing package shown in FIG. 26A–C, with a cut along its longitudinal axis.

In fig. 26E is a partial cross-sectional view of the embodiment shown in FIG. 26A, after inserting the pantograph.

In fig. 26F is a partial sectional view of FIG. 26E, with a heating element wrapped around a package containing a consumable.

In fig. 26G is a cross-sectional view of an embodiment of the package containing the consumables shown in FIG. 26F, with a cut along its longitudinal axis.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below in connection with the accompanying drawings is intended as a description of the presently preferred embodiments of the present invention and is not intended to represent the only forms in which the present invention may be made or used. The description sets forth the functions and sequence of steps for making and operating the present invention in connection with the illustrated embodiments. However, it should be understood that the same or equivalent functions and sequences may be performed by different embodiments, which are also intended to be within the spirit and scope of the present invention.

The present invention according to the present application is a device for generating aerosols from a product containing a consumable for inhalation in a manner that utilizes relatively high temperature while minimizing combustion of the product containing a consumable. For the purposes of this application, the term "consumable" should be construed broadly to cover any type of pharmaceutical, drug, chemical compound, active agent, constituent, any other drug, etc., regardless of whether the consumable is used material for the treatment of a condition or disease, whether it is intended for nutrition, is a supplement, or is used recreationally. By way of example only, consumables may include pharmaceuticals, dietary supplements and over-the-counter drugs such as, but not limited to, tobacco, hemp, marijuana, lavender, kava, coffee, caffeine, lobelia, hoodia, melatonin, epedymium, guarana , ginseng, etc.

With reference to FIG. 1-2E, device 100 includes a package 102 containing consumables and a device 200 for producing an aerosol. The device 100 generates aerosols through a non-combustion heating process in which the block 104 containing the consumable is heated to a temperature at which the block 104 containing the consumable does not burn inside the package 102 containing the consumable, but the consumable is released from the block 104. containing a consumable material in the form of an aerosol product that can be inhaled. Thus, the consumable block 104 is any product containing a consumable that can be released as an aerosol when heated to the proper temperature. Any description of the present invention for a specific application, such as a tobacco product, is presented by way of specific example only and is not intended to be limiting. Thus, the present invention is not limited to the use of tobacco products only.

Packaging containing consumables

With reference to FIG. 2A-6B, the package 102 containing the consumable is a component that is heated to release the consumable in an aerosol form. The consumable-containing package 102 includes a consumable-containing block 104 and a metal 106 (also called a pantograph) surrounding the consumable-containing block 104 for heating the consumable-containing block 104 from the inside by an induction heating system. In some embodiments, the package 102 containing the consumable may have a shell 108 to contain a block 104 containing the consumable and a pantograph 106. How well the package 102 containing the consumable heats depends on the consistency of the product. Product consistency takes into account various factors such as the position, shape, orientation, composition and other characteristics of the block 104 containing the consumable. Other characteristics of the consumable-containing unit 104 may include limiting the amount of oxygen contained in the unit. The goal is to ensure maximum product consistency while keeping each of these factors constant throughout the manufacturing process.

The casing 108 is configured to be aerosol permeable to allow aerosol to escape from the casing 108. A unit 104 containing a consumable material may be housed within the housing 150. The housing 150 is less permeable or impervious to aerosol. The housing 150 may simulate a cigarette. Thus, housing 150 may be an elongated structure having a first end 152 and a second end 156 opposite the first end 152. When the consumable block 104 is heated by the pantograph 106, an aerosol containing the consumable is generated. When the user retracts the housing 150, such as by suction at the second end 156, the aerosol exits the housing 108 but not the housing 150. Due to the negative pressure created by the suction at the second end 156, the aerosol is drawn toward the second end 156 through any space between a consumable-containing unit 104 and a housing 150. In some embodiments, a separator 135 (see FIGS. 3A-3B) may surround the housing 108, separating the housing 150 from the housing 108. In such an embodiment, the aerosol may move through the space defined by the separator 135. In some embodiments, the separator 135 may be a filter 140 (see FIGS. 2C-2D). The aerosol generating apparatus 200 includes components for holding the housing 150 in the proper position to heat the pantograph 106.

If the shape of the block 104 containing the consumable is in direct physical contact with the pantograph 106 with a maximum contact area between each of them, then it can be concluded that the thermal energy induced in the pantograph 106 will be largely transferred to the block 104 containing consumables. Thus, the shape and location of the consumable block 104 relative to the pantograph 106 is an important factor. In some embodiments, the consumable block 104 is typically cylindrical in shape. Thus, the consumable block 104 may have a circular or oval cross-section.

Block containing consumables

The design of the consumable containing block 104 is intended to minimize the amount of air to which the consumable containing block 104 is exposed. This eliminates or reduces the risk of oxidation or fire during storage or during the heating process. As a result, under certain settings, it is possible to heat the block 104 containing the consumable to temperatures that would otherwise cause a fire when used with prior art devices that allow greater exposure to air.

Thus, in some embodiments, the consumable containing block 104 is made from a powdered form of the consumable that is compressed into a solid compressed pellet or rod. Compressing the consumable reduces the amount of oxygen trapped within the consumable block 104 and limits the movement of oxygen into the consumable block 104 during heating.

For example, the consumable block 104 may be a single elongated block defining a longitudinal axis L in the form of a rod or stick, as shown in FIG. 2A–2E. The consumable containing block 104 may be an elongated cylinder or tube with a circular cross-section, an oval cross-section, a rectangular cross-section, etc. In some embodiments, the consumable containing block 104 may be a plurality of cylindrical tablets or pellets , stacked on top of each other, as shown in Fig. 3A–4B. Thus, the consumable-containing block 104 may be formed by two opposing ends 105, 107 and a side wall 109 therebetween extending from the first end 105 to the second end 107, defining the length of the consumable-containing block 104.

The current collector 106 may be similarly elongated and integrated into the consumable containing block 104, preferably along the longitudinal axis L and substantially extending the length and width (i.e., diameter) of the consumable containing block 104. In consumable blocks 104 having an oval cross-section, the diameter refers to the major diameter defining the long axis of the oval.

In some embodiments, as shown in FIG. 4C, the consumable block 104 can take any other shape, including spherical, oval, elliptical, and even shapeless. In general, the pantograph 106 can replicate the shape of the consumable-containing block 104 to maximize the surface area contact between the pantograph 106 and the consumable-containing block 104; however, the pantograph 106 may also take other forms, including a plurality of pantographs 106 distributed sporadically within the consumable block 104.

In an alternative embodiment, the consumable may be mixed with a substance that does not interfere with the operation of the device 100, but displaces air from the interstitial spaces of the consumable and/or surrounds the consumable, isolating it from air. For example, the consumable unit 104 may further contain an additive such as a humectant, a flavoring agent, an oxygen displacing agent or a steam generating agent, etc. The additive may further aid in the absorption and transfer of thermal energy, as well as the removal of oxygen from block 104 containing consumables.

In yet another alternative embodiment, the consumable can be formed into tiny pellets, granules, powder, or other form that can be encapsulated to further reduce the amount of air available to the consumable.

In some embodiments, the consumable containing block 104 may contain a ground source of the consumable, converted into a powder form, and then combined with the susceptor 106 by being tightly compressed around the susceptor 106. By way of example only, the supply source may be a plant, seed, flower , root, leaf, plant component, or any other source from which the consumable can be extracted. These components can be dried, crushed and mixed with other components known to create pellets and tablets, which are compressed around the susceptor to form a pellet, tablet or rod around the susceptor 106. The compressed pellet, tablet or rod can be enclosed in a casing 108 to form a package 102 containing consumables.

In some embodiments, the consumable may be removed from its source and incorporated into a new consumable transfer environment 105, as shown in FIG. 4D. This embodiment may be used, for example, if the consumable material is not of plant origin, has been extracted from its natural source, is synthesized, or is not suitable for use as a compressed solid. The medium 105 containing the consumable material forms a block 104 containing the consumable material. For example, the media 105 may be cotton, fiberglass, cloth, paper, cellulose, fibrous material, etc. The consumable material may be combined with the media 105 to form a block 104 containing the consumable and then pressed tightly against the pantograph 106. While in compressed form, the medium 105 may be bound within the casing 108 to maintain its compressed form to create a package 102 containing the consumable. The consumable material may be included in the medium 105 through known vehicles such as liquids, gels, resins, semi-solids, etc. For example, the consumable composition may contain propylene glycol alginate, glycerin, alcohol, water, propylene glycol, propylene alginate, polysorbates and etc. to bind the natural ingredient and some form of binding medium, which may consist of other non-reactive, natural, plant-based materials or some other biodegradable, non-reactive materials, such as paper, cellulose, cotton, etc. In some embodiments, consumable the material may be included in the medium 105 in the form of a particulate solid, such as a powder, granules, particles, etc. In some embodiments, these particulate solid consumables may be applied to the pantograph 106 and encapsulated within a shell 108. In some embodiments, the medium 105 may further comprise an additive such as a humectant, flavoring agent, oxygen displacing agent or vapor generating agent, etc. The additive may further aid in the absorption and transfer of thermal energy, as well as the removal of oxygen from the consumable material containing unit 104.

In some embodiments, the consumable material may be formed into resin, bulk solid, pellets, cellulose, paste, and other suitable forms for extrusion by an extruder. In these forms, the extruder may be designed to extrude on multiple sides of the pantograph 106 to center the pantograph 106 between layers during extrusion.

Pantograph

The current collector 106 is a component that is heated by induction and heats the consumable block 104 from the inside. Thus, the current collector 106 is made of a metal, such as ferrous metal, which can be heated by induction.

The current collector 106 may be machine extruded. Once extruded, the block 104 containing the consumable material may be combined with the pantograph 106 by compressing it around the pantograph 106 along the length of the pantograph 106. Alternatively, the pantograph 106 may be stamped from a flat metal blank or any other suitable manufacturing method prior to assembling the block 104 containing consumables, around pantograph 106.

In some embodiments, as shown in FIG. 2E, the pantograph 106 may be made of steel wool. For example, the pantograph 106 may consist of thin strands of steel wool tied together as a spacer. Thus, the steel wool pad has many thin edges. In some embodiments, the steel wool pad may be impregnated, dipped, or completely filled with an additive, such as a humectant, flavoring agent, steam generating agent, agent to retard steel wool oxidation (rust), and/or filler to remove air between the steel wool strands and etc. As shown in FIG. 2E, there may be cutouts or gaps 112 along the steel wool pad to separate the block 104 containing the consumable into separate segments for individual heating, as described below. Alternatively, individual steel wool pads may be used, separated by space and/or consumables so that each pad can be individually heated during use.

Steel wool can be made from low carbon steel. Advantages of steel wool include, but are not limited to, ease of disposal from an environmental perspective as it begins to oxidize soon after heating; and thus becomes loose and easily broken without dangerous sharp edges. Also, metals consisting of iron and carbon are relatively non-toxic. Carbon also increases rigidity.

Preferably, the pantograph 106 is flattened until it becomes paper thin. Thus, the thickness T of the flattened pantograph 106, particularly steel wool, may be less than 0.1 inch. (2.54 mm) Preferably, the thickness of pantograph 106 may be less than 0.05 inch. (1.27 mm) More preferably, the thickness of pantograph 106 may be less than 0.025 inch, (0.635 mm) or even less than 0.01 inch. (0.254 mm) In some embodiments, the pantograph 106 may be as thin as 0.0039 inch. (0.099 mm). The length of pantograph 106 can vary from about 0.5 inches (12.7 mm) to about 1.25 inches. (31.75 mm) Preferably, the pantograph is approximately 0.75 inches (19.05 mm) in length.

To produce a thin flattened strip of steel wool, a piece of steel wool may be subjected to a series of stretches and compressions until the required thickness T is achieved. This could be achieved by rolling pressing followed by a stamping process to obtain the desired shape and texture.

Once the required thickness is obtained, the pantograph 106 can be cut into the desired shape and dimensions. Using steel wool and thinning the steel wool allows for easy and long cutting as the steel wool cutting blade can last longer compared to traditional metals and thicker pantographs currently on the market. In addition, using steel wool is cheaper to manufacture and requires less energy to heat. In some embodiments, it takes approximately one third less energy to achieve the same temperature as other non-steel wool pantographs.

In some embodiments, the consumable-containing block 104 may be combined with or incorporated into the pantograph 106 by co-extruding it with the pantograph 106 to create a layer of the consumable-containing block 104 on top or bottom of the pantograph 106 layer. In some embodiments, two layers of the consumable-containing block 104a, 104b may be co-extruded with the pantograph 106 therebetween to create a sandwich structure around the pantograph 106, which can be compressed between the two layers of the consumable-containing block 104a, 104b.

In some embodiments in which the consumable-containing unit 104 contains a consumable-containing media 105, the pantograph 106 may be packaged or surrounded by the media 105, and then the media 105 and pantograph 106 may be pressed together and placed within the enclosure 108 (see Fig. 4D).

In some embodiments, the block 104 containing the consumable and the pantograph 106, having the same dimensions, can be placed on top of each other. For example, this may occur through a co-extrusion process. The consumable block 104 and pantograph 106 can then be folded from the first end 111 to the second end 113 as a sleeping bag is folded, as shown in FIG. 4E. Preferably, the pantograph 106 is on top during the folding process. As a result, the pantograph 106 and the consumable containing block form a cylindrical shape defining the longitudinal axis L, with a spiral pattern when viewed along the cross section, but the pantograph 106 remains internal to the consumable containing block 104. The cross section is a section along the diameter of the cylinder perpendicular to the longitudinal axis. This configuration further increases the impact surface area between pantograph 106 and consumable block 104. The current collector 106 may have a plurality of openings 110 to allow the aerosol to escape.

In some embodiments in which the current collector 106 is steel wool or other metal having the porosity characteristics of steel wool, the consumable material may be included directly in the current collector 106, such as a fluid (e.g., liquid, semi-liquid, viscous substance, etc. .) or free-flowing solid (e.g., powder, granules, particles, etc.) form, in which case the pantograph 106 performs the dual function of both the heating element and the block 104 containing the consumable material. Thus, the consumable block 104 may be a pantograph 106 combined with a consumable included therein.

The current collector 106 may be made of any metallic material that generates heat when exposed to alternating magnetic fields, as in the case of induction heating. Preferably the metal includes ferrous metal. To maximize the heating efficiency of the consumable block 104, the pantograph 106 typically matches the shape of the largest cross-sectional area of the consumable block 104 to maximize the surface area with which the consumable block 104 comes into contact with the pantograph 106, but Other configurations may be used. In embodiments in which the consumable-containing block 104 is an oblong cylinder, the largest cross-sectional area will be determined by dividing the elongated cylinder down the longitudinal axis L along its major diameter to form a rectangular cross-sectional area. Thus, the pantograph 106 must also be rectangular with dimensions substantially similar to the cross-sectional area of the elongated cylinder.

In some embodiments, the current collector 106 may be a metal plate. In some embodiments, the current collector 106 may be a metal plate with a plurality of holes 110, as shown in FIG. 2B, like a mesh screen. Induction heating is most effective and efficient at the edges of pantograph 106. The mesh screen creates more edges in pantograph 106 that can contact consumable block 104 as the edges define openings 110.

As shown in FIG. 2D, the pantograph 106 may be a strip with a series of small holes 110 to increase the number of edges that can be used in an effective induction heating process, followed by a larger gap 112 to provide a length of pantograph 106 that does not allow induction heating or at least least reduces induction heating and/or reduces thermal conductivity from the heated segment. This configuration allows the package 102 containing the consumable to be heated in individual segments. An oblong -nuclear current collector 106 can be an oblong metal plate that has a longitudinal direction, and an oblong metal plate contains sets of holes 110a, 110b and gap sets 112a, 112b, while sets of holes 110a, 110b are sequentially alternated with gaps 112a, 112b along the longitudinal direction an elongated metal plate such that each set of holes 110a, 110b is adjacent to one of the gaps 112a, 112b. Therefore, moving from one end of pantograph 106 to the opposite end, there is a first set of holes 110a, then a first gap 112a, then a second set of holes 110b, then a second gap 112b, etc. There is very little metallic material in the area of gaps 112; hence heat transfer is minimal. Thus, even though the consumable block 104 is a single block, it can still be heated in separate sections. The block 104 containing the consumable and the pantograph 106 may then be wrapped, and the pantograph 106 may be placed within the shell 108.

Shell

In some embodiments, the shell 108 may be made of metal. Thus, the shell can be cast or handcrafted and machined. A preferred metal may be aluminum with pre-punched holes 120. In some embodiments, the aluminum may be lined with porous paper or non-porous paper with vent holes to allow aerosol to exit the shell 108.

A block 104 containing a consumable is located within the shell 108 to retain heat generated by the pantograph 106. Openings 120 in the shell 108 can allow the consumable aerosol to escape when heated. Because the openings 120 provide a passage through which air can enter the shell 108 to act on the block 104 containing the consumable, the openings 120 can be temporarily sealed using a coating. The coating is preferably made from a composition that melts at temperatures that create consumable aerosols. Therefore, since the pantograph 106 is heated due to the absence of air within the shell 108, the block 104 containing the consumable material can be heated to extremely high temperatures without igniting. Since the pantograph 106 reaches high temperatures, consumable aerosols that begin to form cannot escape. When the coating melts and opens the opening 120, then the consumable aerosols can exit the shell 108 for inhalation. In a preferred embodiment, the coating may be a propylene glycol alginate (“PGA”) gel. The coating may also contain a flavoring agent. Therefore, as the coating melts and the consumable aerosol is released, the flavoring agent is also released along with the consumable aerosol. In some embodiments, the flavor may be mixed with additives.

In some embodiments, the openings 120 may be a plurality of holes or slits. The holes 120 may be formed along the length of the side wall 122 of the shell 108, located radially around the side wall 122, randomly or evenly spaced throughout the side wall 122, etc. In some embodiments, the holes 120 may be a plurality of holes along opposing ends 124, 126 of the shell 108. In some embodiments, with an elongated block 104 containing a consumable, the shell 108 may also be extended with an opening 120 in the form of one or more elongated slots extending along the length of the shell parallel to the longitudinal axis L, thereby creating the seam. This seam can be folded or crimped but still leave a gap through which consumable aerosols can pass, either along its entire length or in selected areas. Similar to the openings 120 described above, the seam may be sealed with a coating.

In some embodiments, the shells 108 may be manufactured as a two-piece unit having a first shell section 108a and a second shell section 108b. A block 104 containing a consumable may be inserted into the first casing section 108a, and a second casing section 108b may be placed over the first casing section 108a to cover the block 104 containing the consumable. Pre-made holes 120 may be formed in the shell 108 prior to encapsulating the block 104 containing the consumable.

Having established the general principles of packaging 102 containing consumables, variants that achieve the same goals were also considered. For example, in some embodiments, the consumable containing block 104 may include two elongated sections 104a, 104b. Two elongated sections 104a, 104b of the consumable block 104 may be formed by a plane parallel to and intersecting the longitudinal axis L along the diameter. Therefore, the two elongated sections 104a, 104b may be semi-cylindrical sections which, when joined together, form a fully cylindrical block 104 containing the consumables.

In some embodiments, as shown in FIG. 3A-4B, block 104 containing the consumable material may be in the form of a pellet or tablet. Unlike the consumable-containing block 104, which is an elongated cylinder or tube in which the length of the side wall 109 is much greater than the diameter, in the tablet embodiment, the tablet may be a short cylinder defining a longitudinal axis L, wherein the length of the side wall 109 closer to the diameter size or shorter than the diameter. The pantograph 106 may have a flat circular shape to conform to the cross-sectional shape of the tablet when viewed in cross-section perpendicular to the longitudinal axis L. A block 104 containing a consumable may be compressed around the pantograph 106. To simulate a cigarette, a plurality of blocks 104 containing a consumable may be stacked end-to-end along their longitudinal axes L, forming an oblong cylinder. Therefore, each individual consumable block 104 can be heated separately, effectively simulating segments of a consumable block 104 having an elongated tubular body.

Other shapes may also be used, such as square or rectangular with the pantograph 106 being suitably shaped. However, the cylindrical shape can be easily adjusted to a shape that imitates the shape of a real cigarette.

In some embodiments, the consumable containing block 104 may be formed from two sections 104a, 104b of the consumable containing block 104 combined together as a single unit, as shown in FIG. 4A and FIG. 4B. The two sections 104a, 104b are formed by dividing the consumable block 104 in half in the transverse direction along a plane perpendicular to the longitudinal axis L. The pantograph 106 may be sandwiched between the two sections 104a, 104b. With pantograph 106 sandwiched between two consumable-containing sections 104a, 104b, consumable-containing block 104 may be enclosed within shell 108. This process may be repeated to create multiple individual consumable-containing blocks 104 clamping respective pantographs 106. each of which is individually contained in a respective casing 108. A plurality of consumable-containing blocks 104 may be stacked on top of each other to create a consumable-containing package 102 in which each individual consumable-containing block 104 can be heated individually, according to one at a time.

In some embodiments, the shell 108 may be aluminum wrapped around the block 104 containing the consumable. The aluminum may have additional folds 130, 132 at opposite ends as shown in FIG. 3D. These additional folds 130, 132 create a gap between adjacent blocks 104 containing consumables when they are stacked on top of each other.

In some embodiments, the casing 108 may be composed of two parts, having a first casing section 108a and a second casing section 108b that serves as a lid or cap for enclosing a block 104 containing a consumable within the first casing section 108a, as shown in FIG. 4A and FIG. 4B. As previously described, openings 120 on shell 108 may be located along side wall 122 or at ends 124, 126. As previously described, pantograph 106 may be made of any type of metal that is susceptible to induced heat, including steel wool, as shown in FIG. . 4B. In preferred embodiments, multiple edges are created in pantograph 106 by creating multiple holes 110 or by using steel wool strands pressed together. Steel wool threads can range from high to middle grade. As discussed above, the steel wool pad may be impregnated, coated or filled with an additive, flavoring agent, preservative and/or filler.

In some embodiments, multiple consumable-containing blocks 104 may be contained within a single elongated shell 108, as shown in FIG. 5A–6B. The shell 108 may be molded with compartments 111 to accommodate each individual block 104 containing a consumable. In some embodiments, the individual compartments 111 may be connected to each other by a jumper 121. In some embodiments, the jumper 121 may define a conduit 125 that provides fluid communication from one compartment 111 to another. In some embodiments, the web 121 may be folded to prevent fluid communication between one compartment 111 and another through the web 121. In some embodiments, the elongated shell 108 may be a two-piece assembly divided transversely along a longitudinal axis L, as shown in fig. 6A–6B. Blocks 104 containing consumables may be placed in compartments 111 of one of the shell sections 108a. The second shell section 108b may then be mated to the first shell section 108a to cover the consumable-containing blocks 104. The gap between the first shell section 108a and the second shell section 108b can be used as an opening 120. Alternatively, pre-made holes 120 can be provided in one or both shell sections 108a, 108b.

In some embodiments, as shown in FIG. 7A through 7D, the shell 108 may be made of a material that allows the shell 108 to serve as a current collector. For example, shell 108 may be made of steel or otherwise contain ferrous metal, or any other metal that can be heated using induction heating. In such an embodiment, it would not be necessary to integrate the internal pantograph 106 into the consumable block 104. The shell 108 may still contain a plurality of holes 120 and be coated with an additive and/or sealant such as PGA. This embodiment may be in the form of an elongated tube, as shown in FIG. 7A, or in tablet or disc form as shown in FIG. 7B. The shell 108 may be a two-piece shell having a first shell section 108a and a second shell section 108b, as previously discussed.

In some embodiments, the shell 108 may have transverse slots 123 located across the shell 108 generally perpendicular to the longitudinal axis L, as shown in FIG. 7C and FIG. 7D. The slots 123 create segmentations in the shell 108 such that only a small segment of the block 104 containing the consumable is heated upon actuation. The cross slits 123 may be through holes that expose the consumable block 104 from below. In such embodiments, the segments may be filled with a coating or some other plug to seal the opening either permanently or with a substance that melts when heated and allows the aerosol to exit through the slot 123. In some embodiments, the plug may be made of a material that may function as a heat sink, and/or of a substance that is difficult to heat by induction to reduce the effect of heating on the transverse slots 123. In some embodiments, the transverse slot 123 may be a recessed portion or recess in the shell 108. In other words, the transverse the slot 123 may be a thinned portion of the shell 108. Thus, the transverse slot 123 may form a recess. The well may be filled with a plug that may function as a heat sink and/or a substance that is difficult to heat by induction to reduce heat transfer along the transverse slot 123.

In some embodiments, the shell 108 may be a hard covering layer to provide structural integrity to the package 102 containing the consumable. In some embodiments, the sheath 108 may be a flexible wrap, and the block 104 containing the consumable and the pantograph 106 may be wrapped within the sheath 108. For example, in some embodiments, the pantograph 106 may be a flat sheet of cotton wool wrapped in cotton, in which included consumables in liquid or bulk solid form. The cotton wool and cotton can be wrapped with aluminum foil which has 120 holes in it.

In some embodiments, the shell 108 may be made of a porous material, as shown in FIG. 4C. For example, the shell 108 may be a porous paper wrapper or other similar material. Thus, the pores would function as openings 120, allowing the aerosol to exit the consumable block 104 when heated. In addition, since the consumable block 104 is compressed to remove oxygen, combustion is still unlikely at operating temperatures and the short duration of time during which the consumable block 104 is exposed to high temperature. Even though the outer portion of the shell 108 is exposed to oxygen along the passage between the shell 108 and the housing 150, induction heating quickly heats the consumable from the inside so that the outer portion of the shell 108 never reaches combustion temperature. For example, at temperatures above 350 degrees Celsius and even above at 400 degrees Celsius, combustion did not occur in the present invention. On the contrary, since other devices use loose tobacco (or consumables) or heat the consumables from the outside, these devices are susceptible to the consumables catching fire. Additionally, other heated tobacco products heat all of the tobacco at the same time - either from the inside using a blade/rod or using a "oven" surrounding the consumable. This causes a cloying, burnt taste after just 3 puffs. In addition, most other current tobacco heating technologies direct air flow through the tobacco, which reduces the combustion temperature. In contrast, in the present invention, the heat source is a susceptor 106, which is enclosed in a compressed block 104 containing a consumable to create an oxygen-free or oxygen-limited environment, and the consumable aerosol produced by heating is released from that environment into a surrounding channel between the shell 108 and the housing 150.

In embodiments in which the shell 108 is a porous material, the shell 108 may be thin, allowing aerosol to pass through the pores of the shell and exit the shell 108 laterally or radially outward. This allows the aerosol to enter the channel created between the housing 150 and the shell 108. In some embodiments, the shell 108 may be thicker and have sufficient porosity to allow the aerosol to pass through the pores in the longitudinal direction along the length of the shell 108. In such an embodiment, the channel between the housing 108 150 and shell 108 may not be needed. Such porous materials may include cigarette paper, cellulose or other filter materials, or any suitable material for this purpose.

In some embodiments, the shell 108 may include a coating 115. As used herein, the coating 115 is a fluid, such as a liquid, semi-liquid, or viscous substance that has solidified into a coating layer, and in particular, a rigid, porous coating layer that can maintain its shape when handled. An example of coating 115 is a mass made from starch. The starch may be corn starch, potato starch, or starch from any other plant source such as sago, wheat, barley, rice, tapioca, cassava, etc., and in some embodiments may be combined with other fibrous materials such as paper pulp, etc. When starch is mixed with a fluid such as water, the pulp becomes liquid, semi-liquid or viscous. When heated and/or over time, the mass may harden. This is a common method used when preparing fried foods. Likewise, coating 115 in liquid form may be applied to block 104 containing consumables. For example, in liquid form, the mass may be sprayed or spread onto a block 104 containing a consumable, or a block 104 containing a consumable may be immersed in the mass. Heat may be applied to the covered block 104 containing the consumable material. The coating then creates a hardened, but still porous, coating layer around the block 104 containing the consumable material to form the shell 108. In another embodiment, the coating layer shell may be cast using a combination of starch mass. However, oxygen is still largely removed between the consumable and the current collector 106.

In such an embodiment, there is no need to punch holes 120 in the shell 108 due to the porosity of the shell 108. Porosity can be created and/or increased as the shell 108 heats up during use. In addition, starch provides a high flash point and does not impart flavor or aroma. In addition, when using starch, the risk of leakage is very small and the starch can have a long shelf life.

The shell 108 containing the block 104 containing the consumable can then be inserted into the housing 150 to form a package 102 containing the consumable. When the pantograph 106 is heated, the consumable material is atomized and released into the porous shell 108. When the user draws through the mouthpiece 158, the negative pressure created inside the housing 150 causes air to flow towards the mouthpiece 158, and the aerosolized consumable material passes through the pores of the shell to mouthpiece where the user can inhale the consumable.

Similar to the embodiment shown in FIG. 2A-2E, the porous cover layer shell 108 may be a single elongated unit such as tubes or rods. In some embodiments, as shown in FIG. 3A-D, the porous cover layers can be individual, short cylindrical blocks or block blocks that can be stacked. In some embodiments, as shown in FIG. 4C, the porous cover layers may be spherical.

By way of example only, starch powder can be sprayed onto the active ingredient composition around the pantograph to form a porous shell; or the mass can be formed by adding water to the starch powder to give it the consistency of honey, and then the active ingredient and the current collector are immersed in the mass and allowed to dry, forming a porous shell.

Therefore, a method of manufacturing a package 102 containing a consumable for use in an aerosol producing device 200 includes combining a pantograph 106 with a consumable to form a block 104 containing the consumable; coating the block 104 containing the consumable material; heating the coating to create a shell 108 around the block 104 containing the consumable, the shell 108 being porous, resulting in a package 102 containing the consumable. Preferably the coating contains starch. The method may further include extruding the consumable with the current collector 106 to form a block 104 containing the consumable. The method may further include rolling the extruded pantograph 106 and consumable material to form a cylinder with a spiral pattern when viewed along a cross section. The method may further include introducing a consumable into the medium 105 to form a block 102 containing the consumable.

In some embodiments, a method of making a package 102 containing a consumable for use in an aerosol generating device 200 includes flattening a piece of steel wool into a pantograph 106 having a thickness of less than 0.1 inch (0.254 mm); combining the pantograph 106 with the consumable to form a block 104 containing the consumable; placing the block 104 containing the consumable in the casing 108, resulting in a package 102 containing the consumable. The method may further include extruding a pantograph 106 to flatten a piece of steel wool. The method may further include extruding the pantograph 106 with a consumable to combine the pantograph 106 with the consumable. The method may further include rolling the extruded pantograph 106 and consumable material to form a cylinder with a spiral pattern when viewed along a cross section. The method may further include introducing a consumable into the medium 105 to form a block 104 containing the consumable.

In some embodiments, the shell 108 may be completely removed and the consumable containing block 104 is simply surrounded by the housing 150. In such an embodiment, the aerosol is released from the consumable containing block 104 directly into a channel between the consumable containing block 104 and housing 150. As with the shell embodiments, the exterior of the block 104 containing the consumable material does not reach combustion temperature due to rapid induction heating from the inside.

In embodiments where the shell 108 is porous or absent, the freshness of the consumable can be maintained using an airtight package that can be filled with nitrogen or other inert gas to prevent oxidation. Such packaging may be used for large packages 102 containing consumables, such as tobacco products, where multiple packages 102 containing consumables may be used each day. Alternatively, individual packaging may be used for consumable packages 102 containing medicinal products where the consumable is only used periodically.

Delimiter

The package 102 containing the consumable may include a separator 135 to create a space between the housing 150 and the block 104 containing the consumable. The space between the housing 150 and the block 104 containing the consumable provides a passage for air flow to carry the consumable in aerosol form to the mouthpiece 158 for inhalation.

In some embodiments, the separator 135 may be a filter tube 140 for encapsulating the consumable block 104, pantograph 106, and shell 108, as shown in FIG. 2C and 2D. In other words, the porosity of the filter tube 140 creates a passage for air flow to the mouthpiece. By way of example only, filter tube 140 may be made of cellulose or cellulose acetate, although any suitable filter material may be used.

The filter tube 140 may be made of filter material to trap any unwanted debris while allowing the consumable aerosol that is released by heating the sheath to pass transversely through the filter. A filter tube 140 may surround the shell 108 and further cover the coated openings 120. Since the filter tube 140 may be made of a filter material, the consumable aerosol is able to pass through the filter tube 140. By way of example only, the filter tube may be made of cellulose or cellulose acetate, although any suitable filter material may be used.

In some embodiments, the spacer 135 may be any rigid structure that can maintain space between the shell 108 and the housing 150 while providing a passage for air flow from the shell 108 to the mouthpiece 158, as shown in FIG. 3A and 3B. For example, the spacer 135 may be a frame, corrugated material, rods, rings mounted on a shell 108 with transverse holes cut into the wall of the ring, or the like.

In some embodiments, the separator may be optional. For example, in embodiments in which the sheath is made of a rigid but porous material, separator 135 would not be required since the porosity of sheath 108 provides a passage for air flow to move the consumable from the consumable-containing block 104 to the mouthpiece 158.

In some embodiments, separator 135 may be optional. If the consumable block 104 and/or shell 108 are shaped differently from the body 150, a natural channel is formed. For example, if the consumable block 104 and/or shell 108 have a triangular or square cross-section, their placement within the cylindrical shell 108 creates three and four channels, respectively. For a cylindrical body 150, any consumable block 104 and/or shell 108 having a polygonal cross-section or even an oval cross-section will create aerosol channels without the need for a separator 135. Any cross-section that creates one or more channels can eliminate the need in the separator 135. Alternatively, the consumable block 104 and/or shell 108 may be cylindrical, and the body 150 may be polygonal or even square to create channels without the need for the separator 135.

Frame

The package 102 containing the consumable may further include a housing 150 to enclose a shell 108 and a separator 135, if present. In a preferred embodiment, the housing 150 typically simulates a cigarette. Thus, the housing 150 is generally tubular, having a first end 152 with a first opening 153, and a second end 156 opposite the first end 152, the second end 156 having a second opening 157. Thus, the housing 150 may be a hollow tube configured so that the user can draw in on the second end 156, causing air to flow through the first opening 153 on the first end 152 downstream to the second opening 157 on the second end 156. For example, the housing 150 may have a length of from about 1.5 inches ( 38.10 mm) to approximately 3.25 inches (82.55 mm).

The housing 150 contains a material that is less likely to allow sacrificial aerosols to pass through, such as paper, plastic, metal, ceramic, glass, wood, carbon fiber, pressed starch paper, etc. This allows the sacrificial aerosol to follow the inhalation path of the the user's mouth in a direction from the first end 152 of the housing 150 to the second end 156 of the housing 150.

The housing 150 may be closed by an end cap 154 at the first end 152. The end cap 154 may be comprised of a particular type of filter material. As air flows from first end 152 to second end 156, end cap 154 functions as a pre-filter. Another function of the end cap 154 in the housing 150 is to serve as an air flow restrictor, creating negative pressure within the consumable as air is drawn through the end cap 154.

At the opposite end 156 of the body 150 is a mouthpiece 158 through which the user draws a puff to draw the heated consumable aerosol from the sheath 108 along the body 150 to the mouthpiece 158 and into the user's mouth. Thus, mouthpiece 158 may also include a type of filter similar to the type of filter of end cap 154. Any type of filter may be used as end cap 154 and mouthpiece 158. In some embodiments, end cap 154 and/or mouthpiece 158 may be a sheet of filter material , paper or any other suitable material which has been folded from the first end to the second end to create an internal spiral when viewed in cross section as shown in FIG. 2F.

Sheath 108 may be slid into housing 150 through first opening 153 or second opening 157. If sheath 108 is slid out of first opening 153, then mouthpiece 158 may be seated to prevent sheath 108 from slipping out. Likewise, if sheath 108 is slid into housing 150 from the second hole 157, then the end cap 154 can be installed in place to prevent the shell 108 from slipping out of the first hole 153. Thus, the mouthpiece 158 and the end cap 154 hold the shell 108 in place within the housing 150.

The housing 150 wrapped around the filter tube 140 creates a longitudinal channel through the filter tube 140 through which the consumable aerosol moves rather than exits radially from the filter tube 140. This allows the consumable aerosol to follow an inhalation path to the user's mouth. One end 152 of the housing 150 may be closed by an end cap 154. The end cap 154 may be comprised of a particular type of filter material. At the opposite end 156 of the housing 150 is a mouthpiece 158 through which the user takes a puff to draw the heated consumable aerosol from the shell 108 along the filter tube 140 to the mouthpiece 158 and into the user's mouth. Thus, the mouthpiece 158 may also be a type of filter similar to the type of filter of the end cap 154. If the package 102 containing a consumable includes a channel through which the consumable aerosol passes, and this channel leads directly to the mouthpiece 158, which is also part of the package 102 containing the consumable and the channel is isolated from the receiving device 151 and/or housing 202, then the receiving device 151 and/or housing 202 will remain free of any residues or by-products generated during operation of the device. In this configuration, the receiving device 151 and/or housing 202 remains clean and does not require the user to periodically clean the receiving device 151 and/or housing 202.

Induction heating

Heating of the consumable block 104 is achieved using an induction heating process that provides non-contact heating of metal, preferably ferrous metal, by placing the metal in the presence of an alternating magnetic field generated by induction heating element 160, as shown in FIG. 8A–8B. In a preferred embodiment, induction heating element 160 is a conductor 162 wound on a coil that generates a magnetic field when current is passed through the coil. The metal current collector 106 is placed close enough to the conductor 162 to be within the magnetic field. In a preferred embodiment, conductor 162 is wound such that it defines a central cavity 164. This allows a package 102 containing a consumable to be inserted into cavity 164 such that conductor 162 surrounds pantograph 106 without touching pantograph 106. The current passing through conductor 162 represents is an alternating current that creates a rapidly varying magnetic field. The alternating magnetic field can create eddy currents in the pantograph 106, which can generate heat inside the pantograph 106. Thus, the package 102 containing the consumable material is generally heated from the inside. In embodiments in which the shell 108 also serves as a current collector, the package 102 containing the consumable is heated externally. In some embodiments, a plurality of individual conductors 162a-f may be arranged in series to allow individual blocks of the package 102 containing the consumable to be heated.

In a preferred embodiment, the heating is very rapid and short-lived. It takes approximately less than ten seconds for the device to "warm up" and be ready to supply power to the coil, which then almost immediately heats the pantograph to provide the consumable aerosol. Preferably, the warm-up time is from about 1 second to about 7 seconds, or from about 3 seconds to about 6 seconds. Most preferably, the warm-up time is approximately 2 to 3 seconds. The intense, momentary heating heats the consumable block 104 internally and preferably does not raise the temperature of the exterior of the consumable block 104 or the shell 108 (if any) to combustion temperatures. For example, the duration of intense heating may be from about 0.5 to about 5 seconds. Preferably, the heating is from about 0.5 to about 3 seconds. Most preferably, the heating is from about 1 to about 2 seconds. The heat is sufficient to create a consumable aerosol that must be removed from the block 104 containing the consumable.

In a preferred embodiment, the segments of the package 102 containing the consumable material must be individually heated. Thus, conductor 162 may also be provided as separate sets of helical conductors 162a-f, as shown in FIG. 8A. Each conductive coil 162a-f may be attached to a controller 166, which can be controlled to activate one conductive coil 162a-f at a time. Although in FIG. 8A shows six (6) conductive coils 162a-f, more or fewer coils may be used. In an alternative embodiment, a single conductive coil 162 may be used with a mechanical mechanism that moves the coil along the package 102 containing the consumable to individually heat each segment of the package 102 containing the consumable.

The individual conductive coils 162a-f may be combined with individual segments of the package 102 containing the consumables, as described above and shown in FIG. 3A–6B. Alternatively, each conductive coil 162a-f may correspond to a specific length of a continuous package 102 containing a consumable, such as shown in FIG. 2A–2D, 7A and 7D, to heat only that specific length. In preliminary testing of such embodiments, heating along individual lengths of the consumable-containing package 102 does not appreciably heat adjacent portions of the consumable-containing package 102 because the adjacent unheated consumable material appears to act as an insulator. Thus, designs to limit heat transfer may not be necessary, although such designs have been discussed in this document and may be useful.

The efficiency of converting electrical energy to thermal energy in the current collector 106 is referred to herein as the "conversion ratio" and is based on a variety of factors such as volumetric resistivity of the metal, dielectric constant of the metal, metal geometry and heat loss, power supply constancy and efficiency, coil geometry , losses and overall frequency of operation - to determine some of these factors. The device 100 is designed and configured to maximize conversion efficiency.

To further improve the efficiency of the heating process, a preheating method can be used. Preferably, the pantograph 106 is preheated to a moderate temperature as measured by the temperature sensor, then when the user is ready to inhale, the pantograph 106 receives a charge of energy that quickly increases the temperature to a higher aerosolization temperature. For example, when a package 102 containing a consumable is inserted into the device 100, it may activate a heating system 160 that heats the pantograph 160 to approximately a moderate temperature (i.e., above room temperature but below the aerosolization temperature), e.g. 200 degrees Celsius. Then, when the user begins to take a puff on the mouthpiece, the pressure difference created within the package 102 containing the consumable is detected by the pressure sensor 426, and the system controller 166 generates a burst of energy to rapidly increase the temperature to a higher aerosolization temperature, such as 350 degrees Celsius.

In some embodiments, an external actuator may be used such that when the user prepares to inhale, the user may actuate the external actuator to begin the preheating process to a moderate temperature. Then, when the user is ready to inhale, a second external actuator can be activated, or the vacuum created internally by the suction action can be detected by a pressure sensor 426 or other device that can signal the heating system 160 to generate a burst of energy to quickly raise the temperature to aerosolization temperatures. After the user has finished inhaling the vapor, the temperature may drop again to a moderate temperature or an intermediate temperature between moderate temperature and aerosolization temperature. Therefore, when the user is ready to take the next dose, the heating system is started.

For example, when the package 102 containing a consumable is first used in the aerosol generating device 200, the aerosol generating device 200 heats the susceptor in a range of from about 100 degrees Celsius to about 250 degrees Celsius depending on the active ingredient. Then, when a puff is taken, the aerosol generating device 200 raises the temperature to approximately 400 degrees Celsius or higher to create the puff. This increase can reach approximately 0.01 seconds. Once a puff has been taken, aerosol generating device 200 begins to extrapolate the temperature drop using a time curve to calculate the temperature before the next puff. Since the aerosol generating device 200 has a thermostat on one of the chips, the initial ambient temperature of the device is known. By extrapolating the temperature versus time curve as a function of when the next puff is taken, the aerosol generating device 200 accurately calculates how much energy is needed to reach 400 degrees Celsius on the next puff. This happens again and again after every puff. So, if a puff is taken within 5 seconds of the first puff, or 30 seconds after the first puff, the fuzzy logic process will bring the next puff to 400 degrees Celsius (or whatever temperature is set) of the second/next puff. System controller 166 may be operatively coupled to a temperature sensor to measure temperatures. This system provides a consistent puff, which will be similar to moving a spool to obtain a consistent puff. Therefore, this feature may be a preferred embodiment in which the heating coil is not moved.

Thus, a preferred embodiment of the method of aerosolizing a consumable by the aerosol generating device 200 may include preheating the pantograph 106 surrounded by the consumable to a moderate temperature that is above room temperature but below the aerosolization temperature; and heating the current collector 106 from a moderate temperature to an aerosolization temperature, causing the consumable material to become an aerosol. After the pantograph 106 has been heated to the aerosolization temperature, the pantograph can be brought back to a moderate temperature. Alternatively, after pantograph 106 has been heated to the aerosolization temperature, pantograph 106 may be brought back to an intermediate temperature that is below the aerosolization temperature but above the moderate temperature. Preferably, preheating of the pantograph 106 occurs upon insertion of the package 102 containing the consumable into the aerosol generating device 200. In addition, heating of the pantograph 106 to the aerosolization temperature occurs when the pressure sensor 426 detects a pressure drop within the aerosol receiving device 200, such as the receiving device 151.

Device for producing aerosol

To effect heating and converting the consumable into an aerosol, a package 102 containing the consumable is placed inside the aerosol generating device 200, as shown in FIG. 1 and fig. 9A–9C. The aerosol receiving device 200 includes a receiving device 151 for containing a package 102 containing a consumable material, an induction heating element 160 for heating the pantograph 106, and a system controller 166 for controlling the induction heating element 160. The housing 202 is designed for ergonomic use. For ease of nomenclature, housing 202 is described using terms such as front, rear, side, top, and bottom. These terms are not intended to be limiting, but rather are used to describe the positions of various components relative to each other. For purposes of describing the present invention, the front portion 210 will be the portion of the housing 202 that faces the user when used as intended, as described herein. As envisioned, when a user grips the housing 202 for use, the user's fingers wrap around the rear portion 212 of the device 100 while the thumb wraps around the front portion 210. The housing 202 defines a cavity 214 (see FIG. 1) that contains the components of the device 100. Thus Thus, the housing 202 is designed to contain a substantial portion of the package 102 containing the consumables, the controller 166, the induction heating element 160, and the power supply 220. In a preferred embodiment, the upper front portion of the housing 202 defines an outlet opening 216. The mouthpiece portion 158 of the package 102 containing the consumable material protrudes from the outlet opening 216 so that the user has access to the package 102 containing the consumable material. The mouthpiece 158 protrudes far enough from the housing 202 to allow a user to wrap their lips around the mouthpiece 158 to inhale the consumable aerosol.

The housing 202 is designed to be convenient for use by the user and easy to carry. In a preferred embodiment, housing 202 may be approximately 85 mm (3.35 inches) high (measured from top 222 to bottom 224), 44 mm (1.73 inches) deep (measured from front 210 to rear part 212) and 22 mm wide (0.87 inch) (measured from side part 226 to side part 228). This can be made through proto-molding to produce higher quality/stronger plastic parts.

In some embodiments, the package 102 containing the consumable may be held in a retractor that allows the package 102 containing the consumable to be drawn into the housing 202 for storage and handling. Due to the configuration of the package 102 containing the consumable, the receptacle 151 and/or housing 202 does not require a through-hole for cleaning, as in other devices in which some combustion still predominates with the formation of residual combustion by-products. In embodiments where the consumable-containing package 102 includes a user mouthpiece 158 and filter tube 140, if any by-products are generated during operation, they will remain in the disposable consumable-containing package 102, which is replaced when the user inserts a new package 102 containing the consumables and filter tube 140, if necessary, into the receiving device 151 and/or housing 202. Thus, the interior of the receiving device 151 and/or housing 202 remains clean during operation.

In a preferred embodiment, the top portion 222 of the housing 202 includes a user interface 230. The placement of the user interface 230 in the top portion 222 of the housing 202 allows the user to easily check the status of the device 100 before use. The user could potentially view the user interface 230 even while inhaling. The user interface 230 may be a multi-color LED (RGB) display for indicating the status of the device during use. A light guide can be used to provide wide-angle visibility to this display. By way of example only, the UI 230 has a 0.96-inch (diagonal) OLED display with a 128x32 resolution and an I2C (or SPI) interface. The user interface 230 is capable of supporting haptic feedback 234 (vibration) and audio feedback 250 (piezoelectric transducer). In some embodiments, a clear plastic coating (PC or ABS) may be placed on top of the OLED glass to protect it from damage/scratches.

The rear housing portion 212 has a trigger 232, which is a finger-activated (squeeze) button for activating the device/initiating a “puff.” Preferably, the trigger 232 is adjacent to the top 212. In this configuration, the user can hold the housing 202 at its intended location with the index finger on or adjacent to the trigger 232 for convenient actuation. In some embodiments, the trigger 232 may be provided with an interlocking mechanism, either mechanical or electrically interlocking, which requires the housing 202 to be opened before the trigger 232 is electrically actuated. In some embodiments, the haptic feedback motor 234 may be mechanically coupled to the trigger hook 232 to improve the user's recognition of haptic feedback during operation. Actuation of the trigger 232 supplies power to the induction heating element 160 to heat the pantograph 106.

The device 100 is powered by a battery 220. Preferably, the battery 220 is a two-cell lithium-ion battery pack (connected in series) with a continuous draw capability of 4A and a nominal capacity of 650-750 mAh. The two-element unit may include protection circuitry. The battery 220 can be charged using a USB type "C" connector 236. The 236 USB Type "C" connector can also be used for communication. The controller 166 may also provide battery voltage monitoring 238 to indicate the charge/discharge state of the battery.

The trigger 232 is operatively coupled to the induction coil driver 240 through the controller 166. The induction coil driver 240 activates the induction heating element 160 to heat the current collector 106. The present invention eliminates the motor driven coil design of the prior art. Telecoil drive 240 can provide drive/multiplexing for multiple coils. For example, telecoil drive 240 can provide drive/multiplexing for 6 or more coils. Each reel is wrapped around one segment of a package 102 containing a consumable and can be activated at least one or more times. Therefore, one segment of the package 102 containing the consumable can be heated twice, for example. In the six-coil device 100, the user can remove 12 puffs from the device 100.

The induction coil drive circuit in the preferred embodiment can be directly controlled by microprocessor controller 166. A dedicated peripheral device in this processor (computer numerical control oscillator) allows it to generate frequency converter signals with minimal CPU processing overhead. An induction coil circuit can have one or more capacitors connected in parallel, making it a parallel resonant circuit.

The drive circuitry may include current monitoring using a "peak detector" that feeds data back to the processor's analog input. The function of the peak detector is to record the maximum current value for any voltage cycle of the drive circuit, providing a stable output voltage for conversion by the A/D converter (part of the microprocessor chip) and then used in the induction coil drive algorithm.

The induction coil drive algorithm is implemented in hardware and software running on a microprocessor. The resonant frequency of the induction coil and capacitors will be known with reasonable accuracy by design as follows:

Resonance frequency (in Hertz) = 1/(2*pi* SQRT{L*C} )

where: pi = 3.1415...,

SQRT stands for the square root of the contents in brackets {...},

L = measured inductance of the induction coil, and

C = known capacitance of capacitors connected in parallel.

There will be manufacturing tolerances on the values of L and C (listed above) which will cause the actual resonant frequency to vary slightly from that calculated by the formula above. Additionally, the inductance of an induction coil will vary depending on what is inside that coil. In particular, the presence of ferrous metal inside (or in close proximity to) this coil will cause some amount of inductance variation, resulting in a small change in the resonant frequency of the L–C circuit.

The hardware/software algorithm for driving the induction coil will move the operating frequency over the maximum expected frequency range while controlling the current, seeking the frequency at which current draw is minimal. This minimum value will occur at the resonant frequency. Once this "center frequency" is found, the algorithm will continue to move the frequency a small amount on either side of the center frequency and adjust the value of the center frequency as necessary to maintain the minimum current value.

The electronics are connected to controller 166. Controller 166 allows processor control of frequency to optimize heating of pantograph 106. The relationship between frequency and temperature rarely correlates directly, in large part because temperature is a result of frequency, duration, and the manner in which the packaging is made 102 containing consumables. The controller 166 may also provide current control to determine power delivery and peak induction coil voltage control to establish resonance. By way of example only, the controller may provide a frequency of about 400 kHz to about 500 kHz and preferably 440 kHz with a three second preheat cycle to bring the pantograph temperature from 106 to 400 degrees Celsius or higher in one second. In some embodiments, the temperature of pantograph 106 can be raised to 550 degrees Celsius or higher in one second. In some embodiments, the temperature may be increased to 800 degrees Celsius. Thus, the present invention has an effective range of 400-800 degrees Celsius. In prior art devices, such temperatures would cause the consumable material to burn, rendering prior art devices ineffective at these temperatures. In the present invention, such high temperatures can still be used to improve aerosol production efficiency and provide faster heating times.

[001] The device 100 may also include a communication system 242. In a preferred embodiment, Bluetooth low energy wireless technology may be used to communicate with a peripheral device. The communications system 242 may have a serial data interface to the main processor for reporting information to, for example, a telephone. A ready-to-use RF module (pre-certified: FCC, IC, CE, MIC) can also be used. One example uses the Laird BL652 module because SmartBASIC support allows for rapid application development. The communication system 242 allows the user to program the device 100 according to personal preferences related to aerosol density, amount of flavor and aroma released, etc., by controlling the frequency and the 3-stage operating cycle, specifically, the preheating stage, the heating stage, and a step of gradually slowing down the induction heating elements 160. The communication system 242 may have one or more USB ports 236.

In some embodiments, a battery-backed RTC (real time clock/calendar) can be used to track usage information. The RTC can measure and store relevant user data for use in conjunction with an external application downloaded to a peripheral device such as a smartphone.

In some embodiments, a micro-USB connector (or USB Type C connector or other suitable connector) may be located on the bottom of the housing 202. A plastic support connector may be provided on all sides to reduce stress on the connector due to cable forces.

By way of example only, device 100 may be used as follows. The device may be powered by momentarily activating the trigger 232. For example, briefly pressing the trigger (less than 1.5 seconds) may turn on the device 100 but will not initiate a heating cycle. A second short press of trigger 232 (less than 1 second) during this time will keep device 100 turned on for a longer period of time and trigger a Bluetooth wireless technology message if there is no currently active (associated) Bluetooth wireless technology connection. with phone. A longer pull on trigger 232 (more than 1.5 seconds) initiates the heating cycle. The power of the device 100 may remain turned on for a short period of time after each heating cycle (e.g., 5 seconds) to display an updated state of the device on the OLED user interface 230 before turning off the power. In some embodiments, the device 100 may turn on power when the package 102 containing the consumable is removed from the housing 202. In some embodiments, a separate power switch 246 may be used to turn the device on and off.

When an active connection to a smartphone is detected and a user application is running on the smartphone, then the device 100 will remain on for 2 minutes before turning off. When the battery level is too low to operate, the user interface display 230 flashes several times (showing a battery icon at "0%") before the device turns off.

In some embodiments, the user interface 230 may display a segmented cigarette showing which segments are left (solid fill) versus which segments have been used (dashed outline), as an indicator of how much of the package 102 contains the consumable. , still contains consumable products to be released. The user interface 230 may also display a battery icon with updated current battery status, a charging icon (lightning bolt symbol) when the device is connected, and a Bluetooth icon when there is an active connection to the smartphone. User interface 230 may display a Bluetooth icon flashing slowly when there is no connection but device 100 is reporting.

The device may also have an indicator 248 to inform the user of power status. The 248 indicator may be an RGB LED. By way of example only, an RGB LED may show a green LED lit when the device is first turned on, a red LED blinking during preheat, a red LED lit (steady) during “inhalation,” and a blue LED blinking while charging. The flashing duty cycle indicates the relative state of charge of the battery (20-100%) in 20% increments (steady blue means fully charged). A fast flashing blue LED may be shown when an active Bluetooth wireless technology connection is detected (the phone is connected to the device and a user application is running on the phone).

Haptic feedback can provide the user with additional information during use. For example, 2 short pulses can be sent immediately when the power is turned on (from the trigger button). A long pulse at the end of the preheat cycle can be given to indicate that the devices are sending to inhale (beginning of the HNB "inhalation" cycle). A short pulse may occur when connecting or disconnecting power from USB for the first time. A short pulse may be emitted when an active Bluetooth wireless technology connection is established with an active smartphone application running on the smartphone.

The Bluetooth wireless technology connection can be started after turning on the power by briefly (less than 1.5 seconds) pressing the button on the handle. If there is no "paired" BLE (Bluetooth Low Energy) connection, devices may start a slow message ("pairing" mode) when detecting a second short press after detecting the initial short press that turns on the device. Once a connection to the smartphone application is established, the Bluetooth icon on the user interface display 230 may stop flashing and the blue LED will turn on (solid). If device 100 is turned on and has a “paired” connection to a smartphone, then it may begin communicating an attempt to reestablish that connection to the phone until it turns off. If the connection to that smartphone can be restored, the unit may remain on for up to 2 minutes before switching off. To remove an associated connection, the user can turn on the device with a short press followed by another short press. While the BLE icon is flashing, the user can press and hold the trigger 232 until the device 100 vibrates and the Bluetooth icon disappears.

Thus, by tightly controlling the above-mentioned conversion efficiency coefficients and product constancy coefficients, it is possible to provide controlled heat supply to the consumable material containing unit 104. This controlled heat supply includes a microprocessor controller 166 to control the induction heating system 160 to maintain various levels of power supply to the pantograph 106 for controlled time intervals. These properties provide a user control feature that would allow the selection of specific consumable flavors and aromas determined by the temperature at which the consumable aerosol is received.

In some embodiments, a microprocessor or custom logic block may be used to control the frequency and power delivery of the induction heating system. As shown in FIG. 10A, the induction heating system 160 may include a wire coil 162 connected in parallel with one or more capacitors 260 to and from an oscillator operating at its resonant frequency. The inductance of coil 162 combined with the capacitance of capacitor(s) 260 largely determines the resonant frequency at which the circuit will operate. However, in this embodiment, microprocessor/microcontroller 166 may instead be used to operate power switches and therefore control the oscillation frequency of the circuit. In this approach, peak voltage and current are used as feedback, allowing the microprocessor control program to provide a closed-loop tuning to find resonance. The advantage of this approach is that it allows efficient control of the power supplied to the pantograph by synchronously turning the circuit oscillations on and off under the control of the microprocessor control program 166 and provides optimal turning on/off of the power controls driving the induction coil system.

Based on these concepts, the inventors have considered a number of options. Thus, as discussed above, the present invention includes a consumable-containing block 104, a pantograph 106 integrated within the consumable-containing block 104, a heating element 160 configured to at least partially surround the consumable-containing block 104, a controller 166 for controlling the heating element 160, and a receiver 151 and/or a housing 202 containing a block 104 containing a consumable, a pantograph 106, a heating element 160, and a controller 166. Preferably, the block 104 containing a consumable is included with the pantograph 106 in a package 102 containing consumables. Thus, any description of the relationships between the package 102 containing a consumable and other components of the present invention can also be applied to the block 104 containing a consumable, since some embodiments may not necessarily require packaging of the block 104 containing a consumable.

In some embodiments, as shown in FIG. 10A, the apparatus includes a self-resonant frequency oscillator for driving the induction heating element 160. The self-resonant frequency oscillator includes a capacitor 260 operably coupled in parallel with the induction heating element 160. In some embodiments, as shown in FIG. 10B, multiple heating elements 160 may be connected in parallel to their respective capacitors 260a, 260b. Preferably, the heating elements are in the form of coiled wire 162a, 162b.

To allow a single package 102 containing a consumable to generate an aerosol multiple times, multiple heating elements 160 and/or movable heating elements 160 can be used. Thus, the heating element 160 includes multiple helical wires 162a, b, where each helical wire can be operably connected with controller 166 to activate independently of other spiral wires.

In some embodiments, the heating element 160 may be movable. In such embodiments, the package 102 containing the consumable may be an elongated member defining a first longitudinal axis L, and the heating element 162 may be axially movable along the first longitudinal axis L. For example, as shown in FIG. 11A-E, the heating element 160 may be attached to the holder 270. The holder 270 may be operatively coupled to the receiving device 151 so as to move along the length of the package 102 containing the consumable while the heating element 160 remains wound around the package 102 containing consumables. The coil span S (measured as the linear distance from the first coil turn 272 to the last coil turn 274) may be short enough only to cover a segment of the package 102 containing the consumable. Once the heating element 160 is activated in that segment, the holder 270 is advanced along the package 102 containing the consumable along its longitudinal axis L to another segment of the package 102 containing the consumable. The distance of movement of the holder 270 is such that the first coil turn 272 stops adjacent to the location where the last coil turn 274 was previously located. Thus, a new segment, equal in size to the previously heated segment, is ready to be heated. This may continue until the holder 270 is moved from the first end 105 of the package 102 containing the consumable to the opposite end 107. Alternatively, the reel may be stationary and the package 102 containing the consumable can be made to move to accomplish the same. heating segments. In such an embodiment, the receiving device 151 may need to be extended in length to allow movement of the package 102 containing the consumable, and the holder 270 should be adapted to move the package 102 containing the consumable rather than the spools.

In embodiments in which the package 102 containing the consumable contains a plurality of blocks 104 containing the consumable, the coil span S may be approximately the same size as the length of the block 104 containing the consumable. The holder 270 may be configured to align the coil with the block 104 containing the consumable so that the coil can heat the entire block 104 containing the consumable. The holder 270 may be configured to move the coil from one unit 104 containing a consumable to the next, again allowing one package 102 containing a consumable to be heated repeatedly, releasing an aerosol each time.

Recognition system

In some embodiments, it is desirable to be able to determine whether the block 104 containing the consumable, or a portion thereof, has been heated. If the consumable block 104 has already been heated, then the heating element 160 may heat the next consumable block 104 or the next segment of the consumable block 104 to prevent energy loss to the used portion of the consumable block 104. Therefore, in some embodiments, as shown in FIG. 11A, a recognition system 500 that is used to detect segments of the package 102 containing a consumable that have been used is provided in the device, allowing the device to autonomously determine the next unused segment available for use. For example, the device may include an optical sensor 320 for determining whether a portion of the package 102 containing a consumable that is susceptible to detection has been heated above a predetermined temperature. In some embodiments, the optical sensor 320 may detect visual changes in the package 102 containing the consumable that indicate heating. In some embodiments, the optical sensor 320 may detect thermal changes in the package 102 containing the consumable that are indicative of heating. In some embodiments, optical sensor 320 may detect textural changes (i.e., changes in texture) in the package 102 containing the consumable that are indicative of heating. In some embodiments, the optical sensor 320 may be a controller that monitors where the heating element 160 is located along the package 102 containing the consumable and when it has been heated relative to its movement along the package 102 containing the consumable. For example, the controller may include a memory device for storing the locations of parts of the package 102 containing a consumable that have been heated to a predetermined temperature.

In a preferred embodiment, the optical sensor 320 is a photoreflective sensor. The photoreflective sensor may be configured to detect changes in the package 102 containing the consumable from its original state compared to a state when the package 102 containing the consumable was exposed to significant heat (i.e., above normal daytime temperatures). More preferably, the package 102 containing the consumable may consist of a heat-sensitive dye that changes colors when heated to a predetermined temperature. This color change can be detected by a photoreflective sensor. A heat-sensitive dye may be applied around the outer surface of the package 102 containing the consumable. When a segment of packaging 102 containing a consumable is heated, the tape 322 in close proximity to the heated segment changes colors. For example, tape 322 may change color from white to black. An optical sensor 320 mounted with the heating element 160 has an optics 324 focused directly above—or below—the heating element to provide a side view of the package 102 containing the consumable material throughout the entire range of movement of the heating element 160.

In some embodiments, a limit switch 326 is also mounted on one end 105 of the package 102 containing the consumable and is used to detect when the package 102 containing the consumable is removed or reinserted into the device. When the package 102 containing the consumable has been reinserted, the device activates the motorized heating element assembly and moves it through its full range of motion, allowing the optical sensor 320 to determine whether any segments have previously been heated by detecting dark ribbons 322 of heat-sensitive dye. Thus, the device may further include a limit switch 326 for resetting the storage device when a new package 102 containing a consumable is inserted into the housing.

In addition, the recognition system 500 uses recognition technology to determine the presence, type, and other information about a consumable to configure the aerosol receiving device 200 to perform an application protocol designed to consume that consumable. The various consumables that may be used by the present system may have a specific temperature and duration of heat exposure to optimize and release the proper dose of the consumable. In some situations, there may be restrictions on the number of doses a user can take in a given period of time. Therefore, rather than a single temperature and duration that may be optimal for one consumable and not others, or which may be the maximum allowable temperature and duration sufficient to aerosolize all potential consumables, the recognition system 500 automatically adjusts the temperature and duration based on consumable and any prescription instructions, and also performs other functions such as determining the presence of a consumable, whether a consumable has been used up, whether the user has exceeded the number of uses in a set period of time, etc.

For example, with reference to FIG. 11B-11E, in some embodiments, the recognition system 500 may include an optical sensor 320. The optical sensor 320 may be configured to read an indicia 504 on a package 102 containing a consumable and associate this indicia 504 with a set of commands related to how the device 200 to produce an aerosol must behave in relation to the consumable material contained in the package 102 containing the consumable material. For example, indicia 504 may be a particular pattern as seen in bar codes, QR codes, etc., or a particular spectrum of light, a sequence of colors, a particular application of a pattern, or any combination thereof. In some embodiments, the optical sensor 320 may include a light source 506 covering either a narrow or a broad portion of the visible or invisible (ultraviolet or infrared) light spectrum to illuminate at least one portion of the package 102 containing the consumable. The optical sensor 320 may further include a light sensor 508 for the purpose of sensing reflected light/light spectrum from that portion of the package 102 containing the consumable.

A light sensor 508 that is sensitive in the same spectral range as the light source 506 is positioned to optimally detect reflected light from the light source 506 beyond the perimeter of the package containing the consumable. Light sensor 508 can either detect light intensity in one or more spectrum bands of visible or invisible light, or it can detect both light intensity and wavelengths (color) of reflected light.

In some embodiments, the indicia 504 may be one or more ribbons of color, grayscale, and/or invisible (UV sensitive) ink applied to the package 102 containing the consumable, and preferably around the perimeter of the package 102 containing the consumable. Preferably, the indicia 504 is located near the first end 152 of the package 102 containing the consumable, so that the indicia 504 can be detected when the package 102 containing the consumable is fully inserted into the aerosol receiving device 200 or while the package 102 containing the consumable , is in the process of being inserted into the aerosol receiving device 200.

Electronic circuitry and a system controller 166 located in the aerosol generating device 200 controls the light source 506 and monitors the light sensor 508 for the presence of a package 102 containing a consumable and processes the data received by the light sensor 508 to determine one or more characteristics of that consumable. package 102 containing consumables, so as not to go beyond the application protocol.

Thus, the light sensor 508 may be able to read the sign as the package 102 containing the consumable is inserted into the aerosol receiving device 200 or after it has been properly installed.

In some embodiments, the recognition system 500 may further include optical modifiers 512 to direct, deflect, focus, and select the desired light in the desired area. For example, optical modifiers 512 may be optical waveguides (light guides), reflective surfaces, light apertures, prisms, lenses, filters, polarizers, beam splitters, optical fibers, etc. Likewise, there may be optical modifiers 512 arranged to direct light reflected from package 102 containing the consumable back into the active area on light sensor 508.

The use of different types of light sources 506 and light sensors 508 provides a variety of detection modes. For example, an invisible UV light source/detector may be used in combination with a colored light source/detector allowing the device to potentially detect a counterfeit product in use versus a non-counterfeit product. In other words, since the counterfeiter would not see the invisible light, the counterfeiter would not place such tape 510 on the counterfeit package 102 containing the consumable, and the device 100 would not operate.

By way of example only, light source 506 may emit the entire spectrum of visible light and some invisible light such as infrared and ultraviolet. One package 102 containing a consumable may have a tape 510 that reflects light in the blue spectrum. Thus, light sensor 508 detects blue color. The blue color may correspond to packaging containing consumables containing nicotine. Thus, the aerosol containing device 200 will adjust the heating system to heat to the proper temperature for the proper length of time to release the nicotine from the package 102 containing the consumable. If, on the other hand, the package 102 containing the consumable contains a tape 510 that reflects the red spectrum, the light sensor detects the color red. The red color may correspond to packaging containing hemp-containing consumables. Thus, the aerosol containing device 200 will adjust the heating system to heat to the proper temperature for the proper length of time to release the cannabis from the package 102 containing the consumable. Many different colors and combinations of colors or patterns can be used to code many different supplies.

Additionally, recognition system 500 may provide a notification flag. For example, the color of a package 102 containing a consumable may change after it has been used for a specifically programmed number of puffs, indicating when the consumable has been completely consumed. Such an indication would then render the package 102 containing the consumable material unsuitable for further use in the device.

Additionally, recognition system 500 may be used to initiate a shutdown response to render the consumable unusable. For example, a power surge could occur that would cause a hole to appear in the package 103 containing the consumable, rendering it no longer usable.

Therefore, in a preferred embodiment, the aerosol generating device 100 may include a consumable containing package 102 that contains the consumable, a pantograph 106 surrounding the consumable, and a sign 504; an aerosol generating device 200 comprising a heating element 160 for induction heating of the pantograph 106 and a recognition system 500 configured to read the character 504; and a system controller 166 operably coupled to the sensing system 500 and the heating element 160, wherein information received from the sensing system 500 is used to control the heating element 160. The sensing system 500 includes an optical sensor 320. The optical sensor 320 includes a light sensor 508 for detection light, specifically the wavelength of light reflected by the sign 504. The optical sensor 320 may further include a light source 506 configured to emit a spectrum of light in the direction of the sign 504. The system controller 166 may then execute an application protocol specific to the consumable associated with sign 504.

When used in such a case, a method of executing an application protocol for aerosolizing a consumable includes reading an indicia 504 on a package 102 containing a consumable that contains a consumable through an optical sensor 320; identifying the application protocol for the consumable associated with the sign 504 by the system controller 166; execution of the application protocol, as a result of which the consumable material turns into an aerosol. The method may further include detecting a pattern on the sign 504 or detecting a wavelength of light reflected from the sign 504 using a light sensor 508 . The method may further include the light source 106 emitting a spectrum of light towards the sign 504 such that the sign 504 reflects a specific wavelength of light back to the sensor 508. The method may further include the system controller 166 executing a shutdown response to render the consumable unusable.

Leveling tool

As shown in FIG. 12A-12E, to facilitate proper alignment of the heating element 160 around the package 102 containing the consumable, the device 200 may include a package alignment device. For example, the package alignment device may be a magnet 280. Preferably, the magnet 280 is a cylindrical magnet defining a second longitudinal axis M. In embodiments in which the heating element 160 is a cylindrical coil wrapped around the package 102 containing the consumable, the cylindrical the coil defines a third longitudinal axis C. The cylindrical magnet 280 and the heating element 160 are configured to maintain alignment of the second longitudinal axis M with the third longitudinal axis C. Preferably, the cylindrical magnet 280 is a circular annular magnet with the center being a path for air flow. Preferably, any magnet 280 is of the rare earth neodymium type. It is magnetized in the axial direction.

In an embodiment that uses an alignment magnet 280, one end 105 of the package 102 containing the consumable may include an element 281 that is attracted to the magnet. Preferably, the magnet attraction member 281 is a stamped iron sheet metal component that is formed at the first end 105 of the package 102 containing the consumable. The cylindrical magnet 280 may be part of the aerosol generating device 200, and the package 102 containing the consumable may include an element 281 attracted to the magnet or a washer attached to its end 105 such that the package 102 containing the consumable is attracted to a magnet 280 attached to the aerosol receiving device 200. Other combinations of magnets 280 and magnet attraction elements 281 in various positions may be used to achieve the desired alignment.

In some embodiments, preferably those that utilize a package 102 containing a consumable with a filter tube 140 and a housing 150, the package alignment device may be a receiving device 151, such as a close-fitting cylinder (if the housing 150 is cylindrical) , which may be used to align the package 102 containing the consumable, and the reel 162 may be located outside the receiving device 151, as shown in FIG. 12E. The receiver 151 may be attached to the device 200 and properly aligned with the coils 162 such that when a package 102 containing a consumable is inserted into the coils 162, the pantograph 106 is properly aligned with the coils 162.

In some embodiments, housing 150 may function as a receiving device 151. Therefore, instead of a separate receiving device 151, housing 150 may have the characteristics described above and insertion into coils 162 may be essentially an alignment process, or the housing may be attached within coils 162. and a filter tube 140 including a consumable material containing block 104 and a current collector 106 may be inserted into the housing 150.

In some embodiments, multiple activations of a single package containing a consumable can be accomplished by a pantograph 106 having multiple spikes 290, as shown in FIG. 13A–D. A multi-bar pantograph is a pantograph 106 with two or more blades 290. In some embodiments, a pantograph may have three blades 290a, 290b, 290c. In some embodiments, the pantograph 106 may have four pointed elements. In some embodiments, the pantograph 106 may have more than four points. In a preferred embodiment, the multi-point pantograph 106 has three or four points.

The multiple points 290a, 290b, 290c of the multi-point pantograph 106 are generally parallel to each other, as shown in FIG. 13C and 13D. The multi-bar susceptor 106 is configured and may be incorporated into a package 102 containing a consumable such that each bar 290a, 290b, 290c is parallel to and equidistant from the longitudinal axis L of the package containing the consumable, and also located at equal distances from each other along the perimeter of an imaginary circle. Thus, when viewed in cross section as shown in FIG. 14A-C, the pointed pantograph members 290a, 290b, 290c are equidistant from each other relative to the circular surface of the package 102 containing the consumable. This arrangement allows each blade 290a, 290b, 290c to maximize the non-overlapping heating zones for each blade when each blade is maximally activated. In other words, when the pantograph tip 290a, 290b, 290c is heated, it will radiate heat radially away from the pantograph tip 290a, 290b, 290c, creating a circular heating zone at the pantograph tip 290a, 290b, 290c at the center. Each pantograph tip 290a, 290b, 290c will heat its own circular zone, although some overlap may be inevitable. Collectively, the entire cross-sectional area of the block 104 containing the consumable can be heated, one cross-sectional area at a time.

When the heating element 160 is a cylindrical coil wrapped around the current collector 106, the maximum amount of energy is transferred to the center of the cylindrical coil. Therefore, when the pantograph 106 is aligned with the center of the cylindrical coil, the pantograph 106 will receive the maximum amount of energy from the electricity passing through the coil. In other words, when the pantograph tip 290a, 290b, 290c is in line with the cylindrical coil, the pantograph tip 290a, 290b, 290c will receive the maximum amount of energy from the cylindrical coil. Thus, to independently heat each susceptor tip 290a, 290b, 290c, the susceptor tip 290a, 290b, 290c and the center of the coil must be moved relative to each other such that the center of the coil is aligned with one of the susceptor tips 290a, 290b, 290c pantograph in series. This may be accomplished by moving the pantograph tip relative to the coil, or by moving the coil relative to the pantograph tip, or both.

Moving the heating element

In a preferred embodiment, the heating element 160 moves relative to the susceptor 106. For example, a cylindrical coil may be wrapped around a package 102 containing a consumable and is rotatable along an eccentric path such that during one rotation of the cylindrical coil, each of the pointed elements 290a , 290b, 290c will be aligned with the center of the coil at different times, as shown in FIG. 14A–16D. The package 102 containing the consumable may be an elongated piece having a first longitudinal axis L, wherein the heating element 160 is a coil wrapped around the package 102 containing the consumable to form a cylinder having a second longitudinal axis C, and thereby heating element 160 is configured to rotate about the package 102 containing the consumable in an eccentric path such that the second longitudinal axis C is aligned with each of the points 290a, 290b, 290c of the multi-point pantograph at some point during movement heating element around the package 102 containing the consumables. Therefore, the multi-point pantograph 106 is stationary, and the coil rotates in an eccentric path such that the center of the coil is aligned with the linear axis of each pantograph tip 290a, 290b, 290c in turn by rotation. Electrical slip rings will provide energy to the coil structure with rotation in an eccentric path.

Rotation of the heating element 160 may be accomplished by a series of gears 300a, 300b operatively coupled to the motor 302. For example, as shown in FIG. 17A-18B, the heating element 160 may be mounted on the first gear 300a such that the heating element can rotate with the first gear 300a. The second gear 300b may be operatively coupled to the first gear 300a such that rotation of the second gear 300b causes rotation of the first gear 300a. The second gear 300b may be operably coupled to the motor 302 to cause the second gear 300b to rotate. The heating element 160 is mounted on the first gear 300a such that rotation of the first gear 300a causes the longitudinal axis C of the heating element 160 to move along an eccentric path rather than causing the heating element to rotate about a fixed, non-moving center. Thus, the center of the heating element 160 can be shifted to align with different pointed elements 290a, 290b, 290c.

In some embodiments, heating element 160, gears 300a, 300b, and motor 302 may be mounted on holder 270 as shown in FIG. 19. The holder 270 allows the heating element, gears 300a, 300b, and motor 302 to move axially along the length of the package 102 containing the consumable. The holder 270 may be operatively coupled to an actuator 306, which is operably coupled to a second motor 304. For example, the actuator 306 may be threaded. The holder 270 may have a threaded hole 276 through which the actuator 306 is inserted. Activation of the second motor 304 causes the actuator 306 to rotate. Rotation of the actuator 306 causes the holder 270 to move along the actuator 306, as indicated by the double arrow in FIG. 19.

In some embodiments, instead of rotating the heating element 160 along an eccentric path, the heating element 160 may be translated along an X-Y axis when viewed in cross-section. Therefore, the package 102 containing the consumable may be an elongated member defining a longitudinal axis L, and wherein the heating element 160 is movable in a radial direction relative to the longitudinal axis L, when viewed in cross-section, to align the center of the cylindrical helical heating element 160 with each of the points 290a, 290b, 290c of the multiple point collectors 106 in turn. In the X-Y axis scenario, the coil energy can be supplied through a flexible electrical conductor or through movable electrical contacts.

For example, heating element 160 may be operatively mounted on a pair of translational plates 310, 312, as shown in FIG. 20. Specifically, the heating element 160 may be mounted directly on the first translation plate 310, and the first translation plate 310 may be mounted on the second translation plate 312. The first translation plate 310 may be configured to move in the X or Y direction, and the second translation plate 312 may be configured to move in the Y or X direction, respectively. In the example shown in FIG. 20, the first translation plate 310 is configured to move in the X direction, while the second translation plate 312 is configured to move in the Y direction. This configuration can be switched such that the first translation plate 310 is configured to move in the direction Y, and the second translation plate 312 is movable in the X direction. The first and second translation plates 310, 312 may be operably coupled to their respective motors, for example through gears, to cause the translation plates to move in the proper direction. Between the two translational plates 310, 312, the heating element 160 can be moved such that its longitudinal axis C can be aligned with any of the pointed elements 290a, 290b, 290c.

In other arrangements, the coil assembly may move along the linear axis of the pantograph, independent of rotating or non-rotating mechanisms as discussed above. Therefore, the three susceptor points will cause the device to heat the package 102 containing the consumable three times in the same linear position by heating three different points 290a, 290b, 290c at three different times before it moves to its next linear position. , where it will be able to heat again three times. In a package 102 containing a consumable with four linear positions, one package containing the consumable will be able to provide 12 separate "puffs", i.e., 3 pointed elements in 4 positions along the length of the package 102 containing the consumable.

In some embodiments, instead of moving the heating element 160 relative to the package 102 containing the consumable, the package 102 containing the consumable can be moved relative to the heating element. Therefore, the package 102 containing the consumable is configured to rotate within the heating element 160 in an eccentric path such that the second longitudinal axis C defined by the coils is aligned with each of the multi-point pantograph elements 290a, 290b, 290c. elements at some point during rotation of the package 102 containing the consumable material within the heating element 160. Alternatively, the package 102 containing the consumable material is configured to move radially within the heating element 160 such that the second longitudinal axis C is aligned at one line with each of the multi-point pantograph cusps at some point during movement of the package 102 containing the consumable within the heating element 160. In some embodiments, both the package 102 containing the consumable and the heating element 160 may be moved. For example, the heating element 160 may move linearly along the longitudinal axis of the package 102 containing the consumable, and the package 102 containing the consumable may move in an eccentric or radial path to move the pantograph 106 into position relative to the heating element 106 so that all of the consumables heat up sequentially as the user takes individual puffs. Other movement variations may also be used.

The movement mechanisms described above are just examples. The mechanism in an X-Y-Z motion scenario can be implemented using many combinations of motors, linear actuators, gears, bands, cams, solenoid valves, etc.

Referring to FIG. 21, closed loop control of the induction heating system can be based on measuring the magnetic flux density produced by the induction heating system. Induction heating systems operate by creating a concentrated alternating magnetic field within a heating element in the form of an induction coil. This field will produce a heating effect in the metal pantograph due to the eddy currents and magnetic flux reversals (assuming the receiver material is iron) that occur in the pantograph material. Induction heating is typically an "open loop" type that has a limiting means of monitoring the temperature of the current collector inside the induction coil as it operates. Under controlled conditions, a magnetic field external to the induction coil and within reasonable proximity of the coil can be used to determine the intensity of the flux within the coil. For example, a small coil 310 may be placed in reasonable proximity to an induction coil type heating element 160, with its axis approximately parallel to the magnetic flux field lines 312 passing through the small coil 310, providing a means of detecting the amount of magnetic flux of an induction coil type heating element 160 existing due to the voltage induced on the small coil 310 due to the changing magnetic flux passing through the small coil 310. The magnitude of this external flux can then be calibrated to relate to the magnetic flux density within the heating element 160 and therefore can be used as a control over closed loop of the induction system to ensure stable operation as the current collector 106 heats up. The magnetic flux is symmetrical around the axis of the induction coil. A flux density measurement taken at any location adjacent to the induction coil can be used to extrapolate the magnetic flux density within the heating element based on the characteristics of the relative magnitudes of the magnetic flux at each location (inside the induction coil and inside the parasitic pickup coil). In practice, there is no need to quantify this since the flux measurement is instead used to determine the rate of heating that will occur in the current collector 106 that is present in this magnetic field. Thus, the small coil 310 configured in this manner functions as a magnetic flux sensor.

Therefore, in some embodiments, the device may further comprise a magnetic flux sensor located adjacent to the induction heating element 160 and configured to measure the magnetic flux produced by the induction heating element 160. The magnetic flux sensor may be operatively coupled to the controller 166 to control activation of the induction heating element. element 160 based on feedback from the magnetic flux sensor.

Heat absorber

In some embodiments, to control the dissipation of thermal energy from heating element 160, the device may further include a heat absorber 330 operably coupled to induction heating element 160. Induction heating involves circulating large currents through an induction coil, resulting in resistive heating in the wire used to form coils. Thermal energy dissipation takes advantage of high thermal conductivity materials that are electrically insulated to form heat sinks 330. Preferably, the heat sinks 330 may be formed by either injection molding or casting processes. Since the preferred embodiment uses a cylindrical coil as the heating element 160, the heat sink 330 may also be a cylinder formed around the induction coil so that it encloses the coil, as shown in FIG. 22. A cylindrical heat absorber 330 enclosing a heating element 160 is located within a vertical cavity within the housing 202, forming a type of "vent tube" within which air convection occurs. The exhaust tube requires a vent at the top to maintain air flow. This method also eliminates electromagnetic field fringing, providing a very focused heating method on each segment of the package 102 containing the consumable. As a result of this focusing, it is not necessary to wrap the block 104 containing the consumable within the package 102 containing the consumable in non-conductive foil or the like, paper, or the like will suffice.

In a preferred embodiment, heat sink 330 is a finned cylinder surrounding heating element 160. The fin cylinder is a cylindrical shaped heat sink with fins 332 extending away from its outer surface 334. Preferably, each fin 332 extends substantially the length of the cylinder to provide a significant surface area from which heat from heating element 160 can be dissipated. The thermally conductive material of the heat absorber 330 may be a polymer. The thermally conductive polymer may be a thermoset, thermoplastic moldable or castable compound. Heat absorber 330 may be machined, cast, or formed from these materials. The material can be hard or elastic. Some examples of thermally conductive compounds used in thermally conductive polymers are aluminum nitride, boron nitride, carbon, graphite and ceramics. In the preferred embodiment, heating element 160 is an induction coil wrapped in a finned cylinder of thermally conductive polymer that has been molded around the coil, with the open center creating ventilation through a vent tube-like effect.

Pressure control

Removal of the aerosol from the consumable block 104 is aided by negative pressure created within housing 150. There are several purposes for which this negative pressure is used. First, the negative pressure promotes and accelerates the extraction of the heated and expanding aerosol produced within the consumable material containing block 104 as a result of the induction heating of the pantograph 106 within the shell 108 and the maximum contact between the pantograph 106 and a primarily plant matter such as tobacco or cannabinoid.

Second, the negative pressure within the housing 150 provides a means of detecting when a user draws air through the housing 150 through the use of a pressure sensor that is monitored by a system controller 166 integral with the aerosol generating device 200, which is then used to initiate a change in control. circuitry used to heat the block 104 containing the consumable material.

Third, the negative pressure within the housing 150 provides a means of controlling the amount of aerosol production to modify the user experience by providing user-controlled or automatic control of the air outlet.

Negative pressure within housing 150 can be created simply by restricting the flow of air created by end cap 154 while the user draws air from mouthpiece 158.

In some embodiments, as shown in FIG. 23A, the apparatus may further include an air flow controller 340 to provide a means for controlling the flavor stability of the consumable-containing unit 104 by controlling the flow of air that is drawn through the consumable-containing package 102. The design of the package 102 containing the consumable is such that the amount of vapor/flavor that is introduced into the air flow passages depends on the duration and intensity of induction heating, as well as the air pressure difference between the air passage(s) through the package 102 containing consumables. For example, air flow controller 340 may include an adjustable flow control valve 342, such as a needle valve, butterfly valve, ball valve, or adjustable orifice. Adjustable flow control valves allow the user to control the air flow even while in use. However, the air flow controller 340 may also be a membrane 344 with fixed openings, such as a porous or fibrous membrane or element. The membrane 344 may also function as a suction filter to trap particles. Therefore, the flow control mechanisms may or may not be user adjustable. In embodiments of the membrane 344, multiple membranes 344 with openings of different sizes may be provided. Thus, the user can select the desired opening size and apply this membrane 344 to the first end 105 of the device. If the user prefers increased or decreased airflow, the user may select a different membrane 344 with larger or smaller openings, respectively. In some embodiments, the air flow controller 340 may utilize both a control valve 342 and a membrane 344. For example, a membrane 344 may be positioned in front of the control valve 342 to control air flow and filter particles before the control valve 342, then the control valve 342 may optionally Control airflow for finely tuned airflow control.

In some embodiments, a receptacle 151 may be provided to better control the efficiency of drawing the heated consumable aerosol from the shell 108, as shown in FIG. 23B. The receptacle 151 has a proximal end 402 with a main opening 404 and a distal end 406 with a distal opening 408. The first end 105 of the package 102 containing the consumable can be inserted through the main opening 404 of the receptacle 151 and is located at the distal end 406 adjacent to the distal end. opening 408. Thus, the main opening 404 has substantially the same size and shape as the outer surface of the package 102 containing the consumable (eg, the outer dimensions of the housing 150). The distal opening 408 of the receiving device 151 is smaller than the main opening 404 and the first and second openings 153, 157 of the housing 150. The smaller size of the distal opening 408 relative to the openings 153, 157 of the housing 150 restricts the air flow into the receiving device 151, thereby reducing the pressure inside receiving device 151 and housing 150.

It is preferable that the receiving device 151 be made of a non-conductive material to avoid induction heating, such as borosilicate ceramic, plastic, wood, carbon fiber, glass, quartz glass, Pyroceram glass, Robax glass, high temperature plastics such as Vespel, Torlon, polyimide , PTFE (polytetrafluoroethylene), PEEK (polyetheretherketone) or other suitable materials. Alternatively, receiver 151 may be made of a conductive material that has a lower resistivity than pantograph 106 in package 102 containing consumables that provides some inductive heating to receiver 151, but not as much as pantograph 106. Examples of Materials lower resistivity may include copper, aluminum and brass, where the pantograph 106 is made from higher resistivity materials such as iron, steel, tin, carbon or tungsten, although other materials may be used. In some embodiments, a receiver 151 with the same or higher resistivity than the pantograph 106 may be used, which will heat the exterior of the package 102 containing the consumable as the receiver 151 is heated by induction. The receiver 151 may be attached to the device 200 and properly aligned with the coils 162 wrapped around the receiver 151 such that when the package 102 containing the consumable is inserted into the receiver 151, the pantograph 106 is properly aligned with the coils 162.

In certain induction heating but non-combustion methods, a consumable contained in a package 102 containing the consumable is inserted into a receiving device 151 by the user. In this case, there may be a gap between the package 102 containing the consumable and the receiving device 151. Such a gap can cause three significant problems. First, in embodiments with valve 342, clearance will in certain cases cause air flow from the top and outside of intake 151 to flow to the bottom, causing valve 342 to operate ineffectively and resulting in an unsatisfactory user experience. Second, users experience sticky lips when their lips stick to the mouthpiece 158, and therefore they accidentally pull out the package 102 containing the consumable from the receptacle 151 after inhaling the active ingredient due to the package containing the consumable sticking to the consumer's lip, and lacking a seal to protect the package 102 containing the consumable during normal use otherwise. Third, in certain consumable embodiments where the consumable is pellet-shaped and compressed around the pantograph 106, a gap between the mouthpiece and the consumable may make it difficult to supply the proper amount of air to the heating receiver 151.

In some embodiments, a seal 420 may be provided at the proximal end 402 of the receiving device 151. The seal 420 may surround the housing 150 to create an airtight seal around the housing 150. For example, the seal 420 may be a ring placed around the housing 150 at the proximal end 402 of the receiving device 151. In a preferred embodiment, the seal 420 is a retaining and sealing structure, which may be described as a clamping sleeve, gasket, O-ring, gland, or other similar term that describes a sealing structure. The seal 420 is made of a flexible polymer such as silicone, rubber, plastic, or other material (thermoset or thermoplastic).

Purely as an example of the seal 420, the design of the seal 420 may be a cylinder with edges at right angles and an opening 421 through the center (see FIGS. 23C to 23D). In some embodiments, the seal 420 may be toroidal or "toroidal shaped" with round edges with an opening 421 through the center (see FIGS. 23E-23F). In some embodiments, the shape of the seal 420 may be conical with angled walls and an opening 421 through its center (see FIGS. 23G through 23H). In some embodiments, the seal 420 may have multiple sealing surfaces at the contact points (see FIGS. 23I-23J).

Before using the device 100, a package 102 containing a consumable is inserted into the main opening 404 of the receptacle 151 at the proximal end 402. A seal 420 is located upstream of the main opening 404 within the receptacle 151 and surrounds the perimeter or outer surface of the block 102 containing the consumable. material. In some embodiments, the seal 420 is configured to apply a biasing force against the inner wall of the receptacle 151 and the outer wall of the package 102 containing the consumable, thereby sealing the block 102 containing the consumable against the receptacle 151.

In some embodiments, the pressing device 422 causes the seal 420 to be activated from a released state to an active state. The released state allows the package 102 containing the consumable to move freely into and out of the receiving device 151. When active, the pressing device 422 radially presses the seal 420 against the package 102 containing the consumable. For example, in some embodiments, the pressing device 422 may axially press the seal. The seal 420, which is resilient, when pressed in the axial direction, expands in the radial direction, thereby reducing its inner diameter so that it contracts and seals around the perimeter wall of the block 102 containing the consumable. This type of pressing may be achieved through rotational or linear movement of the pressing device 422 within the hand-held device 100. This pressing and contact with the consumable block 102 may either serve the function of holding the consumable block 102 within the device 100 during operation. preventing it from being easily dislodged or prematurely removed from the hand-held device 100, or they may also function to hold and provide a seal around the perimeter of the block 104 containing the consumable. Thus, the pressing device 422 may be a mechanical or electromechanical mechanism for pressing the seal 420 by actuating an actuator 424 such as a button, knob, slider, touch screen, switch, dial, etc., or any combination thereof.

Receiver 151 in combination with seal 420 restricts the source of all air flow drawn through the package 102 containing the consumable to be delivered through the distal opening 408. This precise control of the air flow translates directly into control of the negative pressure generated inside the package 102 containing the consumable. . After the package 102 containing the consumable is inserted into the receiving device 151 of the device 100 by actuating the seal 420, the user inhales through the open mouthpiece 158 (with filter) of the unit 102 containing the consumable, and a stream of air is drawn through the distal opening 408, resulting in the pressure drop at the first end 105 of the package 102 containing the consumable, as well as inward to the block 104 containing the consumable. This pressure drop (vacuum) at the first end 105 of the package 102 containing the consumable can be measured by a pressure sensor 426 operably coupled to the system controller 166 to initiate and control heating of the drug or vapor forming components within the package 102 containing the consumable. .

In some embodiments, the seal 420 and the air flow controller 340 may be used together. Preferably, the air flow controller 340 is connected to the package 102 containing the consumable at the first end 105. Remote from the first end 105 of the package 102 containing the consumable is a distal end 345 of the air flow controller 340 having a distal opening 343. Between the distal opening 343 of the air flow controller 340 and the first end 105 of the package 102 containing the consumable material contains a control valve 342. The control valve 342 may be a needle valve, a butterfly valve, a spherical valve, a check valve, or any other adjustable flow valve or adjustable orifice. The control valve 342 allows the user to control the air flow even during use. The distal opening 343 may be smaller than the opening 153 at the first end 152 of the housing 150 to provide restriction of air flow through the first end 152 of the housing 150, providing a controlled pressure drop depending on the air flow by throttling the air flow through the distal opening 343 or valve 342. Valve Control 342 may be operatively coupled to system controller 166 to control 342 the opening and closing of valve 342.

The air flow controller 340 may be used in place of the end cap 154 or in addition to the end cap 154. If the air flow controller 340 is used with the end cap 154, the air flow controller may be positioned adjacent to the end cap 154 on the housing 150. In some embodiments In an embodiment, instead of having an end cap 154 on the housing 150, the end cap 154 may be positioned upstream or downstream of the control valve 342 within the air flow controller 340. With or without the end cap 154, the air flow controller 340 provides a means for controlling the flow of air that is drawn upstream in the downstream direction through the package 102 containing the consumable, and a vacuum or air pressure difference is created within the housing 150. This pressure difference draws steam from the package 102 containing the consumable into the air stream. If the air flow into the first end 105 of the package 102 containing the consumable can be controlled, this pressure difference can be varied, allowing more (or less) steam to be introduced into the air flow, effectively changing the persistence of flavor and aroma. This ability to change the stability of flavor and aroma is closely related to the heating of the package 102 containing the consumable, since it is the increase in temperature of the consumable that leads to the formation of this vapor. By precisely controlling the heating process (time and speed) and air flow through the first end 105 of the package 102 containing the consumable, a wide range of flavor and aroma consistency experiences can be achieved.

In some embodiments, the air flow controller 340 may be part of the receiving device 151. For example, the air flow controller 340 may be attached to or integral with the distal end 406 of the receiving device 151. Thus, the air flow controller 340 creates an extension of the receiving device 151. To prevent the first end 152 of the housing 150 from falling into the control valve 342, a stop 428 may be placed toward the distal end 406 of the receiving device 151, but downstream of the valve 342 management. For example, the stop 428 may be a protrusion, wall, protrusion, or the like that projects radially inward from the inner wall to abut the first end 152 of the housing 150 and prevent movement of the housing into the air regulator 340 .

The control valve 342 serves as a controller for the flow of air into the first end 152 of the housing 150 when a user draws air through the package 102 containing the consumable. By restricting this air flow, a negative pressure (vacuum) is created at the first end 152 of the housing 150, as well as internally relative to the housing 150. In a preferred embodiment, the air flow through this valve 342 can be controlled by either mechanical or electromechanical means configured as one piece with device 100. The operation of control valve 342, pressure sensor 426, and seal 420 may be coordinated by system controller 166 to control the precise creation of a pressure difference within the package 102 containing the consumable.

By using the seal 420 with the control valve 342, better operation of the control valve 342 is achieved because it allows for better control of the control valve 342 because the seal 420 ensures that air flow cannot flow from the top on the mouthpiece 158 or any other areas through which air may leak into device 100 except at holes 408, 343 specifically designed for air flow. Thus, the operation of the valve 342 is improved by the seal 420.

The 420 seal also provides another benefit. When using devices such as the present invention, there may be a tendency for the lips to stick to the mouthpiece. When this occurs, the sticky lips may pull the package 102 containing the consumable from the aerosol receiving device 200. This phenomenon does not occur in regular cigarettes due to the one-piece design; however, in the case of a device where the package 102 containing the consumable is separate from 104 of the aerosol device 200, the aerosol device 200 must hold the package 102 containing the consumable. The seal 420 of the present invention makes it impossible for the adhesive lips to pull the package containing the consumable material out of the aerosol generating device 200 unless specifically required.

In embodiments that use the receiving device 151, the housing 150 becomes optional since the receiving device 151 essentially functions as the housing 150. Therefore, the block 104 containing the consumable can be inserted directly into the receiving device 151, in which case the receiving device 151 is a housing 150. The mouthpiece 158 may be inserted and sealed into the main opening 404 of the receptacle 151 with a seal 420. In such a case, the seal 420 between the receptacle 151 and the mouthpiece 158 will be essential to its operation, and the only air allowed will be that , which enters through the distal opening 408 or valve 342.

Therefore, in some embodiments, the aerosol generating device 100 includes a unit 104 containing a consumable; a current collector 106 combined with a block 104 containing a consumable material; a receiving device 151 having a proximal end 402 defining a main opening 404 for receiving a consumable block 104 and a distal end 406 defining a distal opening 408; a mouthpiece 158 inserted into the main hole 404 of the receiving device 151; and a seal 420 to form an airtight seal between the mouthpiece 158 and the main opening 404 of the receiving device 151. The device 100 may further include a shell 108 enclosing a block 104 containing the consumable and a susceptor 106 for forming a package 102 containing the consumable. The device 100 may further include a housing 150 for housing a package 102 containing a consumable. In such an embodiment, the mouthpiece 158 is included in the housing 150. The device 100 may further include a separator 135 between the package 102 containing the consumable and the housing 150 to maintain a passage for air flow to the mouthpiece 158. To control the pressure difference inside the receiving device 151 relative to the outside. receiving device 151, the device 100 may further include an air flow controller 340 at the distal end 406 of the receiving device 151. The air flow controller 340 includes a control valve 342 and a pressure sensor 426. The pressure sensor 426 is operatively coupled to the system controller 166, and the system controller 166 is operatively coupled to the control valve 342 to control the pressure difference within the receiving device 151 relative to the outside of the receiving device 151 to optimize aerosolization and air flow of the consumable.

Hollow pantographs

In some embodiments, instead of having an aerosol flow from the consumable block 104 through the openings 120 of the shell 108 into the filter tube 140 and towards the mouthpiece 158, air flows into the pantograph 106, drawing the active agent from the consumable block 104 to create aerosol that flows through pantograph 106 towards mouthpiece 158, as shown in FIG. 25A–E. In such embodiments, the pantograph 106 may have one or more hollow points 350 with at least one inlet 352 along the length of each point 350 and at least one outlet 354. The point 350 includes an attached end 356 operably connected to a base 358 of the pantograph, and a free end 360 opposite the base 358 of the pantograph. The hollow point 350 is connected to the pantograph base 358 at the attached end 356. The outlet 354 of the hollow point 350 is positioned toward the free end 360. For example, the outlet may be located at the tip 362 of the free end 360, or there may be multiple outlets 354 located at a distance at an angle around the perimeter surface of the hollow pointed member 350 on the side of the free end 360.

In some embodiments, the tip 362 of the free end 360 may be pointed or sharp to facilitate penetration into the block 104 containing the consumable. The particle size, density, binders, fillers, or any component used in the consumable-containing block 104 may be designed to allow penetration of the susceptor points 290, 350 and/or perforation needles without causing excessive compression or alteration density of the block 104 containing the consumable material. Density changes due to the compression "pack" of the consumable-containing block 104 may adversely affect the flow of air or steam through the consumable-containing block 104.

Any consumable particles that may be forced through the shell 108 after entering the pantograph 106 will be retained in the cavity 368 between the consumable block 104 and the mouthpiece 158. Since the tips 362 of the pointed elements 290, 350 are sharp, it is unlikely that the consumable will be pushed out of the shell 108.

In some embodiments, the outlets 354 and/or the inlets 352 may be coated with a coating that melts at heating temperatures. In a preferred embodiment, the block 104 containing the consumable is long enough to cover the entire hollow point 350 except for the outlet 354.

The pantograph base 358 may include an opening 364 that corresponds to a hollow point 350. In embodiments with multiple hollow points 350a-d, each hollow point 350a-d has its own corresponding hole 364.

In some embodiments, there may be multiple hollow pointed elements 350a-d. The hollow pointed elements 350a-d may be arranged in a circle, making them compatible with the movable heating element 160 or the movable package 102 containing the consumables. In some embodiments, there may be a single hollow pointed element 350, with the hollow pointed element 350 located centrally at the base 358 of the pantograph. In some embodiments, there may be a central hollow pointed element 350 surrounded by multiple hollow pointed elements 350a-d. A different arrangement of hollow pointed elements 350 may be used.

Each hollow point 350 may have at least one inlet 352 and at least one outlet 354. Preferably, the hollow point 350 includes a plurality of inlet holes 352 and a plurality of outlets 354. The inlet holes 352 may be arranged in series along the length of the hollow point 350. element 350. In some embodiments, inlets 352 may be arranged in a circular manner around the perimeter of the hollow point 350. The increased number of inlets 352 on the hollow point 350 increases the number of points through which the generated aerosol can exit the consumable block 104, and from package 102 containing consumables. Likewise, there may be multiple outlets 354 arranged in a circular manner around the perimeter of the pointed member 350 on the side of the free end 360.

In some embodiments, the consumable-containing block 104 does not extend from one end 105 of the consumable-containing package 102 to the mouthpiece 158. Thus, there is a cavity 368 between the consumable-containing block 104 and the mouthpiece 158. This cavity 368 may be filled with heat-conducting material, flavoring substance, etc.

As shown in the sectional view of FIG. 25E, in use, the current collector 106 is integrated into a block 104 containing a consumable. When the current collector 106 is heated by induction heating by the heating element 160, the unit containing the consumable material releases an aerosol. As the user draws from the mouthpiece 158, the pressure difference within the package 102 containing the consumable causes an aerosol to enter the hollow tip 350 through the inlet 352 and exit through the outlet 354 (see arrows indicating air flow). The aerosol then enters the cavity 368 of the package 102 containing the consumable and is filtered through the mouthpiece 158 for inhalation by the user. Thus, the shell 108 should not have any openings 120.

In some embodiments, as shown in FIG. 26A-G, there may be a single hollow point 350 centrally located on the pantograph base 358, with multiple points 290a-d surrounding the hollow point 350. In such an embodiment, the hollow point 350 need not be capable of being inductively heated. , although this possibility is allowed. In this embodiment, the block 104 containing the consumable may have a central hole 366 through which a hollow pointed member 350 can be inserted for a tight fit.

As shown in FIG. 26G, in use, when the current collector points 290 are heated, the generated aerosol enters through the inlets 352 of the hollow point 350 and exits through the outlets 354 and into the mouthpiece 158, as indicated by the air flow arrows.

The aerosol produced by the methods and devices described herein is effective and reduces the toxic byproducts observed in traditional cigarettes and other non-combustion heating devices.

EXAMPLE

As shown in FIG. 24A-C, testing was conducted on consumable packages 102 that were prepared by compressing powdered tobacco mixed with a humectant and PGA to form a consumable block 104 around a pantograph 106 enclosed in a foil covering as a shell 108 inserted into filter tube 140 such that holes 120 are present on three sides as air passages, covered with standard cigarette paper as the body 150, capped at one end by a high flow proximal filter as a mouthpiece 158 and at the other end by a distal filter tip as an end cover 154. The current collector 106 is made in the form of a metal sheet twisted into a spiral. The consumable block 104 and the shell 108 have triangular cross-sections. The filter tube 140 is a spiral paper tube.

The Durham, North Carolina test was conducted using a prototype device and was determined to heat the pantograph to 611°C (degrees Celsius) by calibrating the electrical power that was used during the test.

The Durham test was conducted using an SM459 20-port linear analytical smoking machine and was performed by technicians familiar with the equipment and all associated accessories. Technicians placed three packages 102 containing consumables into the smoking machine. Each package 102 containing the consumable was then puffed 6 times for a total of 18 puffs. The resulting aerosol was then collected onto filter pads. The “smoking” regimen was a puff every 30 seconds with a puff duration of 2 seconds and a volume of 55 ml collected using a bell curve profile. Analysis of the collected aerosol determined that 0.570 mg of carbon monoxide (CO) was present in the aerosol of each disposable stick, which is well below levels at which combustion would be expected to have occurred, despite the temperatures typically expected to occur at above 350°C.

The second set of tests was conducted in Richmond, Virginia. The Richmond tests were conducted using a similarly designed package 102 containing consumables and a prototype device that was calibrated to heat pantograph 106 at three different settings: 275°C, 350°C, and 425°C. CO data were generated by Enthalpy Analytical (EA) (Richmond, VA, USA), LLC according to EA Method AM-007. Packages 102 containing consumables were smoked using an analytical smoking machine in accordance with the established Canadian intensive smoking procedure. The vapor phase of the smoke (i.e., aerosol) was collected in gas sampling bags attached to a smoking machine set to the required puff parameters. The non-dispersive infrared absorption (NDIR) method is used to measure the concentration of CO in the vapor phase in percent volume (volume percent). Using the number of packages 102 containing consumables, the number of puffs, puff volume, and environmental conditions, the percentage of CO was converted to milligrams per package containing consumables (mg/cigarette).

At calibrated temperature settings, it was determined that no CO was detected in the aerosol produced at each setting, even though combustion is typically expected to occur at temperatures above 350°C.

The tests performed are tests in accordance with industry standards. In similar industry standard testing, commercially available non-combustion heating products report CO at 0.436 mg/cigarette. A standard combustible cigarette reports CO at 30.2 mg/cigarette.

The above description of a preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed. In view of the above idea, many modifications and variations are possible. The scope of the present invention is not intended to be limited by this detailed description, but rather by the claims and equivalents of the appended claims.

Claims (8)

1. A method of making a package containing a consumable material for use in an aerosol producing device, the method comprising: a) combining the pantograph with the consumable material to form a block containing the consumable material; b) coating the block containing the consumable material; c) heating the coating to harden the shell around the block containing the consumable, the shell being porous, resulting in a package containing the consumable. 2. The method according to claim 1, characterized in that the coating contains starch. 3. The method according to claim 2, characterized in that it additionally includes extruding a consumable material with a current collector to form a block containing the consumable material. 4. The method according to claim 3, characterized in that it further includes rolling the extruded pantograph and consumable material to form a cylinder with a spiral pattern when viewed along the cross section. 5. The method according to claim 1, characterized in that it additionally includes introducing a consumable into the medium to form a block containing the consumable.