US20250204597A1 - An aerosol-generating device and a method of controlling aerosol production thereof - Google Patents

An aerosol-generating device and a method of controlling aerosol production thereof Download PDF

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Publication number
US20250204597A1
US20250204597A1 US18/851,823 US202318851823A US2025204597A1 US 20250204597 A1 US20250204597 A1 US 20250204597A1 US 202318851823 A US202318851823 A US 202318851823A US 2025204597 A1 US2025204597 A1 US 2025204597A1
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aerosol
temperature
heating
forming substrate
heating element
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Maxime Clément Charles CHATEAU
Farhang MOHSENI
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Philip Morris Products SA
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Philip Morris Products SA
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Assigned to PHILIP MORRIS PRODUCTS S.A. reassignment PHILIP MORRIS PRODUCTS S.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHATEAU, Maxime Clément Charles, MOHSENI, Farhang
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    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/20—Devices using solid inhalable precursors
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46—Shape or structure of electric heating means
    • A24F40/465—Shape or structure of electric heating means specially adapted for induction heating
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/50—Control or monitoring
    • A24F40/51—Arrangement of sensors
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/50—Control or monitoring
    • A24F40/57—Temperature control

Definitions

  • the present disclosure relates to a method of controlling aerosol production in an aerosol-generating device that is configured to heat an aerosol-generating article comprising a solid or a gel aerosol-forming substrate.
  • the present disclosure also relates to the aerosol-generating device and a system comprising the aerosol-generating device and the aerosol-generating article.
  • Aerosol-generating devices may comprise an electrically operated heat source that is configured to heat an aerosol-generating article comprising an aerosol-forming substrate to generate an aerosol.
  • an aerosol is generated by the transfer of heat from the heat source to a physically separate aerosol-forming substrate.
  • volatile compounds are released from the aerosol-forming substrate by heat transfer to the aerosol-forming substrate from the heat source and entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol that is inhaled by the user.
  • a number of handheld aerosol-generating devices configured to heat aerosol-forming substrates of heated aerosol-generating articles are known in the art. These include electrically-operated aerosol-generating devices in which an aerosol is generated by the transfer of heat from one or more electrical heating elements of the aerosol-generating device to the aerosol-forming substrate of the heated aerosol-generating article.
  • Known handheld electrically operated aerosol-generating devices typically comprise a battery, control electronics and one or more electrical heating elements for heating the aerosol-forming substrate of a heated aerosol-generating article.
  • a method of controlling aerosol production in an aerosol-generating device comprises: a heating chamber configured to at least partially receive an aerosol-generating article comprising an aerosol-forming substrate; a heating system associated with a heating element that is configured to heat the aerosol-forming substrate; and a power source providing power to the heating system.
  • the method comprises controlling the power during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user to: in a first heating mode, adjust a temperature of the heating element to increase the temperature from an initial temperature to a first temperature, wherein said first temperature is maintained for a first predetermined time period; in a second heating mode, adjust the temperature of the heating element to one or more second temperatures during a second predetermined time period, wherein the second predetermined time period is subsequent to the first predetermined time period; in a third heating mode, adjust the temperature of the heating element to be constant and equal to a third temperature in a third predetermined time period, wherein the third temperature approximately corresponds to the first temperature and the third predetermined time period is subsequent to the second predetermined time period.
  • Performing the heating of the aerosol-forming substrate to form an aerosol for inhalation by a user into three heating modes in which the temperature of the heating element is adjusted to a respective temperature, enables improved control of aerosol delivery.
  • the amount of desired volatile compounds to be vaporized for inhalation by the user will be depleted.
  • Increasing the temperature of the heating element to approximately the first temperature enables the amount of vaporized desired volatile compounds in the aerosol inhaled by the user to remain consistent with the amount in the first and second heating modes.
  • the second predetermined time period may be directly subsequent to the first predetermined time period.
  • the third predetermined time period may be directly subsequent to the second predetermined time period.
  • aerosol-generating device is used to describe a device that interacts with the aerosol forming substrate of an aerosol generating article to generate an aerosol.
  • the aerosol-generating device may be a handheld electrically-operated device.
  • aerosol-generating article is used to describe an article comprising an aerosol-forming substrate that is heated to generate an inhalable aerosol for delivery to a user.
  • An aerosol-generating article may be disposable.
  • the term “aerosol” is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas.
  • the aerosol may be visible or invisible.
  • the aerosol may include vapors of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.
  • aerosol-forming substrate is used to describe a substrate comprising aerosol-generating material that is capable of releasing upon heating volatile compounds that can generate an aerosol.
  • the power source is a battery, such as a lithium ion battery.
  • the power source may be another form of charge storage device such as a capacitor.
  • the power source may require recharging.
  • the power source may have sufficient capacity to allow for the continuous generation of aerosol for a period of around six minutes or for a period that is a multiple of six minutes.
  • the power source may have sufficient capacity to allow for a predetermined number of puffs or discrete activations of the heating system.
  • the term “mode” refers to a mode of operation that the controller is programmed to perform.
  • the controller in a calibration mode, the controller is configured to perform a pre-programmed calibration process.
  • a pre-heating mode the controller is configured to perform a pre-programmed pre-heating process.
  • a heating mode the controller is configured to perform a heating process.
  • phase may be used herein interchangeably with the term “mode”.
  • the controller may be a microcontroller.
  • the controller may comprise a microprocessor, such as a programmable microprocessor.
  • the controller may comprise a non-volatile memory.
  • the aerosol-generating device may comprise an interface configured to allow for the transfer of data to and from the controller from external devices.
  • the interface may allow for the uploading of software to the controller to run on the programmable microprocessor.
  • the interface may be a wired interface, such as a micro USB port, or may be a wireless interface.
  • the heating system may comprise the heating element.
  • the heating system may be configured to internally heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • the heating element may be a resistive heating element, which, during use, engages with the aerosol-forming substrate to heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • the heating system may be inductively coupled to the heating element internal to the aerosol-forming substrate, the heating element configured to internally heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • the term “inductively couple” refers to the heating of a heating element, such as a susceptor when penetrated by an alternating magnetic field.
  • the heating may be caused by the generation of eddy currents in the heating element.
  • the heating may be caused by magnetic hysteresis losses.
  • the heating element may be a susceptor.
  • susceptor refers to an element comprising a material that is capable of converting the energy of a magnetic field into heat. When a susceptor is located in an alternating magnetic field, the susceptor is heated. Heating of the susceptor may be the result of at least one of hysteresis losses and eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material.
  • the susceptor may be an elongate susceptor. As used herein with reference to the invention, the term “elongate” is used to describe a susceptor having a length that is greater than the width thereof. For example, the length of the susceptor may be at least twice the width thereof.
  • the first temperature may be between 245 and 285 degrees Celsius.
  • Controlling the power may further comprise: in a pre-heating mode, increasing the temperature of the heating element from an ambient temperature to the initial temperature.
  • the initial temperature may be between 140 and 170 degrees Celsius.
  • the pre-heating mode may have a duration between 10 and 20 seconds.
  • the pre-heating mode ensures that, whatever the physical condition of the aerosol-forming substrate (dry or humid, for example), the time duration of the pre-heating phase is sufficient for the aerosol-forming substrate to reach a minimum operating temperature, in order to be ready to feed continuous power and reach the first operating temperature as quickly as possible for generating sufficient aerosol to be inhaled by the user.
  • This is particularly advantageous for aerosol-forming substrates having a high aerosol former content (greater than 30 percent by weight) because such substrates typically have a higher moisture content after thermal equilibrium has been reached.
  • Controlling the power may further comprise, in a calibration mode, calibrating the heating element, wherein the calibration mode is subsequent to the pre-heating mode.
  • Calibrating the heating element during heating of the aerosol-forming substrate for generating an aerosol advantageously provides for more accurate determination of the calibration values used in the temperature control, and therefore improved temperature control is achieved.
  • the heating system may comprise the heating element, wherein the heating element may be configured to externally heat the aerosol-forming substrate.
  • the heating element may be a resistive heater.
  • the first temperature may be between 180 and 230 degrees Celsius.
  • Controlling the power may further comprise: in a pre-heating mode, increasing the temperature of the heating element from an ambient temperature to the initial temperature.
  • the initial temperature may be between 140 and 170 degrees Celsius.
  • the one or more second temperatures may approximately correspond to the first temperature. This advantageously makes the programming required for the controller less complex, thus reducing firmware complexity.
  • the one or more second temperatures may be different to the first temperature.
  • Adjusting the temperature of the heating element to one or more second temperatures during the second predetermined time period may comprise lowering the temperature of the heating element from the first temperature.
  • the one or more second temperatures may be between 190 and 220 degrees Celsius when the aerosol-forming substrate is internally heated.
  • the one or more second temperatures may be between 180 and 230 degrees Celsius when the aerosol-forming substrate is externally heated.
  • Lowering the temperature of the heating element from the first temperature may comprise two consecutive temperature steps.
  • a temperature of a first temperature step may be lower than a temperature of a second temperature step.
  • Having two temperature steps in the second heating mode allows for improved control of the amount of vaporized desired volatile compounds in the aerosol inhaled by the user, thereby providing the same sensorial experience for the user. Further, if the temperature of the second heating step is higher than the temperature of the first heating step, the amount of desired vaporized volatile compounds remains consistent even though the amount of desired volatile compounds depletes over time with heating.
  • Adjusting the temperature of the heating element to one or more second temperatures during the second predetermined time period may comprise increasing the temperature of the heating element from the first temperature.
  • a duration of the second predetermined time period may be between 100 and 280 seconds.
  • the power may be controlled during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user based on a heating profile of a plurality of heating profiles, wherein each heating profile defines how to adjust the temperature of the heating element during each of the heating modes.
  • the heating profile may be selected based on identifying the aerosol-generating article.
  • the power may be controlled during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user based on a heating profile of a plurality of heating profiles, wherein each heating profile defines how to adjust the temperature of the heating element during the second heating mode.
  • the heating profile may be selected based on at least one of: identifying the aerosol-generating article and identifying the aerosol-forming substrate.
  • a duration of the third predetermined time period may be between 30 seconds and 120 seconds.
  • an aerosol-generating device comprising: a heating chamber configured to at least partially receive an aerosol-generating article comprising an aerosol-forming substrate; a heating system associated with a heating element that is configured to heat the aerosol-forming substrate; a power source providing power to the heating system; and a controller.
  • the controller is configured to control the power during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user to: in a first heating mode, adjust a temperature of the heating element to increase from an initial temperature to a first temperature, wherein the first temperature is maintained for a first predetermined time period; in a second heating mode, adjust the temperature of the heating element to one or more second temperatures during a second predetermined time period, wherein the second predetermined time period is subsequent to the first predetermined time period; in a third heating mode, adjust the temperature of the heating element to be constant and equal to a third temperature in a third predetermined time period, wherein the third temperature approximately corresponds to the first temperature and the third predetermined time period is subsequent to the second predetermined time period.
  • the second predetermined time period may be directly subsequent to the first predetermined time period.
  • the third predetermined time period may be directly subsequent to the second predetermined time period.
  • the heating system may comprise the heating element.
  • the heating system may be configured to internally heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • the heating element may be a resistive heating element, which, during use, engages with the aerosol-forming substrate to heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • the heating system may be inductively coupled to the heating element internal to the aerosol-forming substrate, the heating element configured to internally heat the aerosol-forming substrate.
  • the first temperature may be between 245 and 285 degrees Celsius.
  • Controlling the power may further comprise: in a pre-heating mode, increasing the temperature of the heating element from an ambient temperature to the initial temperature.
  • the initial temperature may be between 140 and 170 degrees Celsius.
  • the pre-heating mode may have a duration between 10 and 20 seconds.
  • Controlling the power may further comprise, in a calibration mode, calibrating the heating element, wherein the calibration mode is subsequent to the pre-heating mode.
  • the heating system may comprise a heating element that is configured to externally heat the aerosol-forming substrate.
  • the heating element may be a resistive heater.
  • the first temperature may be between 180 and 230 degrees Celsius.
  • Controlling the power may further comprise: in a pre-heating mode, increasing the temperature of the heating element from an ambient temperature to the initial temperature.
  • the initial temperature may be between 140 and 170 degrees Celsius.
  • the one or more second temperatures may approximately correspond to the first temperature.
  • the one or more second temperatures may be different to the first temperature.
  • Adjusting the temperature of the heating element to one or more second temperatures during the second predetermined time period may comprise lowering the temperature of the heating element from the first temperature.
  • the one or more second temperatures may be between 190 and 220 degrees Celsius when the aerosol-forming substrate is internally heated.
  • the one or more second temperatures may be between 180 and 230 degrees Celsius when the aerosol-forming substrate is externally heated.
  • Lowering the temperature of the heating element from the first temperature may comprise two consecutive temperature steps.
  • a temperature of a first temperature step may be lower than a temperature of a second temperature step.
  • Adjusting the temperature of the heating element to one or more second temperatures during the second predetermined time period may comprise increasing the temperature of the heating element from the first temperature.
  • a duration of the second predetermined time period may be between 100 and 280 seconds.
  • the power may be controlled during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user based on a heating profile of a plurality of heating profiles, wherein each heating profile defines how to adjust the temperature of the heating element during each of the heating modes.
  • the heating profile may be selected based on identifying the aerosol-generating article.
  • a duration of the third predetermined time period may be between 30 seconds and 120 seconds.
  • a system comprising: the aerosol-generating device described above; and an aerosol-generating article comprising the aerosol-forming substrate.
  • aerosol former is used to describe a compound that, in use, facilitates formation of the aerosol, and that preferably is substantially resistant to thermal degradation at the operating temperature of an aerosol-generating article or aerosol-generating system comprising the aerosol-forming substrate.
  • total aerosol former content is used to describe the combined content of all aerosol formers in the aerosol-forming substrate.
  • the one or more aerosol formers may comprise at least one of 1,3-butanediol, glycerin, 1,3-propanediol, propylene glycol, triethylene glycol, glycerol monoacetate, glycerol diacetate, glycerol triacetate, dimethyl dodecanedioate and dimethyl tetradecanedioate.
  • the aerosol-forming substrate may be a non-tobacco substrate.
  • non-tobacco substrate is used to refer to an aerosol-forming substrate that comprises a non-tobacco material.
  • the aerosol-forming substrate may be a solid or a gel.
  • solid is used to describe an aerosol-forming substrate that has a stable size and shape and does not flow at 23° C.
  • gel is used to describe an aerosol-forming substrate that comprises two or more components, one of which is a liquid.
  • a gel is mostly liquid by weight.
  • a gel is a substantially dilute cross-linked system, which exhibits no flow when in the steady state, although the liquid phase may still diffuse through the system.
  • the aerosol-forming substrate may be a solid film.
  • film is used to describe a solid aerosol-forming substrate having a thickness that is substantially less than the width or length thereof.
  • the term “thickness” is used to describe the minimum dimension between opposite, substantially parallel surfaces of a solid aerosol-generating film.
  • the aerosol-forming substrate may further comprise nicotine.
  • the term “nicotine” is used to describe nicotine, a nicotine base or a nicotine salt.
  • the amounts of nicotine recited herein are the amount of free base nicotine or amount of protonated nicotine, respectively.
  • the aerosol-forming substrate may comprise natural nicotine, or synthetic nicotine, or a combination of natural nicotine and synthetic nicotine.
  • the aerosol-forming substrate may further comprise one or more cellulose based agents and one or more carboxylic acids selected from fumaric acid, maleic acid and malic acid.
  • the aerosol-forming substrate may have a total cellulose based agent content of at least 35 percent by weight and a total carboxylic acid content of at least 0.5 percent by weight.
  • cellulose based agent is used to describe a cellulosic substance.
  • examples of cellulose based agents include cellulose based film-forming agents, cellulose based strengthening agents and cellulose based binding agents.
  • the aerosol-forming substrate comprises a plurality of cellulose based agents consisting of a cellulose based film-forming agent, a cellulose based strengthening agent, and a cellulose based binding agent
  • total cellulose based agent content describes the combined cellulose based film-forming agent content, cellulose based strengthening agent content, and cellulose based binding agent content of the aerosol-forming substrate.
  • total carboxylic acid content is used to describe the combined content of all carboxylic acids in the aerosol-forming substrate.
  • the aerosol-forming substrate comprises a plurality of carboxylic acids consisting of benzoic acid and fumaric acid
  • total carboxylic acid content describes the combined benzoic acid content and fumaric acid content of the aerosol-forming substrate.
  • the aerosol-forming substrate may comprise water.
  • the aerosol-forming substrate may have a water content of between 5 percent by weight and 35 percent by weight.
  • the terms “puff” and “inhalation” are used interchangeably and are intended to mean the action of a user drawing an aerosol into their body through their mouth or nose. Inhalation includes the situation where an aerosol is drawn into the user's lungs, and also the situation where an aerosol is only drawn into the user's mouth or nasal cavity before being expelled from the user's body.
  • a “usage session” refers to a period of use of the device beginning with activation of the device by the user.
  • the usage session may comprise a pre-heating phase in which the aerosol-generating device is configured to supply power to the heating system to heat the aerosol-forming substrate to generate aerosol.
  • the usage session may comprise a calibration phase to calibrate the heating system in order to more accurately control the temperature of the heating element.
  • the usage session may comprise a main phase during which the user may inhale the generated aerosol.
  • the main phase may be 30 long enough for a plurality of puffs.
  • the main phase may be long enough for three, four, five or six puffs.
  • the main phase may be long enough for more than six puffs.
  • the aerosol-generating device may be configured to stop supplying power to the heating system.
  • the aerosol-forming substrate may be removed from the aerosol-generating device at the end of the usage session.
  • the aerosol-forming substrate may be replaced in a later usage session.
  • the duration of the usage session, between a usage session start and a usage session end may be at least one, two, three, four, five or six minutes.
  • the usage session may have a duration of about four and a half minutes.
  • Aerosol-generating devices comprise a proximal end through which, in use, an aerosol exits the device.
  • the proximal end of the aerosol-generating device may also be referred to as the mouth end or the downstream end.
  • the mouth end is downstream of the distal end.
  • the distal end of the aerosol-generating article may also be referred to as the upstream end.
  • Components, or portions of components, of the aerosol-generating device may be described as being upstream or downstream of one another based on their relative positions with respect to the airflow path of the aerosol-generating device.
  • Aerosol-generating articles comprise a proximal end through which, in use, an aerosol exits the article.
  • the proximal end of the aerosol-generating article may also be referred to as the mouth end or the downstream end.
  • the mouth end is downstream of the distal end.
  • the distal end of the aerosol-generating article may also be referred to as the upstream end.
  • Components, or portions of components, of the aerosol-generating article may be described as being upstream or downstream of one another based on their relative positions between the proximal end of the aerosol-generating article and the distal end of the aerosol-generating article.
  • the front of a component, or portion of a component, of the aerosol-generating article is the portion at the end closest to the upstream end of the aerosol-generating article.
  • the rear of a component, or portion of a component, of the aerosol-generating article is the portion at the end closest to the downstream end of the aerosol-generating article.
  • aerosol-cooling element refers to a component of an aerosol-generating article located downstream of the aerosol-forming substrate such that, in use, an aerosol formed by volatile compounds released from the aerosol-forming substrate passes through and is cooled by the aerosol cooling element before being inhaled by a user.
  • An aerosol cooling element has a large surface area, but causes a low pressure drop. Filters and other mouthpieces that produce a high pressure drop, for example filters formed from bundles of fibers, are not considered to be aerosol-cooling elements. Chambers and cavities within an aerosol-generating article are not considered to be aerosol cooling elements.
  • mouthpiece refers to a portion of an aerosol-generating article, an aerosol-generating device or an aerosol-generating system that is placed into a user's mouth in order to directly inhale an aerosol.
  • Example Ex1 A method of controlling aerosol production in an aerosol-generating device, the device comprising: a heating chamber configured to at least partially receive an aerosol-generating article comprising an aerosol-forming substrate; a heating system associated with a heating element that is configured to heat the aerosol-forming substrate; and a power source providing power to the heating system, the method comprising controlling the power during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user to: in a first heating mode, adjust a temperature of the heating element to increase the temperature from an initial temperature to a first temperature, wherein said first temperature is maintained for a first predetermined time period; in a second heating mode, adjust the temperature of the heating element to one or more second temperatures during a second predetermined time period, wherein the second predetermined time period is subsequent to the first predetermined time period; in a third heating mode, adjust the temperature of the heating element to be constant and equal to a third temperature in a third predetermined time period, wherein the third temperature approximately corresponds to the first temperature and the third pre
  • Example Ex2 The method according to example Ex1, wherein the heating system comprises the heating element, and wherein the heating system is configured to internally heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • Example Ex3 The method according to example Ex2, wherein the heating element is a resistive heating element, which, during use, engages with the aerosol-forming substrate to heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • the heating element is a resistive heating element, which, during use, engages with the aerosol-forming substrate to heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • Example Ex4 The method according to example Ex1, wherein the heating system is inductively coupled to the heating element internal to the aerosol-forming substrate, the heating element configured to internally heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • Example Ex5 The method according to one of examples Ex2 to Ex4, wherein the first temperature is between 245 and 285 degrees Celsius.
  • Example Ex6 The method according to one of examples Ex1 to Ex5, wherein controlling the power further comprises: in a pre-heating mode, increasing the temperature of the heating element from an ambient temperature to the initial temperature.
  • Example Ex7 The method according to example Ex6, wherein the initial temperature is between 140 and 170 degrees Celsius.
  • Example Ex8 The method according to example Ex6 or Ex7, wherein the pre-heating mode has a duration between 10 and 20 seconds.
  • Example Ex9 The method according to one of examples Ex6 to Ex8, wherein controlling the power further comprises, in a calibration mode, calibrating the heating element, wherein the calibration mode is subsequent to the pre-heating mode.
  • Example Ex11 The method according to example Ex10, wherein the heating element is a resistive heater.
  • Example Ex12 The method according to example Ex10 or Ex11, wherein the first temperature is between 180 and 230 degrees Celsius.
  • Example Ex14 The method according to example Ex13, wherein the initial temperature is between 140 and 170 degrees Celsius.
  • Example Ex16 The method according to one of examples Ex1 to Ex14, wherein the one or more second temperatures are different to the first temperature.
  • Example Ex18 The method according to example Ex17, wherein the one or more second temperatures are between 190 and 220 degrees Celsius.
  • Example Ex19 The method according to example Ex17 or Ex18, wherein lowering the temperature of the heating element from the first temperature comprises two consecutive temperature steps.
  • Example Ex21 The method according to one of examples Ex1 to Ex14, wherein adjusting the temperature of the heating element to one or more second temperatures during the second predetermined time period comprises increasing the temperature of the heating element from the first temperature.
  • Example Ex22 The method according to one of the preceding examples, wherein a duration of the second predetermined time period is between 100 and 280 seconds.
  • Example Ex23 The method according to one of the preceding examples, wherein the power is controlled during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user based on a heating profile of a plurality of heating profiles, wherein each heating profile defines how to adjust the temperature of the heating element during each of the heating modes.
  • Example Ex24 The method according to example Ex23, further comprising selecting the heating profile based on identifying the aerosol-generating article.
  • Example Ex25 The method according to one of examples Ex1 to Ex22, wherein the power is controlled during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user based on a heating profile of a plurality of heating profiles, wherein each heating profile defines how to adjust the temperature of the heating element during the second heating mode.
  • Example Ex26 The method according to example Ex25, further comprising selecting the heating profile based on at least one of: identifying the aerosol-generating article and identifying the aerosol-forming substrate.
  • Example Ex27 The method according to the preceding examples, wherein a duration of the third predetermined time period is between 30 seconds and 120 seconds.
  • An aerosol-generating device comprising: a heating chamber configured to at least partially receive an aerosol-generating article comprising an aerosol-forming substrate; a heating system associated with a heating element that is configured to heat the aerosol-forming substrate; a power source providing power to the heating system; and a controller configured to control the power during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user to: in a first heating mode, adjust a temperature of the heating element to increase from an initial temperature to a first temperature, wherein the first temperature is maintained for a first predetermined time period; in a second heating mode, adjust the temperature of the heating element to one or more second temperatures during a second predetermined time period, wherein the second predetermined time period is subsequent to the first predetermined time period; in a third heating mode, adjust the temperature of the heating element to be constant and equal to a third temperature in a third predetermined time period, wherein the third temperature approximately corresponds to the first temperature and the third predetermined time period is subsequent to the second predetermined time period
  • Example Ex29 The aerosol-generating device according to example Ex28, wherein the heating system comprises the heating element, wherein the heating system is configured to internally heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • Example Ex30 The aerosol-generating device according to example Ex29, wherein the heating element is a resistive heating element, which, during use, engages with the aerosol-forming substrate to heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • the heating element is a resistive heating element, which, during use, engages with the aerosol-forming substrate to heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • Example Ex31 The aerosol-generating device according to example Ex28, wherein the heating system is inductively coupled to the heating element internal to the aerosol-forming substrate, the heating element configured to internally heat the aerosol-forming substrate from within the aerosol-forming substrate.
  • Example Ex32 The aerosol-generating device according to one of examples Ex28 to Ex31, wherein the first temperature is between 245 and 285 degrees Celsius.
  • Example Ex33 The aerosol-generating device according to one of examples Ex28 to Ex32, wherein controlling the power further comprises: in a pre-heating mode, increasing the temperature of the heating element from an ambient temperature to the initial temperature.
  • Example Ex34 The aerosol-generating device according to example Ex33, wherein the initial temperature is between 140 and 170 degrees Celsius.
  • Example Ex35 The aerosol-generating device according to example Ex33 or Ex34, wherein the pre-heating mode has a duration between 10 and 20 seconds.
  • Example Ex36 The aerosol-generating device according to one of examples Ex33 to Ex35, wherein controlling the power further comprises, in a calibration mode, calibrating the heating element, wherein the calibration mode is subsequent to the pre-heating mode.
  • Example Ex37 The aerosol-generating device according to example Ex28, wherein the heating system comprises a heating element that is configured to externally heat the aerosol-forming substrate.
  • Example Ex38 The aerosol-generating device according to example Ex37, wherein the heating element is a resistive heater.
  • Example Ex39 The aerosol-generating device according to example Ex37 or Ex38, wherein the first temperature is between 180 and 230 degrees Celsius.
  • Example Ex40 The aerosol-generating device according to one of examples Ex37 to Ex39, wherein controlling the power further comprises: in a pre-heating mode, increasing the temperature of the heating element from an ambient temperature to the initial temperature.
  • Example Ex41 The aerosol-generating device according to example Ex40, wherein the initial temperature is between 140 and 170 degrees Celsius.
  • Example Ex42 The aerosol-generating device according to one of examples Ex28 to Ex41, wherein the one or more second temperatures approximately correspond to the first temperature.
  • Example Ex43 The aerosol-generating device according to one of examples Ex28 to Ex41, wherein the one or more second temperatures are different to the first temperature.
  • Example Ex44 The aerosol-generating device according to one of examples Ex28 to Ex41, wherein adjusting the temperature of the heating element to one or more second temperatures during the second predetermined time period comprises lowering the temperature of the heating element from the first temperature.
  • Example Ex45 The aerosol-generating device according to example Ex44, wherein the one or more second temperatures are between 190 and 220 degrees Celsius.
  • Example Ex46 The aerosol-generating device according to example Ex44 or Ex45, wherein lowering the temperature of the heating element from the first temperature comprises two consecutive temperature steps.
  • Example Ex47 The aerosol-generating device according to example Ex46, wherein a temperature of a first temperature step is lower than a temperature of a second temperature step.
  • Example Ex48 The aerosol-generating device according to one of examples Ex28 to Ex41, wherein adjusting the temperature of the heating element to one or more second temperatures during the second predetermined time period comprises increasing the temperature of the heating element from the first temperature.
  • Example Ex49 The aerosol-generating device according to one of examples Ex28 to Ex48, wherein a duration of the second predetermined time period is between 100 and 280 seconds.
  • Example Ex50 The aerosol-generating device according to one of examples Ex28 to Ex49, wherein the power is controlled during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user based on a heating profile of a plurality of heating profiles, wherein each heating profile defines how to adjust the temperature of the heating element during each of the heating modes.
  • Example Ex51 The aerosol-generating device according to example Ex50, further comprising selecting the heating profile based on identifying the aerosol-generating article.
  • Example Ex52 The aerosol-generating device according to one of examples Ex28 to Ex49, wherein the power is controlled during heating of the aerosol-forming substrate to form an aerosol for inhalation by a user based on a heating profile of a plurality of heating profiles, wherein each heating profile defines how to adjust the temperature of the heating element during the second heating mode.
  • Example Ex53 The aerosol-generating device according to example Ex52, further comprising selecting the heating profile based on identifying the aerosol-generating article.
  • Example Ex54 The aerosol-generating device according to one of examples Ex28 to Ex53, wherein a duration of the third predetermined time period is between 30 seconds and 120 seconds.
  • Example Ex55 A system comprising: the aerosol-generating device according to one of examples Ex28 to Ex54; and an aerosol-generating article comprising the aerosol-forming substrate.
  • Example Ex56 The system according to example Ex55, wherein the aerosol-forming substrate comprises one or more aerosol formers, and wherein the aerosol-forming substrate comprises a total aerosol former content greater than or equal to 30 percent by weight.
  • Example Ex57 The system according to example Ex56, wherein the one or more aerosol formers comprise at least one of 1,3-butanediol, glycerin, 1,3-propanediol, propylene glycol, triethylene glycol, glycerol monoacetate, glycerol diacetate, glycerol triacetate, dimethyl dodecanedioate and dimethyl tetradecanedioate.
  • the one or more aerosol formers comprise at least one of 1,3-butanediol, glycerin, 1,3-propanediol, propylene glycol, triethylene glycol, glycerol monoacetate, glycerol diacetate, glycerol triacetate, dimethyl dodecanedioate and dimethyl tetradecanedioate.
  • Example Ex58 The system according to one of examples Ex55 to Ex57, wherein the aerosol-forming substrate is a non-tobacco substrate.
  • Example Ex59 The system according to one of examples Ex55 to Ex58, wherein the aerosol-forming substrate is a solid or a gel.
  • Example Ex60 The system according to one of examples Ex55 to Ex59, wherein the aerosol-forming substrate further comprises nicotine.
  • Examples Ex61 The system according to one of examples Ex55 to Ex60, wherein the aerosol-forming substrate further comprises one or more cellulose based agents and one or more carboxylic acids selected from fumaric acid, maleic acid and malic acid.
  • Example Ex62 The system according to example Ex61, wherein the aerosol-forming substrate has a total cellulose based agent content of at least 35 percent by weight and a total carboxylic acid content of at least 0.5 percent by weight.
  • Example Ex63 The system according to one of examples Ex55 to Ex62, wherein the aerosol-forming substrate comprises water.
  • Example Ex64 The system according to example Ex63, wherein the aerosol-forming substrate has a water content of between 5 percent by weight and 35 percent by weight.
  • FIG. 1 is a schematic cross-sectional view of an aerosol-generating article comprising an aerosol-forming substrate and a susceptor;
  • FIG. 2 is a schematic cross-sectional view of an aerosol-generating system comprising the aerosol-generating article shown in FIG. 1 and an electrically operated aerosol-generating device comprising an inductor;
  • FIG. 3 is a graph of DC current vs. time illustrating the remotely detectable current changes that occur when a susceptor material undergoes a phase transition associated with its Curie point;
  • FIG. 4 is a graph of conductance vs time illustrating changes in conductance corresponding to changes of temperature of the susceptor during user operation of the aerosol-generating device;
  • FIG. 5 shows a schematic cross-sectional view of an aerosol-generating article comprising an aerosol-forming substrate
  • FIG. 6 shows a schematic cross-sectional view of an aerosol-generating system comprising the aerosol-generating article shown in FIG. 5 and an electrically-operated aerosol-generating device comprising a resistive heater for internally heating the aerosol-forming substrate from within the aerosol-forming substrate;
  • FIG. 7 shows a schematic cross-sectional view of an aerosol-generating system comprising the aerosol-generating article shown in FIG. 5 and an electrically-operated aerosol-generating device comprising a resistive heater for externally heating the aerosol-forming substrate;
  • FIG. 8 is a graph of temperature vs. time illustrating part of a heating profile during user operation of the aerosol-generating device illustrated in FIG. 6 or 7 ;
  • FIG. 9 is a graph of temperature vs. time illustrating part of a heating profile during user operation of the aerosol-generating device illustrated in FIG. 2 , 6 or 7 ;
  • FIG. 10 is a graph of temperature vs. time illustrating part of a heating profile during user operation of the aerosol-generating device illustrated in FIG. 2 , 6 or 7 ;
  • FIG. 11 is a graph of temperature vs. time illustrating part of a heating profile during user operation of the aerosol-generating device illustrated in FIG. 2 , 6 or 7 ;
  • FIG. 12 is a graph of temperature vs. time illustrating part of a heating profile during user operation of the aerosol-generating device illustrated in FIG. 2 , 6 or 7 ;
  • FIG. 13 is a graph of temperature vs. time illustrating part of a heating profile during user operation of the aerosol-generating device illustrated in FIG. 2 , 6 or 7 ;
  • FIG. 14 is a graph of temperature vs. time illustrating part of a heating profile during user operation of the aerosol-generating device illustrated in FIG. 2 , 6 or 7 ;
  • FIG. 1 is a schematic cross-sectional view of an aerosol-generating article 10 in which an aerosol-forming substrate of the aerosol-generating article is inductively heated from within;
  • FIG. 2 is a schematic cross-sectional view of an aerosol-generating system 100 comprising the aerosol-generating article 10 shown in FIG. 1 and an electrically operated aerosol-generating device 110 comprising an inductor.
  • the aerosol-generating article 10 comprises a ventilation zone 60 provided at a location along the second hollow tubular segment 34 .
  • the mouthpiece element 42 is in the form of a cylindrical plug of low-density cellulose acetate.
  • the aerosol-generating rod 12 comprises an aerosol-forming substrate.
  • the aerosol-forming substrate may be a solid or a gel.
  • the aerosol-forming substrate comprises one or more aerosol formers, such as glycerin or propylene glycol.
  • the total aerosol former content of the aerosol-forming substrate may be greater than 30 percent by weight.
  • the total aerosol former content of the aerosol-forming substrate may be greater than 40 percent by weight.
  • the total aerosol former content of the aerosol-forming substrate may be greater than 45 percent by weight.
  • the aerosol-forming substrate may be a non-tobacco substrate that does not comprise a tobacco-containing material.
  • the aerosol-forming substrate may comprise tobacco-containing material.
  • the aerosol-forming substrate may comprise water.
  • the aerosol-forming substrate may have a water content of between 5 percent by weight and 35 percent by weight.
  • the aerosol-forming substrate may comprise nicotine.
  • the aerosol-forming substrate may comprise one or more cellulose based agents.
  • the aerosol-forming substrate may comprise one or more carboxylic acids.
  • the one or more carboxylic acids may be selected from fumaric acid, maleic acid, and malic acid.
  • the aerosol-generating device 110 comprises a housing 112 defining a heating chamber 114 configured to receive a distal portion of the aerosol-generating article 10 .
  • the current continues to increase until the maximum skin depth is reached, which coincides with the point where the second susceptor material has lost its spontaneous magnetic properties.
  • This point is called the Curie temperature and is seen as the hill (the local maximum) 320 in FIG. 3 .
  • the second susceptor material has undergone a phase change from a ferro-magnetic or ferri-magnetic state to a paramagnetic state.
  • the susceptor 160 is at a known temperature (the Curie temperature, which is an intrinsic material-specific temperature).
  • the inductive heating of the susceptor 44 continues after the Curie temperature has been reached, the eddy currents generated in the susceptor 44 will run against the resistance of the susceptor 44 , whereby Joule heating in the susceptor 44 will continue, and thereby the resistance will increase again (the resistance will have a polynomial dependence of the temperature, which for most metallic susceptor materials can be approximated to a third degree polynomial dependence for our purposes) and current will start falling again.
  • the second susceptor material undergoes a reversible phase transition when heated through the (known) temperature range between the valley 310 and the hill 320 shown in FIG. 3 .
  • the apparent resistance of the susceptor 44 can be remotely detected by monitoring at least the DC current I DC drawn from the power source.
  • the DC supply voltage V DC is known, the DC supply voltage V PC may be monitored in addition to the DC current I DC .
  • apparent resistance of the susceptor 44 can be remotely detected by monitoring a conductance value (where conductance is defined as the ratio of the DC current I DC to the DC supply voltage V DC ) or a resistance value (where resistance is defined as the ratio of the DC supply voltage V PC to the DC current I DC ).
  • the DC current I DC , the conductance value and the resistance value may be referred to as power source parameters.
  • the apparent resistance of the susceptor 44 may vary with the temperature of the susceptor 44 in a strictly monotonic relationship between the start and end of the reversible phase transition, in other words between the valley 310 and the hill 320 .
  • the strictly monotonic relationship allows for an unambiguous determination of the temperature of the susceptor 44 from a determination of the apparent resistance (R) or apparent conductance (1/R). This is because each determined value of the apparent resistance is representative of only one single value of the temperature, so that there is no ambiguity in the relationship.
  • the monotonic relationship of the temperature of the susceptor 44 and the apparent resistance in the temperature range in which the second susceptor material undergoes the reversible phase transition allows for the determination and control of the temperature of the susceptor 44 and thus for the determination and control of the temperature of the aerosol-forming substrate.
  • the controller regulates the supply of power provided to the heating system based on a measurement of a power source parameter.
  • the heating system may comprise a current sensor (not shown) to measure the DC current I DC .
  • the heating system may optionally comprise a voltage sensor (not shown) to measure the DC supply voltage V DC .
  • the current sensor and the voltage sensor are located at an input side of the DC/AC converter.
  • the DC current I DC and optionally the DC supply voltage V PC are provided by feedback channels to the controller to control the further supply of AC power PAC to the inductor 116 .
  • the controller may control the temperature of the susceptor 44 by maintaining the measured power source parameter value at a target value corresponding to a target operating temperature of the susceptor 44 .
  • the controller adjusts the temperature of the susceptor 44 by controlling the power provided to the heating system to adjust the power source parameter value.
  • the power source parameter measured at the input side of the DC/AC converter is maintained between a first calibration value corresponding to a first calibration temperature and a second calibration value corresponding to a second calibration temperature.
  • the second calibration temperature is the Curie temperature of the second susceptor material (the hill 320 in the current plot in FIG. 3 ).
  • the first calibration temperature is a temperature greater than or equal to the temperature of the susceptor at which the skin depth of the second susceptor material begins to increase, leading to a temporary lowering of the resistance (the valley 310 in the current plot in FIG. 3 ).
  • the first calibration temperature is a temperature greater than or equal to the temperature at maximum permeability of the second susceptor material.
  • the first calibration temperature is at least 50 degrees Celsius lower than the second calibration temperature.
  • At least the second calibration value is determined by calibration of the susceptor 44 , as will be described in more detail below.
  • the first calibration value and the second calibration value may be stored as calibration values in a memory of the aerosol-generating device 110 .
  • the power source parameter will have a polynomial dependence on the temperature, the power source parameter will behave in a nonlinear manner as a function of temperature.
  • the first and the second calibration values are chosen so that this dependence may be approximated as being linear between the first calibration value and the second calibration value because the difference between the first and the second calibration values is small, and the first and the second calibration values are in the upper part of the operational temperature range. Therefore, to adjust the temperature to a target operating temperature, the power supply parameter is regulated according to the first calibration value and the second calibration value, through linear equations.
  • the target conductance value, G R corresponding to the target operating temperature
  • G R G Lower +( ⁇ G )
  • the controller adjusts the power source parameter value based on the power source parameter value measured at the valley 310 during calibration and the difference between the power source parameter value measured at the hill 320 and the valley 310 during calibration.
  • the first and second calibration values are obtained by performing a calibration process.
  • the controller is programmed to perform the calibration process each time the user operates the aerosol-generating device 110 .
  • the controller may be configured to enter a calibration mode for performing the calibration process when the user switches on the aerosol-generating device 110 .
  • the controller may be programmed to enter the calibration mode each time the user inserts an aerosol-generating article 10 into an aerosol-generating device 110 .
  • the calibration process is performed during a first heating phase of the aerosol-generating device, before the main phase in which the user inhales the generated aerosol.
  • the controller controls the DC/AC converter to continuously or continually supply power to the inductor 116 in order to heat the susceptor 44 .
  • the controller monitors the power source parameter by measuring the current I DC drawn by the power source and, optionally the power source voltage V DC . As the susceptor 44 is heated, the measured current decreases until the valley (the first turning point) 310 is reached and the current I DC begins to increase. This first turning point 310 corresponds to a local minimum conductance or current value (a local maximum resistance value).
  • the controller may record the power source parameter value at the first turning point 310 as the first calibration value.
  • the temperature of the susceptor 44 at the first calibration value is the first calibration temperature.
  • the controller continues to control the power provided by the DC/AC converter to the inductor 116 , the controller continues to monitor the power supply parameter until the hill (a second turning point) 320 is reached.
  • the second turning point corresponds to a maximum current (corresponding to the Curie temperature of the second susceptor material) before the measured current begins to decrease.
  • This second turning point 320 corresponds to a local maximum conductance or current value (a local minimum resistance value).
  • the control circuitry records the power supply parameter value at the second turning point 320 as the second calibration value.
  • the temperature of the susceptor 44 at the second calibration value is the second calibration temperature.
  • the controller controls the DC/AC converter to interrupt provision of power to the inductor 116 , resulting in a decrease in susceptor 44 temperature and a corresponding decrease in measured current.
  • this process of continuously heating the susceptor 44 to obtain the first calibration value and the second calibration value may be repeated at least once during the calibration mode.
  • controller regulates the power based on the power source parameter values obtained from minimum repetition of the calibration process, this being more reliable because the heat will have had more time to distribute within the aerosol-forming substrate and the susceptor 44 .
  • the controller is configured to detect the turning points 310 and 320 by measuring a sequence of power source parameter values. With reference to FIG. 3 , the sequence of measured power source parameter values will form a curve, with each value being greater than or less than the previous value.
  • the controller is configured to measure the calibration value at the point where the curve begins to flatten. In other words, the controller records the calibration values when the difference between consecutive power supply parameter values is below a predetermined threshold value.
  • the controller may be optionally programmed to perform a pre-heating process before the calibration process. For example, if the aerosol-forming substrate is particularly dry or in similar conditions, the calibration process may be performed before heat has spread within the aerosol-forming substrate, reducing the reliability of the calibration values. If the aerosol-forming substrate were humid, the susceptor 44 takes more time to reach the valley temperature (due to water content in the aerosol-forming substrate).
  • the controller is configured to continuously provide power to the inductor 116 .
  • the measured current starts decreasing with increasing susceptor 44 temperature until a turning point 310 corresponding to minimum measured current (conductance) is reached.
  • the controller is configured to wait for a predetermined period of time to allow the susceptor 44 to cool before continuing heating. The controller therefore controls the DC/AC converter to interrupt provision of power to the inductor 116 .
  • the controller controls the DC/AC converter to provide power until the turning point 310 corresponding to the minimum measured current is reached again.
  • the controller controls the DC/AC converter to interrupt provision of power to the inductor 116 again.
  • the controller again waits for the same predetermined period of time to allow the susceptor 44 to cool before continuing heating.
  • This heating and cooling of the susceptor 44 is repeated for a predetermined duration of time of the pre-heating process 410 .
  • the predetermined duration of the pre-heating process is between 10 and 20 seconds, preferably 11 seconds.
  • the duration of the calibration process is between 10 and seconds. If the aerosol-forming substrate is dry, the first current minimum of the pre-heating process is reached within the pre-determined period of time and the interruption of power will be repeated until the end of the predetermined time period. If the aerosol-forming substrate has a higher moisture content, the first current minimum of the pre-heating process 410 will be reached towards the end of the pre-determined time period.
  • performing the pre-heating process for a predetermined duration ensures that, whatever the physical condition of the aerosol-forming substrate, the time is sufficient for the aerosol-forming substrate to reach the minimum operating temperature, in order to be ready to feed continuous power and reach the first maximum. This allows a calibration as early as possible, but still without risking that the aerosol-forming substrate would not have reached the first calibration temperature beforehand.
  • aerosol-forming substrates comprising a higher aerosol-former content (for example, greater than 30 percent by weight) and a higher water content (for example greater than percent by weight) will have a higher thermal inertia. Therefore, the pre-heating process ensures that the minimum operating temperature is reached before calibration.
  • the pre-heating process may be performed in response to receiving a user input, for example user activation of the aerosol-generating device 110 .
  • the control circuitry may be configured to detect the presence of an aerosol-generating article 10 in the aerosol-generating device 110 and the pre-heating process may be performed in response to detecting the presence of the aerosol-generating article 10 within the heating chamber of the aerosol-generating device 110 .
  • FIG. 4 is a graph of conductance against time showing a heating profile of the susceptor 44 .
  • the graph illustrates five stages of the heating profile: the pre-heating process performed during pre-heating mode 410 , the calibration process performed during calibration mode 420 , and the main phase in which the user inhales the aerosol, comprising heating modes 430 , 440 and 450 .
  • FIG. 4 is illustrated as a graph of conductance against time, it is to be understood that the controller may be configured to control the heating of the susceptor 44 during each stage of the heating profile based on any measured power source parameter, such as resistance or current as described above.
  • the controller is configured to interrupt the provision of power provided to the heating system to allow the susceptor to cool to an initial temperature.
  • the controller is configured to control the power provided to the heating system in order to increase the temperature of the susceptor 44 from an initial temperature to a first temperature.
  • the controller controls the power provided to the heating system in order to adjust the conductance to correspond to a first operating temperature of the susceptor 44 for a first predetermined time period.
  • the conductance during the first heating mode 430 is 0.75 ⁇ G, in other words 75 percent of the difference in the measured conductance between the hill 320 and the valley 310 .
  • the first operating temperature is chosen so that desired volatile compounds are vaporized from the substrate but undesirable compounds, which are vaporized or generated at higher temperatures, are not released. Further, heating the susceptor 44 to the maximum operating temperature of the susceptor 44 immediately after the calibration process 420 improves the amount of vaporized desired volatile compounds, thereby providing improved delivery to the user from the first puff.
  • the first operating temperature of the susceptor 44 may be a maximum operating temperature of the susceptor 44 .
  • FIG. 5 is a schematic cross-sectional view of an aerosol-generating article 500 .
  • FIG. 6 is a schematic cross-sectional view of an aerosol-generating system 600 comprising the aerosol-generating article 500 of FIG. 5 and an electrically-operated aerosol-generating device 610 comprising a resistive heater configured to heat the aerosol-generating article 500 from within the aerosol-generating article 500 .
  • the aerosol-generating article 500 has generally the same structure as the aerosol-generating article 10 described above with respect to FIG. 1 , where like elements are indicated by like reference signs. Note, however, that the aerosol-generating article 500 does not comprise the susceptor 44 . In addition, the aerosol-generating article does not comprise upstream element 46 .
  • the aerosol-generating device 610 comprises a heating chamber 630 for receiving the aerosol-generating article 500 .
  • a heating element 620 is located within the heating chamber and positioned to engage with the distal end 18 of the aerosol-generating article 500 .
  • the heating element 620 is an electrically resistive heating element shaped in the form of a blade terminating in a point.
  • the heating element 620 may be formed from a ceramic substrate with one or more resistive heating tracks, formed from platinum or another suitable material, deposited on one or both sides of the blade.
  • the heating element 620 may be one or more heating needles or rods that run through the center of the aerosol-forming substrate 510 .
  • the heating element 620 may be deposited in or on a rigid carrier material.
  • the electrically resistive heating element 620 may be formed using a metal having a defined relationship between temperature and resistivity.
  • the metal may be formed as a track on a suitable insulating material, such as ceramic material, and then coated by another insulating material, such as a glass. Heaters formed in this manner may be used to both heat and monitor the temperature of the heating elements during operation.
  • the heating element 620 penetrates into aerosol-forming substrate of the aerosol-generating rod 12 . Further penetration is prevented as the distal end 18 of the aerosol-generating article 500 abuts an end wall 640 of the heating chamber 630 , which acts as a stop.
  • the heating element 620 When the aerosol-generating article 500 is properly engaged with the aerosol-generating device 610 , the heating element 620 is located within the aerosol-forming substrate in contact with aerosol-forming substrate. The heating element 620 heats the aerosol-forming substrate by means of conduction.
  • the aerosol-generating device 610 comprises a power source (not shown) and a heating system (not shown) electrically coupled to the power source.
  • the heating system comprises a controller and the heating element 620 .
  • the power source may be a battery, such as a rechargeable lithium ion battery.
  • the power source is configured to supply power to the heating system in order to heat the heating element 620 .
  • the controller obtains an indication of the temperature of the heating element 620 (for example the electrical resistance of the heating element) by measuring the electrical resistance of the heating element 620 .
  • the indication of the temperature is used to adjust the current supplied to the heating element 620 in order to maintain the heating element 620 close to a target temperature. In other words, the controller adjusts the temperature of the heating element by adjusting the current supplied to the heating element 620 .
  • This scheme relies on three or more temperature calibration points at which the resistance of the heating element 620 is measured. For temperatures intermediate the calibration points, the resistance values are interpolated from the values at the calibration points. The calibration point temperatures are chosen to cover the expected temperature range of the heating element 620 during operation. The calibration of the heating element 620 to obtain the calibration points may be performed at manufacture and the calibration points stored in a memory of the controller.
  • the heating element 620 When the heating element 620 is heated, the aerosol-forming substrate is heated and volatile substances are formed. As a user draws on the proximal end 20 of the aerosol-generating article 500 , air is drawn into the aerosol-generating article 500 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the proximal end 20 of the aerosol-generating article 500 and into the user's mouth.
  • the aerosol-generating device 700 comprises a heating chamber 710 for receiving the aerosol-generating article 500 .
  • the heating chamber 710 is formed by a stainless steel tube 730 and has at an upstream end a base 750 .
  • the heating system further comprises a temperature sensor 740 .
  • the temperature sensor 740 may be a Pt1000 type temperature sensor.
  • the temperature sensor 740 is in thermal contact with heater tracks of the heating element 745 and is configured to measure the temperature of the heater tracks of the heating element 745
  • the first adhesive layer is used to adhere the heating element 745 to the stainless steel tube 730 .
  • Sandwiching the heater tracks between the first and second polyimide layers provides a means of supporting the heater tracks in place and provides electrical insulation between the heater tracks and other components of the aerosol-generating device 700 , particularly the stainless steel tube 730 .
  • Polyimide is advantageously flexible, electrically insulating and able to withstand the normal operation temperatures of the aerosol-generating device, in particular the heater tracks, in use.
  • the heater tracks are continuous, electrically conductive tracks of stainless steel that are deposited on one of the first or second polyimide layers during manufacture. The heater tracks are configured to heat up when an electrical current is passed through them.
  • the heat shrink layer comprises a material that can withstand the normal operation temperatures of the aerosol-generating device, in particular the heater tracks, in use.
  • the aerosol-generating device 700 further comprises a power source 775 , such as a battery.
  • the power source 775 and the temperature sensor 740 are connected to a controller 755 via electrical wires and connections not shown completely in FIG. 7 .
  • the power supply 775 is configured to power the heating element 745 and is connected to connectors of the heater tracks. The heating of the heating element 745 by the power source 775 is controlled by the controller 755 .
  • an aerosol-generating article 500 is inserted to the heating chamber 710 by a user of the system.
  • the user then activates the device. This may be by, for example, pressing a button or inhaling through the mouthpiece 42 of the aerosol-generating article 500 which is detected by a puff sensor, not shown in FIG. 7 .
  • controller 755 is configured to control the supply of power from the power source 775 to the heating element 745 to cause the heating tracks to heat up.
  • the heat from the heating tracks is conducted to the aerosol-forming substrate of the aerosol-generating article 500 through the stainless steel tube 730 .
  • This heating of the aerosol-forming substrate results in vapor being generated that is released into air drawing into the aerosol-forming article 500 via the airflow channel 765 .
  • the vapor then cools and condenses into an aerosol.
  • the controller 755 may measure a value of electrical resistance of the heating element to obtain an indication of the temperature of the heating element 745 in the same manner as the controller of aerosol-generating device 610 described in relation to FIG. 6 .
  • the temperature sensor 740 is an optional component of the aerosol-generating device 700 . Controller 755 then adjusts the temperature of the heating element 745 by adjusting the current supplied to the heating element 745 based on the measured resistance value.
  • the aerosol-generating device generates an aerosol for inhalation by the user and the controller is configured to control the power provided to the heating element in order to adjust the temperature of the heating element in accordance with a heating profile.
  • One or more heating profiles may be stored on a memory of the controller described in relation to FIGS. 1 , 2 , 6 and 7 .
  • the controller may be configured to select a heating profile during user operation of the device to generate an aerosol.
  • the aerosol-generating device may comprise a means for identifying the aerosol-generating article or the aerosol-forming substrate and may select a heating profile based on the result of the identification.
  • FIGS. 9 to 14 are graphs of heating element temperature against time showing exemplary heating profiles of the heating element during the main phase of heating of the aerosol-forming substrate to form an aerosol for inhalation by a user.
  • the illustrated heating profiles define temperature of the heating element during each heating mode and a corresponding duration of each heating mode heating modes. However, it is to be understood that the heating profiles may comprise more than three heating modes.
  • Each of the heating profiles in FIGS. 9 to 14 illustrate that the temperature of the heating element increases from an initial temperature (not shown) to a first temperature in the first heating mode 920 , 1020 , 1120 , 1220 , 1320 , 1420 .
  • the controller may be configured to enter the first heating mode 920 , 1020 , 1120 , 1220 , 1320 , 1420 in response to a user actuation of the aerosol-generating device, or detection of a user puff.
  • the temperature remains constant at the first temperature for the duration of the first time period.
  • the initial temperature is greater than ambient temperature and is between 140 and 170 degrees Celsius. In the case of inductive heating, the initial temperature may be a temperature reached during the calibration process 420 .
  • the heating element 44 may be allowed to cool to a temperature between the first and the second calibration temperatures.
  • the temperature to which the heating element 44 cools may be the initial temperature.
  • the initial temperature may be the pre-heating temperature of the heating element 620 , 745 .
  • the first temperature may be between 245 and 285 degrees Celsius when the aerosol-forming substrate is internally heated.
  • the first temperature may be between 180 and 230 degrees Celsius when the aerosol-forming substrate is externally heated.
  • heating the heating element to the first temperature of the heating element in the first heating mode 920 , 1020 , 1120 , 1220 , 1320 , 1420 the thermal inertia of the aerosol-forming substrate is overcome and the amount of vaporized desired volatile compounds in the aerosol inhaled by the user, such as nicotine and the aerosol former, is improved from the first puff.
  • the controller After a first predetermined time period, the controller enters a second heating mode 930 , 1030 , 1130 , 1230 , 1330 , 1340 .
  • the controller adjusts the temperature of the heating element to one or more second temperatures during a second predetermined time period.
  • the one or more second temperatures may be between 190 and 220 degrees Celsius when the aerosol-forming substrate is internally heated.
  • the one or more second temperatures may be between 180 and 230 degrees Celsius when the aerosol-forming substrate is externally heated.
  • the controller may adjust the temperature of the heating element to be lower than the first temperature, as shown in FIGS. 10 , 11 , 12 and 13 .
  • the first heating mode 920 , 1020 , 1120 , 1220 , 1320 , 1420 heat will have spread throughout the aerosol-forming substrate. Lowering the temperature of the heating element in the second heating mode therefore enables the amount of vaporized desired volatile compounds in the aerosol inhaled by the user to remain consistent with the amount in the first heating mode 920 , 1020 , 1120 , 1220 , 1320 , 1420 , thereby providing the same sensorial experience for the user.
  • the controller may adjust the temperature of the heating element to be higher than the first temperature, as shown in FIG. 14 .
  • the length of the first predetermined time period is chosen so that the aerosol-forming substrate can provide good delivery of volatilized desired compounds in the aerosol.
  • the first predetermined time period being shorter than at least the second predetermined time period ensures good aerosol delivery to the user, while ensuring consistency in the user experience throughout the usage session.
  • the length of the second predetermined time period being longer than at least the first predetermined time period, in particular when the second temperature is lower than the first temperature, provides for improved control of the amount of vaporized desired volatile compounds in the aerosol inhaled by the user, thereby providing a consistent user experience for as long as possible throughout the usage session.
  • FIG. 15 is a flow diagram illustrating a method of controlling aerosol production in one of the aerosol-generating devices by heating a heating article inserted into the heating chamber of the aerosol-generating device as described above.
  • the method begins at step 1510 when the user actuates heating of the heating element as described above.
  • the user may press one or more buttons of the aerosol-generating device to begin the heating of the heating element.
  • the user may insert an aerosol-generating article into the heating chamber of the aerosol-generating device to being the heating of the heating element.
  • step 1520 the controller controls the power provided to the heating system to increase the temperature of the heating element from an ambient temperature to an initial temperature.
  • the controller is in the pre-heating mode and maintains the temperature of the heating element at the initial temperature for a predetermined time period.
  • the pre-heating mode is followed by a calibration process at step 1530 to obtain the first and the second calibration values.
  • the controller uses the first and the second calibration values to adjust the temperature of the susceptor as described above.
  • the controller enters a first heating mode.
  • the controller adjusts the temperature of the heating element to increase the temperature from the initial temperature to a first temperature.
  • the first temperature is maintained for a first predetermined time period.
  • the controller enters a second heating mode at step 1550 .
  • the controller adjusts the temperature of the heating element to a second temperature.
  • the second temperature may be maintained for a second predetermined time period.
  • the second temperature may be a first step of a plurality of temperature steps, each having a predefined duration, where the sum of the predefined duration of each temperature step is the duration of the second predetermined time period of the second heating mode.
  • the second temperature may be lower than, approximately equal to, or greater than the first temperature.
  • the controller enters a third heating mode at step 1560 .
  • the controller adjusts the temperature of the heating element to a third temperature.
  • the third temperature is maintained for a third predetermined time period.
  • the third temperature is approximately equal to the first temperature and is maintained constant for the duration of the third time period.
  • the number A in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. Further, the expression a number A “approximately corresponds to” a number B in the context of this invention, is to be understood as the number A is equal to B ⁇ 10% of B.

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