WO2023117949A1 - Aerosol provision device - Google Patents

Abstract

An aerosol provision device (101) for generating an aerosol from aerosol-generating material is provided. The device has a receptacle (212) defining a heating zone (215) for receiving at least a portion of an article (110) comprising aerosol-generating material, a heating assembly (201) comprising a heating element (320, 420) arranged to heat the article in the heating zone and a detector arrangement (180) configured to detect a characteristic indicative of a density of aerosol-generating material in a portion of an article received in the heating zone. The device further comprises a control module (244) in communication with the detector arrangement and configured to control an operation of the device in dependence on the characteristic indicative of a density.

Description

AEROSOL PROVISION DEVICE

Technical Field

The present invention relates to aerosol provision device for generating an aerosol from aerosol-generating material. The present invention also relates to a system comprising an aerosol provision device and an article comprising aerosolgenerating material arranged to be at least partially received in the aerosol provision device.

Background

Methods of, and devices for, extraction of compounds from materials have long been used to provide users with the pleasurable or medicinal benefits of the inhalation of such compounds. Attempts have been made to provide products that release compounds without burning. Examples of such products are heating devices which release compounds by heating, but not burning, the material. The material may, for example, contain nicotine.

Summary

In accordance with some embodiments described herein, there is provided an aerosol provision device for generating an aerosol from aerosol-generating material, comprising: a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol-generating material; a detector arrangement configured to detect a characteristic indicative of a density of aerosol-generating material in a portion of an article received in the heating zone; and a control module in communication with the detector arrangement and configured to control an operation of the device in dependence on the characteristic indicative of a density.

The detector arrangement may comprise a sensor.

The detector arrangement may comprise an optical sensor arrangement.

The optical sensor arrangement may include an optical emitter and an optical sensor.

The control module may be configured to determine the characteristic indicative of a density based at least in part on an input from the optical sensor arrangement. The detector arrangement may be configured to determine an image.

The image may be an optical image.

The control module may be configured to determine a characteristic of the image.

The control module may be configured to determine the characteristic of a density based at least in part on the characteristic of the image.

The detector arrangement may be an x-ray imaging arrangement configured to output an x-ray image.

The control module may be configured to determine a characteristic of the x- ray image based at least in part on a grey to black contrast of the x-ray image.

The control module may be configured to determine a characteristic of the x- ray image based at least in part on a pattern recognition analysis of the x-ray image.

The control module may be configured to determine a characteristic of the x- ray image based at least in part on a dot count analysis of the x-ray image.

The control module may be configured to determine the characteristic of a density based at least in part on the characteristic of the x-ray image.

The aerosol provision device may comprise a heating assembly including a heating element arranged to heat the article in the heating zone.

The aerosol provision device may comprise a protruding member protruding in the heating zone configured to pierce at least a portion of an article comprising aerosol-generating material when the article is received in the heating zone.

The protruding member may comprise the heating element.

The aerosol provision device may comprise a load sensor configured to determine an axial force exerted on the protruding member.

The protruding member may be elongate. The protruding member may be a pin-shaped member. The receptacle may comprise a base and the protruding member may upstand from the base in the heating zone. The control module may be configured to determine the characteristic of a density based at least in part on an output from the load sensor.

The detector arrangement may be configured to determine a characteristic of a density for each of two or more distinct regions of the article.

The control module may be configured to operate two or more distinct regions of the heating element independently.

The control module may be configured to control the operation of two or more distinct regions of the heating element based at least in part on the characteristic of a density for each of the two or more regions of the article.

The detector arrangement may comprise a detector module arranged to determine a characteristic indicative of an airflow volume through the device when in use, and wherein the control module is configured to determine the characteristic of a density based at least in part on the characteristic indicative of an airflow volume through the device.

The characteristic indicative of an airflow volume through the device may comprise at least one of a change in temperature and a rate of change of temperature of a temperature sensitive component in the device.

The temperature sensitive component may comprise the heating element.

The detector module may be configured to determine the at least one of a change in temperature and a rate of change of temperature using a measurement of a change in electrical resistance of the temperature sensitive component.

The detector module may be configured to determine a characteristic indicative of an airflow volume through the device by measuring the pressure drop across the heating zone during use.

The detector arrangement may comprise a pressure sensor. The detector arrangement may comprise at least two pressure sensors. The detector module may be configured to measure the pressure drop across the heating zone during use using the outputs from the or each pressure sensor.

The pressure sensor may be a barometer.

The control module may be programmed with a preset heating profile. The control module may be configured to control the airflow through the device in response to the determination of the characteristic of a density.

The control module may be configured to control the operation of the heating assembly in response to the determination of the characteristic of a density.

The control module may be configured to modify a heating profile of the device in response to the determination of the characteristic of a density.

The control module may be configured to determine a type, model or manufacturer of the article in response to the determination of the characteristic of a density.

In accordance with some embodiments described herein, there is provided an aerosol provision system comprising an aerosol provision device of any described above, and an article containing aerosol generating material arranged to be at least partially received in the aerosol provision device.

In accordance with some embodiments described herein, there is provided a method of operating an aerosol provision device for generating an aerosol from aerosol-generating material, the method comprising: detecting a characteristic of at least a portion of an article indicative of a density of aerosol-generating material in the portion of the article received in a heating zone defined by a receptacle of the device; and controlling an operation of the device in dependence on the characteristic indicative of a density.

Controlling an operation of the device may comprise controlling an operation of a heating assembly comprising a heating element arranged to heat the portion of the article received in the heating zone.

In accordance with some embodiments described herein, there is provided a computer program product comprising instructions which, when the program is executed by a processor, cause the processor to carry out the method of any of those described above.

In accordance with some embodiments described herein, there is provided a computer readable medium having stored therein the computer program product described above.

In accordance with some embodiments described herein, there is provided a non-transitory computer readable medium comprising computer readable instructions that, when executed by a processor, cause performance of the method of any described above.

Brief Description of the Drawings

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

Figure 1 shows a front perspective view of an aerosol generating system with an aerosol generating device and an article inserted into the device;

Figure 2 shows schematically the aerosol generating system of Figure 1 ;

Figure 3 shows schematically the aerosol generating system of Figure 1 with a tubular receptacle heating element defining the heating zone;

Figure 4 shows schematically the aerosol generating system of Figure 1 with a heating element protruding into the heating zone; and

Figure 5 shows schematically the aerosol generating system of Figure 1 with a heating element protruding into the heating zone and a load sensor in communication with the heating element.

Detailed Description

As used herein, the term “aerosol-generating material” is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. Aerosolgenerating material may include any plant based material, such as tobaccocontaining material and may, for example, include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Aerosol-generating material also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. Aerosol-generating material may for example be in the form of a solid, a liquid, a gel, a wax or the like. Aerosol-generating material may for example also be a combination or a blend of materials. Aerosol-generating material may also be known as “smokable material”. The aerosol-generating material may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosolgenerating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating material may comprise or be an “amorphous solid”. The amorphous solid may be a “monolithic solid”. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosolgenerating material may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The aerosol-generating material may comprise an aerosol-generating film. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially tobacco free.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosolgenerating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosolgenerating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

An aerosol generating device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article.

Figure 1 shows an example of an aerosol generating system 100. The system 100 comprises an aerosol generating device 101 for generating aerosol from an aerosol generating material, and a replaceable article 110 comprising the aerosol generating material. The device 101 can be used to heat the replaceable article 110 comprising the aerosol generating material, to generate an aerosol or other inhalable material which can be inhaled by a user of the device 101.

The device 101 comprises a housing 103 which surrounds and houses various components of the device 101. The housing 103 is elongate. The device 101 has an opening 104 in one end, through which the article 110 can be inserted for heating by the device 101. The article 110 may be fully or partially inserted into the device 101 for heating by the device 101.

The device 101 may comprise a user-operable control element 106, such as a button or switch, which operates the device 101 when operated, e.g. pressed. For example, a user may activate the device 101 by pressing the switch 106.

The device 101 defines a longitudinal axis 102, along which an article 110 may extend when inserted into the device 101. The opening 104 is aligned on the longitudinal axis 102.

Figure 2 is a schematic illustration of the aerosol generating system 100 of Figure 1 , showing various components of the device 101. It will be appreciated that the device 101 may include other components not shown in Figure 2 and that some components shown in Figure 2 may not be present in some embodiments.

As shown in Figure 2, the device 101 includes an apparatus for heating aerosol-generating material 200. The apparatus 200 includes a heating assembly 201 , a controller (control circuit) 202, and a power source 204. The apparatus 200 comprises a body assembly 210. The body assembly 210 may include a chassis and other components forming part of the device. The heating assembly 201 is configured to heat the aerosol-generating material of an article 110 inserted into the device 101, such that an aerosol is generated from the aerosol generating material. The power source 204 supplies electrical power to the heating assembly 201 , and the heating assembly 201 converts the supplied electrical energy into heat energy for heating the aerosol-generating material. The power source 204 may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery.

The power source 204 may be electrically coupled to the heating assembly 201 to supply electrical power when required and under control of the controller 202 to heat the aerosol generating material. The control circuit 202 may be configured to activate and deactivate the heating assembly 201 based on a user operating the control element 106. For example, the controller 202 may activate the heating assembly 201 in response to a user operating the switch 106.

The end of the device 101 closest to the opening 104 may be known as the proximal end (or mouth end) 107 of the device 101 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 110 into the opening 104, operates the user control 106 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the article 110 along a flow path towards the proximal end of the device 101.

The other end of the device furthest away from the opening 104 may be known as the distal end 108 of the device 101 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device, the aerosol flows in a direction towards the proximal end of the device 101. The terms proximal and distal as applied to features of the device 101 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the axis 102.

The heating assembly 201 may comprise various components to heat the aerosol generating material of the article 110 via an inductive heating process or a resistive heating process, for example. Induction heating is a process of heating an electrically conducting heating element (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive element and the susceptor, allowing for enhanced freedom in construction and application. Resistive heating instead utilises the Joule heating effect arising from the electrical resistance of a material in response to application of a current directly therethrough.

The apparatus 200 includes a heating chamber 211 configured and dimensioned to receive the article 110 to be heated. The heating chamber 211 defines a heating zone 215. In the present example, the article 110 is generally cylindrical, and the heating chamber 211 is correspondingly generally cylindrical in shape. However, other shapes would be possible. The heating chamber 211 is formed by a receptacle 212. The receptacle 212 includes an end wall 213 and a peripheral wall 214. The end wall 213 acts as a base of the receptacle 212. The receptacle 212 in embodiments is a one-piece component. As used herein, the term ‘one-piece component’ is intended to mean that the features are formed together such that no joints are defined therebetween. In other embodiments the receptacle 212 comprises two or more components.

The heating chamber 211 is defined by the inner surfaces of the receptacle 212. The receptacle 212 acts as a support member. The receptacle 212 comprises a generally tubular member. The receptacle 212 extends along and around and substantially coaxial with the longitudinal axis 102 of the device 101. However, other shapes would be possible. The receptacle 212 (and so heating zone 215) is open at its proximal end such that an article 110 inserted into the opening 104 of the device 101 can be received by the heating chamber 211 therethrough. The receptacle 212 is closed at its distal end by the end wall 213. The receptacle 212 may comprise one or more conduits that form part of an air path. In use, the distal end of the article 110 may be positioned in proximity or engagement with the end of the heating chamber 211. Air may pass through the one or more conduits forming part of the air path, into the heating chamber 211 , and flow through the article 110 towards the proximal end of the device 101.

The receptacle 212 may be formed from an insulating material. For example, the receptacle 212 may be formed from a plastic, such as polyether ether ketone (PEEK). Other suitable materials are possible. The receptacle 212 may be formed from such materials ensure that the assembly remains rigid/solid when the heating assembly 201 is operated. Using a non-metallic material for the receptacle 212 may assist with restricting heating of other components of the device 101. The receptacle 212 may be formed from a rigid material to aid support of other components.

Other arrangements for the receptacle 212 would be possible. For example, in an embodiment the end wall 213 is defined by part of the heating assembly 201. In embodiments, the receptacle 212 comprises material that is heatable by penetration with a varying magnetic field. In some embodiments, the receptacle 212 comprises a material heatable by resistive Joule heating.

As illustrated in Figure 3, the heating assembly 201 may comprise a heating element 320 positioned surrounding the heating zone 215. In such an arrangement, the heating element 320 forms the receptacle 212. The heating element 320 defines the peripheral wall 214. The heating element 320 is configured to heat the heating zone 215. The heating zone 215 is defined in the heating chamber 211. In embodiments the heating chamber 211 defines a portion of the heating zone 215 or the extent of the heating zone 215.

The heating element 320 is heatable to heat the heating zone 215. The heating element 320 may be an induction heating element or a resistive heating element. That is, the heating element 320 may comprise a susceptor that is heatable by penetration with a varying magnetic field or a resistive material heatable by passing a current directly therethrough from a power source. If the heating member 320 comprises a susceptor, the susceptor comprises electrically conducting material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from a carbon steel. It will be understood that other suitable materials may be used, for example a ferromagnetic material such as iron, nickel or cobalt. As shown in Figure 2, the heating assembly 201 comprises a magnetic field generator 250. The magnetic field generator 250 is configured to generate one or more varying magnetic fields that penetrate the heating element 320 so as to cause heating in the heating element 320. The magnetic field generator 250 includes an inductor coil arrangement 251. The inductor coil arrangement comprises an inductor coil 252, acting as an inductor element. The inductor coil 252 may be a helical coil, however other arrangements are envisaged. In embodiments, the inductor coil arrangement 251 comprises two or more inductor coils. The two or more inductor coils in embodiments are disposed adjacent to each other and may be aligned co-axially along the axis.

In some examples, in use, the magnetic field generator 250 is configured to heat the heating element 320 to a temperature of between about 200 °C and about 350 °C, such as between about 240°C and about 300°C, or between about 250°C and about 280°C. In examples where the heating element is a resistive heating element, similar or the same temperatures may be reached by resistive heating therein.

The inductor coil 252 may be a helical coil comprising electrically-conductive material, such as copper.

In embodiments, such as that shown in Figures 4 and 5, the heating element 420 extends in the heating zone 215. The heating element 420, acting as a protruding element, protrudes in the heating zone 215. The heating element 420 upstands from the base. The heating element 420 is spaced from the peripheral wall 214. The heating assembly 201 is configured such that when an article 110 is received by the heating chamber 211 , the heating element 420 extends into a distal end of the article 110. The heating element 420 is positioned, in use, within the article 110. The heating element 420 is configured to heat aerosol generating material of an article 110 from within, and for this reason is referred to as an inner heating element.

The heating element 420 extends into the heating chamber 211 from the distal end of the heating chamber 211 along the longitudinal axis 102 of the device (in the axial direction). In embodiments the heating element 420 extends into the heating chamber 211 spaced from the axis 102. The heating element 420 may be off-axis or non-parallel to the axis 102. Although one heating element 420 is shown, it will be understood that in embodiments, the heating assembly 201 comprises a plurality of heating elements 420. Such heating elements in embodiments are spaced from but parallel to each other.

When the heating element 320, 420 of any of the described embodiments utilises heating via magnetic susceptibility, the inductor coil 252 may be disposed external to the receptacle 212. The inductor coil may encircle the heating zone 215. The helical inductor coil may extend around at least a portion of the heating element 320, 420, acting as a susceptor. The helical inductor coil is configured to generate a varying magnetic field that penetrates the heating element 320, 420. The helical inductor coil is arranged coaxially with the heating chamber 211 and longitudinal axis 102.

Although the illustrated embodiments show devices including either a heating element 320 disposed around the heating zone 215 and at least one heating element 420 disposed within the heating zone 215, any of the described embodiments may utilised both a heating element 320 surrounding the heating zone 215 and one or more heating elements 420 within the heating zone 215.

The heating element 420 protrudes in the heating zone 215 and is received by the article 110. Figure 2 shows the article 110 received in the device 101. The article 110 is sized to be received by the receptacle 212. The outer dimensions of the article 110 perpendicular to the longitudinal axis of the article 110 substantially correspond with the inner dimensions of the chamber 211 perpendicular to the longitudinal axis 102 of the device 101 to allow insertion of the article 110 into the receptacle 212. In embodiments, a gap 216 is defined between an outer side 111 of the article 110 and an inner side 217 of the receptacle 212. The gap 216 may act as an air passage along at least part of the axial length of the chamber 211. An insertion end 112 of the article 110 is arranged to lie adjacent to the base of the receptacle 212.

Figure 2 illustrates a basic structure of the device 101. Figure 2 shows an article 110 disposed within the heating zone 215 of a device 101. This is an in-use configuration in which the aerosol-generating material in the article may be heated and a user may draw the aerosolised material from the article/device.

One of the problems associated with the device and article systems described herein is that the articles themselves can often not be produced to have absolute uniformity. This is typically due to the use of organic materials in the aerosol-generating material, such as dried tobacco leaf products. An article for use with a device as described herein may comprise compacted strips of dried tobacco leaf or strips of tobacco derived material such as band-cast reconstituted tobacco. It can be appreciated that the exact arrangement of such small strips of aerosolgenerating material when compacted cannot be easily predicted or controlled. Such variation in arrangement of aerosol-generating strips in an article inevitably leads to a non-uniform density profile within the article. This means that produced articles may vary in terms of their internal distribution and density. Whilst this does not usually render the articles unsuitable for their purpose, as known devices do not account for such variation, the article may not be consumed in a most efficient manner. For example, when the same heating power/profile is applied to articles with varying overall density, the articles with a lower density may be exposed to a higher then optimal heat and be spent too quickly. In this way, the aerosolised material may not be delivered in a consistent manner across an intended time span. On the other hand, if an article with a higher expected density is consumed, the aerosol-generating material may not be fully consumed when the allotted time span is over, or the heating element may not be provided with enough power to effectively generated an aerosol from the relatively dense material. This results in a waste of aerosol-generating material and/or a reduction in the desired user experience.

In addition to variations in overall density, if the density of an article varies with location, i.e. portions of the article comprise denser regions of compacted strips of aerosol-generating material as compared with others, the denser regions will experience different rates of generation of aerosolised material to the less dense regions. Again, this may result in waste of aerosol-generating material and also a reduction in the desired user experience due to inconsistent and/or ineffective aerosol generation.

Another problem with such devices is that the density of articles for use in the devices may vary between model and/or between manufacturer (third party articles). If the heating assembly 201 is incapable of distinguishing between these differing articles, the heating of the articles may not be optimised. The ability of the device to distinguish between different article types, and therefore adjust its operation accordingly, may be used to either prevent or facilitate the use of third party or alternate model articles in the device.

The density fluctuations between articles as discussed above also give rise to fluctuations in the airflow through the article/device during operation. For example, generally less dense articles will promote a greater airflow. This may either compromise the heating of the aerosol-generating material or further accelerate the heating thereof, depending on the particular configuration of the device and its heating assembly 201. In articles with varying density regions, the airflow may tend to only or mostly flow through those regions with a lower density, making the denser regions under-exposed to the airflow and therefore unutilised. This fluctuation in aerosol generation intensity and quantity further decreases the user experience and increases wastage.

To address these problems, a device 101 comprising a detector arrangement 180 is provided. The detector arrangement 180 is configured to detect a characteristic indicative of a density of aerosol-generating material in an article. A control module 244 is also provided within the control circuit 202 of the device, which is capable of controlling/modifying the operation of the heating assembly 201 based on the detected characteristic indicative of density. A processor 220 is provided. The processor 220 is part of the control module 244 configured to control the device 101. The processor 220 is part of the control module 244 configured to control the heating assembly 201 and the detector arrangement 180. The control module 244 is configured to control the heating assembly 201 in dependence on the output of the detector arrangement 180. The control module 244 comprises a memory 230. The processor 220 is operable to control the heating assembly 201 to control heating in the heating zone. The processor 220 is operable to control the detector arrangement 180 to determine a characteristic of the article 110 received in the heating zone 215. The control module 244 in some embodiments is part of the heating assembly 201 and/or detector arrangement 180.

The density of an article 110 inserted into the device may be approximated in a number of ways. One such method requires the presence of a protruding member in the heating zone 215, which is configured to be inserted into the article 110 when said article 110 is inserted into the device 101. This may be, for example, the heating element 420, as shown in figures 4 and 5, although it is also envisaged that a similar element can be provided, which is not a heating element 420, but it still configured to be inserted into the article 110. This embodiment will however be from here on described in relation to the heating element 420.

The device 101 of this embodiment may comprise either, or both, of heating elements 320 and 420. As shown in figure 5, the heating element 420 is provided with a load sensor 500. This load sensor 500 is configured to sense an axial force exerted on the heating element 420 in a direction towards the distal end 213 of the receptacle 212. During insertion of the article 110 into the device 101 , and therefore insertion of the heating element 420 into the article 110, since the article 110 will exhibit some resistance to the insertion of the heating element 420 therein, an axial force will be imparted onto the heating element 420 towards the distal end 213 of the receptacle, where it is sensed by the load sensor 500.

It can be appreciated that the magnitude of this sensed axial force will vary depending on the density of the article 110 inserted on the heating element 420. The denser the article 110, the higher axial force must be imparted onto the article 110, and therefore onto the load sensor 500, in order to fully insert the article 110 into the device 101. The sensed force therefore provides an indication of the density of the article 110, in particular the density of the aerosol-generating material therein. The force sensed by the load sensor 500 is passed electronically to the controller 202 and is used subsequently by the control module 244, which forms part of the controller 202. The controller 202 then uses preset models or tables to generate an approximated value for the density of the article 110.

The force information passed to the controller 202 may be a maximum force experienced during insertion of the article 110 by the load sensor 500. The force information could be an average force experienced by the load sensor 500 during the insertion of the article 110. These parameters would provide a singular approximated value for the density of the article 110. In embodiments, the load sensor 500 may record sensed force information over the insertion of the article 110, i.e. provide a relationship between the amount of the heating element 420 inserted into the article 110 (as a linear distance) and the force sensed at a selected number of points along the full insertion of the heating element 420. This would map a distribution of the density of the article 110 at least along the length of the article 110 into which the heating element 420 extends. The device 101 may further be provided with a sensor (not shown) configured to determine the length of the heating element 420 inserted into the article 110 at any given time, to aid in the density distribution mapping, as the controller 202 would then have inputs of both force and distance of insertion.

Other methods of approximating the density of an article 110 inserted into the device 101 may utilise optical analysis. In some embodiments, an optical sensor arrangement 181 comprising an optical emitter (not shown) may be included in the device, positioned such that it is able to emit light towards the article 110 when the article 110 is inserted into the device 101. For example, the optical sensor arrangement 181 may comprise two or more optical emitters, which may be placed at multiple locations inside the heating zone 215, at various axial and circumferential positions around the article 110. The optical sensor arrangement may further comprise one or more optical sensors, which are placed in the device, positioned such that they can detect light emitted by the one or more optical emitters, which has passed through at least a portion of the article 110. The one or more optical sensors may also be positioned at various locations around the length and circumference the article 110. In one embodiment, the number of optical emitters and number of optical sensors is equal and each optical emitter is paired with an optical sensor. The use of a multitude of paired optical emitters and optical sensors in opposing positions around the length and circumference of an article 110 can be used, using the respective intensities of light emitted by an optical emitter of a pair and sensed by an optical sensor of a pair, to generate information indicative of the density of the article 110 at different locations therein, which is then sent to the controller 202. Alternatively, just one optical emitter and optical sensor pair can be provided, which is used to determine an intensity of light passing through the article 110 from the optical emitter to the optical sensor. This would provide a singular intensity value which may be used by the controller 202 to determine a singular approximated value for the density of the article 110.

Alternatively, the optical sensor arrangement 181 may be configured to determine an optical image. The optical image may comprise a spatial intensity distribution of light detected from the one or more optical emitters, having passed through the article 110. The image may be transmitted electronically to the controller 202 and therein subject to analysis to approximate the density distribution of the article 110. The controller 202 is configured to determine a characteristic of the image, such as the overall brightness (representative of intensity of sensed light), or the brightness distribution. In some embodiments, the optical sensor arrangement 181 is an x-ray imaging arrangement 182, the one or more optical emitters emit x-ray light, and the one or more optical sensors are configured to sense x-ray light. In such embodiments, the controller 202 may be configured to measure a grey to black contrast of an image produced by the one or more optical sensors. The controller 202 may also, alternatively or additionally, be configured to use pattern recognition on an optical image produced by the one or more optical sensors, and/or use dot count analysis to approximate the density of the article.

As an alternative, or in addition, to the aforementioned methods of approximating the density of an article 110 inserted into the device 101 , the device 101 may utilise the airflow through the device 101 in use to approximate the density of an article 110 inserted therein. One of the ways in which this may be done is to provide a sensor arrangement capable of determining the resistance of the heating element 320 and/or 420. This could be, for example, a sensor arrangement comprising a voltmeter and an ammeter, configured to determine the potential difference and current flowing through the heating element 320 and/or 420 at any given time, and thereby measure the resistance of the heating element 320 and/or 420. In embodiments where the heating element 320 and/or 420 is a resistive heating element, this sensor arrangement may be easily implemented, since an electrical current-carrying circuit is already in operative connection with the heating element, and a current is passed therethrough during use of the device 101. It is known that the resistance of a conductor varies with the temperature of the conductor. It is also known that the flow of a relatively cool fluid through/past a relatively warm object will cause cooling of the object. Therefore, the amount of airflow passing through the heating zone 215 of the device 101, during use, and contacting the heating element 320 and/or 420, is proportional to the cooling of the heating element 320 and/or 420. Using a known relationship between the temperature of the heating element 320 and/or 420, the controller 202 is able to approximate the magnitude of airflow through an article 110 during use of the device 101. The controller 202 is then able to use the approximated magnitude of airflow to approximate the density of the article 110. In general, a higher airflow through the article 110 will mean a lower density of the article 110. The controller 202 may be pre-configured to recognise normal ranges of airflow through the device 101 in order to determine whether the article 110 deviates from the normal range, and therefore whether the article 110 is more or less dense for the current device configuration.

Another way in which the airflow through the device 101 may be utilised to approximate the density of an article 110 located therein is to measure the pressure drop, or change in airflow magnitude, across the article 110. To achieve this, one or more sensors 190 may be provided with the device 101. The sensors 190 are each capable of sensing a parameter indicative of a magnitude of airflow or an ambient pressure at the location of the sensor. The sensors 190, may be microphone sensors, for example, which measure noise due to air turbulence. Additionally or alternatively, the sensors 190 are pressure sensors, which may comprise barometers. In some embodiments, a first sensor 190 is placed proximate an airflow inlet to the article 110 or device 101. A second sensor 190 is placed at a position further along the airflow path of the device 101 and article 110. For example, the second sensor 190 is proximate the distal end of the article 110, where air enters the article 110. The second sensor 190 may alternatively be proximate the proximal end of the article 110, where air leaves the article 110. The second sensor 190 may also be located within the article 110, when the article 110 is located in the heating zone, for example situated on the heating element 420. Each sensor is in operative communication with the controller 202. The controller 202 is configured to receive a sensor reading from each of the first and second sensors characteristic of an airflow magnitude or ambient pressure. The controller 202 is configured to compare the inputs from the first and second sensors 190 and generate a comparison result. The comparison result is indicative of the density of the article 110. In other embodiments, only one sensor 190 is included with the device. The controller 202 in these embodiments is configured to estimate the density of the article 110 based on the reading from this sensor alone. In devices with a mouthpiece defining the opening 104, the second sensor may be positioned within the mouthpiece in the airflow path directly proximate the opening and the users mouth in use.

The controller 202 of the device 101 may be programmed with a heating profile. This heating profile defines a preset relationship between the airflow through the device and the heating power applied to an article 110. In devices 101 wherein airflow can be manually adjusted, the controller 202 is able to adjust the heating power of the heating element 320 and/or 420 to accommodate for the change in airflow. Similarly, when heating power is manually increased by a user, the controller 202 may adjust the airflow through the device to accommodate for the change in heating power. Such adjustments may also be made by the controller 202 in situations without manual adjustment. For example, the controller 202 may increase or decrease heating power after detection of a high airflow through the device caused by a strong draw of air therethrough by a user. The controller 202 may also adjust the heating power of the device in response to determination of ambient air temperature, in order to deliver a consistent heating of the article 110 and therefore consistent level of aerosol generation. This preset relationship between airflow and heating power may be called the heating profile of the device 101.

Using any of the abovementioned methods of approximating the density of an article 110, the controller 202 may use the approximated value of the density to modify the heating profile of the device 101. For example, after detection of a denser-than-normal article 110, the heating profile may be adjusted such that the controller 202 causes more heating power to be delivered to the article, for any given airflow setting of the device 101. Similarly, the controller 202 may adjust the airflow through the device 101 , in response to detecting such an article density, for any such heating power. In this way, the controller 202 does not simply adjust the heating power or airflow of the device in response to the approximation of the density of an article 110, but adjusts the heating profile itself, such that the device 101 can operate in a modified airflow and heating power relationship. This means that the device 101 may automatically adjust its heating power in response to a measured airflow through the device and vice versa, but the relationship of this automatic adjustment is further optimised by the density measurement of the article 110.

It is also envisaged that some devices 101 do not operate using a defined heating profile, and there is no automatic adjustment of heating power in response to a measured airflow through the device and vice versa. In such devices 101 , the controller 202 may be configured to simply adjust either, or both, of the heating power and airflow through the device in response to an approximation of the density of an article 110 inserted therein. For example, the controller 202 may be configured to modify the magnitude of the airflow through the device 101 proportional to the approximated density of the article 110. The controller 202 may additionally or alternatively be configured to modify the heating power of the heating assembly 201 , i.e. to increase the operating temperature of the heating element 320 and/or 420, proportional to the approximated density of the article 110.

As discussed above, some methods of the approximation of the density of the article 110 are capable of not only determining a value for the overall density of the article 110, but also determining a spatial density distribution of the article 110. The analysis performed by the controller 202 in such embodiments may determine such spatial density distribution with various degrees of resolution. For example, the article 110 may be notionally divided into any number of cylindrical axial segments, and the density of each axial segment approximated. Alternatively, the controller 202 may be configured to analyse the density of the article 110 in each of two or more circumferential segments defined by the full axial length of the article 110, two or more radii of the axial cross-section of the article 110 and the arc length between two neighbouring defined radii. For example, analysing the article 110 in terms of two circumferential segments would be equivalent to splitting the article 110 into two semi-cylinders. The article 110 may be notionally split into any combination of axial and circumferential segments by the controller 202, or any other geometric division, and the density of each whole segment assigned an approximated value for its density. The benefits of providing a spatial density analysis are such that the controller 202 may adjust operating parameters of the device such as airflow and heating power in localised regions of the heating zone 215. In other words, the device 101 may comprise complex heating elements 320 and/or 420, which are themselves segmented, and are capable of delivering heat to specific portions of an article 110 inserted in the device 101 through individually controlled heating of each heating element segment. The device 101 may additionally or alternatively comprise a complex airflow passage through the heating zone 215, which can be manipulated to not only change the overall airflow through the device 101 , but also the direction and magnitude across particular regions of the heating zone 215. In one example, the controller 202 is configured to approximate the density of two distinctly defined segments of an article 110 inserted in the heating zone 215. The controller 202 determines that a first of these article segments is more dense than the second. In this scenario, the controller 202 operates the heating assembly 201 to provide more heating power to a first heating element segment, proximate the first article segment, than to a second heating element segment proximate the second article segment. In another example, the controller 202 may adjust the airflow through the device 101 such that, when a user draws air through the device 101 , a greater quantity of air flows past/through the first denser article segment, as compared with the relatively less dense second article segment. Of course, it will be appreciated that the controller 202 may be provided with both of these functionalities.

In devices with a heating profile, the heating profile may also be defined in the controller 202 with respect to localised heating element segments and airflow path manipulation parameters. In such devices, the controller 202 may adjust the heating profile of the device 101 in a manner such that the heating profile airflow and heating power relationships are modified in a localised manner. In this way, the modified heating profile adjusts the airflow and localised heating power to account for density variations in the article 110, but still further allows automatic adjustments of airflow and heating power based on variable external parameters, such as user draw strength, ambient temperature and manual airflow/heating power adjustments. This combination of features optimises the user experience by providing greater efficiency, both in terms of power consumption of the device 101 and utilisation of the aerosol-generating material in the article. The user also experiences a more uniform delivery of aerosolised material over the course of consumption of the article 110.

In addition to the abovementioned advantages, which result from all embodiments in which the density of an article 110 is determined and device operating parameters are adjusted in response thereto, the ability of the device 101 to approximate the density of an article 110 inserted therein also presents further benefits. For example, the density of an article 110 may be a unique identifier of a particular model of article 110, or a brand of article 110. If the controller 202, through approximation of a density of an article 110, is able to identify a particular brand or model of article 101, it is able to either facilitate or hinder the consumption of third party articles 110 with the device 101. Furthermore, the controller 202 may contain pre-stored data, which is used to identify a particular model and/or brand of article 110, and then utilise a corresponding preset heating profile therefor, thereby optimising the heating and consumption of the article 110.

In any of the embodiments described, the device 101 may be configured to heat the article 110 by producing a varying magnetic field configured to heat a susceptor heating element positioned within the article 110. That is, the article itself may further comprise a susceptor heating element. When located in the heating zone, the susceptor heating element positioned within the article generates heat in the presence of the varying magnetic field and thereby heats the article and produces aerosolised material from the aerosol-generating material.

In some of the above described embodiments, the heating arrangement is an inductive heating arrangement. In other embodiments, other types of heating arrangement are used, such as resistive heating. The configuration of the device is generally as described above and so a detailed description will be omitted. In such arrangements the heating assembly 201 comprises a resistive heating generator including components to heat the heating element via a resistive heating process. In this case, an electrical current is directly applied to a resistive heating component, and the resulting flow of current in the heating component causes the heating component to be heated by Joule heating. The resistive heating component comprises resistive material configured to generate heat when a suitable electrical current passes through it, and the heating assembly 201 comprises electrical contacts for supplying electrical current to the resistive material.

In embodiments, the heating element forms the resistive heating component itself. In embodiments the resistive heating component transfers heat to the heating element, for example by conduction.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

24 CLAIMS

1. An aerosol provision device for generating an aerosol from aerosolgenerating material, comprising: a receptacle defining a heating zone for receiving at least a portion of an article comprising aerosol-generating material; a detector arrangement configured to detect a characteristic indicative of a density of aerosol-generating material in a portion of an article received in the heating zone; and a control module in communication with the detector arrangement and configured to control an operation of the device in dependence on the characteristic indicative of a density.

2. The aerosol provision device of claim 1, wherein the detector arrangement comprises an optical sensor arrangement.

3. The optical sensor arrangement of claim 2, wherein the optical sensor arrangement comprises an optical emitter and an optical sensor.

4. The aerosol provision device of claim 2 or 3, wherein the control module is configured to determine the characteristic indicative of a density based at least in part on an input from the optical sensor arrangement.

5. The aerosol provision device of any of claims 1 to 4, wherein the detector arrangement is configured to determine an image.

6. The aerosol provision device of claim 5, wherein the control module is configured to determine a characteristic of the image.

7. The aerosol provision device of claim 6, wherein the control module is configured to determine the characteristic of a density based at least in part on the characteristic of the image.

8. The aerosol provision device of any of claims 5 to 7, wherein the detector arrangement is an x-ray imaging arrangement configured to output an x-ray image.

9. The aerosol provision device of any of claims 1 to 8, comprising a heating assembly including a heating element arranged to heat the article in the heating zone.

10. The aerosol provision device of claim 9, comprising a protruding member protruding in the heating zone configured to pierce at least a portion of an article comprising aerosol-generating material when the article is received in the heating zone.

11 . The aerosol provision device of claim 10, wherein the protruding member comprises the heating element.

12. The aerosol provision device of claim 10 or 11 , comprising a load sensor configured to determine an axial force exerted on the protruding member.

13. The aerosol provision device of claim 12, wherein the control module is configured to determine the characteristic of a density based at least in part on an output from the load sensor.

14. The aerosol provision device of any of claims 1 to 13, wherein the detector arrangement comprises a detector module arranged to determine a characteristic indicative of an airflow volume through the device when in use, and wherein the control module is configured to determine the characteristic of a density based at least in part on the characteristic indicative of an airflow volume through the device.

15. The aerosol provision device of claim 14, wherein the characteristic indicative of an airflow volume through the device comprises at least one of a change in temperature and a rate of change of temperature of a temperature sensitive component in the device.

16. The aerosol generating device of claim 14, wherein the detector module is configured to determine a characteristic indicative of an airflow volume through the device by measuring the pressure drop across the heating zone during use.

17. The aerosol generating device of any of claims 1 to 16, wherein the control module is configured to modify a heating profile of the device in response to the determination of the characteristic of a density.

18. An aerosol provision system comprising an aerosol provision device of any of claims 1 to 17, and an article containing aerosol generating material arranged to be at least partially received in the aerosol provision device.

19. A method of operating an aerosol provision device for generating an aerosol from aerosol-generating material, the method comprising: detecting a characteristic of at least a portion of an article indicative of a density of aerosol-generating material in the portion of the article received in a heating zone defined by a receptacle of the device; and controlling an operation of the device in dependence on the characteristic indicative of a density.

20. The method of claim 19, wherein controlling an operation of the device comprises controlling an operation of a heating assembly comprising a heating element arranged to heat the portion of the article received in the heating zone.