Aerosol Provision Device

The present application is a National Phase entry of PCT Application No. PCT/EP2023/062046 filed May 5, 2023, which claims priority to GB Application No. 2206677.3 filed May 6, 2022, each of which is hereby incorporated by reference in their entirety.

The present invention relates to an aerosol provision device. The present invention also relates to an aerosol provision system comprising an aerosol provision device and an article comprising aerosol generating material.

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles that burn tobacco by creating 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 be for example tobacco or other non-tobacco products, which may or may not contain nicotine.

In accordance with some embodiments described herein, there is provided an aerosol provision device for generating an aerosol from aerosol-generating material comprising a housing and a heating assembly, the heating assembly comprising: a heating chamber arranged to receive at least a portion of an article comprising aerosol generating material, an inductor coil encircling at least part of the heating chamber, and a coil support on which at least a portion of the inductor coil is positioned, wherein the coil support comprises a locating feature which engages with the housing to locate the heating assembly in position within the housing.

The locating feature may project outwardly from the coil support. The housing may comprise a receiving feature arranged to engage with the locating feature. The receiving feature on the housing may comprise at least one of a channel and groove. The receiving feature may extend axially in a direction from a first end to a second end of the housing.

The locating feature may comprise a protrusion or a tab. The locating feature may comprise a first protrusion and a second protrusion. The first protrusion may be radially offset from the second protrusion.

The receiving feature may comprise a first receiving element arranged to engage with the first protrusion, and a second receiving element arranged to engage with the second protrusion.

The housing may comprise an axially extending aperture, and the first and second receiving elements may be on opposing sides of the axially extending aperture. The housing may be a first housing and the device may comprise a second housing mounted with the first housing. The second housing may cover the axially extending aperture. The device may comprise a second housing mount in which the second housing mount defines the receiving feature. The second housing mount may be attached to the first housing and arranged to attach the first housing to the second housing.

Each locating feature may have a corresponding receiving feature in the housing to receive and locate the coil support within the housing.

The heating assembly may comprise an end support. The end support may be arranged to at least partially support the heating element. The end support may be arranged to at least partially support the coil support.

The device may comprise a connecting configuration arranged to connect the coil support and the end support. The connecting configuration may rotatably align the coil support and the end support. The connecting configuration may be arranged to restrict axial separation of the coil support and the end support. The connecting configuration may comprise at least one of a clip, latch, fastener or hook. The connecting configuration may attach to an attachment feature on the end support. The attachment feature may comprise a protrusion or hook.

The end support may be at least one of at and proximal to a second end of the coil support.

The locating feature may be at least one of at and proximal to a first end of the coil support. The locating feature may comprise a first locating feature, and the end support may comprise a second locating feature. The first and second locating features may be in axial alignment. The first and second locating features may be axially offset.

The receiving feature may be arranged to engage with the second locating feature. The first locating feature may restrict relative rotation between the housing and the coil support. The second locating feature may restrict relative rotation between the housing and the end support. The receiving feature may allow for axial movement of the coil support and the end support within the housing during assembly.

The end support may comprise an engagement feature arranged to engage with the housing. The engagement feature may comprise a clip, latch, fastener or hook.

The housing may comprise a retention feature arranged to engage with the engagement feature. The retention feature may comprise a projection or indentation onto or into which the engagement feature attaches. The engagement feature may restrict axial movement of the end support relative to the housing. The housing may comprise a positioning feature that contacts the end support when the end support is fully inserted into the housing.

In accordance with some embodiments described herein, there is provided an aerosol provision device for generating an aerosol from aerosol-generating material comprising a housing and a heating assembly, the heating assembly comprising: a heating chamber arranged to receive at least a portion of an article comprising aerosol generating material, an inductor coil encircling at least part of the heating chamber, and a coil support on which at least a portion of the inductor coil is positioned, wherein the coil support comprises a locating feature which engages with the housing to locate the heating assembly in position within the housing.

In accordance with some embodiments described herein, there is provided an aerosol provision system comprising the aerosol provision device described above and an article comprising aerosol-generating material.

In accordance with some embodiments described herein, there is provided a method of manufacturing an aerosol provision device for generating an aerosol from aerosol-generating material, comprising: assembling a heating assembly comprising a heating chamber arranged to receive at least a portion of an article comprising aerosol generating material, an inductor coil encircling at least part of the heating chamber, and a coil support on which at least a portion of the inductor coil is positioned; the method comprising engaging a locating feature on the coil support with a receiving feature on the housing to locate the coil support and the housing, and inserting the heating assembly into the housing in an axial direction.

The method may comprise attaching a coil support to an end support. The locating feature may be a first locating feature, the method may comprise comprising engaging a second locating feature on the end support with the receiving feature on the housing to locate the end support and the housing. The method may comprise engaging an engagement feature with the housing to prevent axial movement. The method may comprise inserting the heating assembly into the housing until the end support contacts a positioning feature on the housing.

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 flavorants. Aerosol-generating material may include any plant based material, such as tobacco-containing 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 aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In 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 aerosol-generating material may, for example, comprise from about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % 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 aerosol-generating material is not a requirement.

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

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

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

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

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

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

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

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 volatilize 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.

shows an aerosol provision devicefor generating aerosol from an aerosol generating material. The devicemay be used to heat a replaceable article (not shown) comprising the aerosol generating material, to generate aerosol or other inhalable medium which is inhaled by a user of the device.

The devicecomprises a body. The bodycomprises a housing. In, the housingis shown in partial cutaway. The housingsurrounds and houses various components of the device. An article apertureis formed in one end of the body, through which the article may be inserted for heating by an aerosol generator(refer to). In use, the article may be fully or partially inserted into the aerosol generatorwhere it may be heated by one or more components of the aerosol generator. The aerosol generatorcomprises a heating assembly. The article and the devicetogether form an aerosol provision system.

The housingcomprises a first housingand a second housing. The first housingis attached to the second housing.

The devicemay also include a user-operable control element, such as a button or switch, which operates the devicewhen pressed. For example, a user may turn on the device by operating the switch.

The bodyhas end surfaces of the device. The end of the deviceclosest to the article aperturemay be known as the proximal end (or mouth end)of the devicebecause, in use, it is closest to the mouth of the user. In use, a user inserts an article into the aperture, operates the aerosol generatorto begin heating the aerosol generating material, and draws on the aerosol generated in the device. This causes the aerosol to flow through the devicealong a flow path towards the proximal endof the device.

The other end of the device furthest away from the aperturemay be known as the distal endof the devicebecause, 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 endof the device. The terms proximal and distal as applied to features of the devicewill be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the longitudinal axis.

As used herein, one-piece component refers to a component of the devicewhich is not separable into two or more components following assembly of the device. Integrally formed relates to two or more features that are formed into a one-piece component during a manufacturing stage of the component.

shows a perspective view of the heating assemblyand the housingin axial alignment before assembly. The heating assemblydefines a longitudinal axis. The heating assemblydefines a heating chamber. The article is received in the heating chamberto be heated by the heating assembly. The aerosol generatoris received by the first housing. The heating chamberis inserted axially into the first housing.

The devicecomprises a first housingand a second housing. The first housinghouses the heating assembly. The second housinghouses a power source and at least one electronics module. The first and second housing,are fixedly mounted.

The power source is housed within the second housing. The power source may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the aerosol generatorto supply electrical power when required and under control of a controller to heat the aerosol generating material.

The electronics module may comprise, for example, a printed circuit board (PCB). The PCB may support at least one controller, such as a processor, and memory. The PCB may also comprise one or more electrical tracks to electrically connect together various electronic components of the device. For example, the battery terminals may be electrically connected to the PCB so that power can be distributed throughout the device.

The heating assemblycomprises an induction-type heating system, including a magnetic field generator comprising an inductor coil assembly. The heating assemblycomprises a heating element. The heating element is also known as a susceptor.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

The heating assembly, forming part of the aerosol generator, is an inductive heating assembly and comprises various components to heat the aerosol generating material of the article via an inductive heating process. Induction heating is a process of heating an electrically conducting object (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 heater and the susceptor, allowing for enhanced freedom in construction and application.

The heating element may be hollow and therefore define at least part of a receptacle within which aerosol generating material is received. For example, the article can be inserted into the heating element. The heating element is tubular, with a circular cross section. The heating element has a generally constant diameter along its axial length. In embodiments, the heating element protrudes in the receptacle. Other arrangements are anticipated.