Aerosol Provision Device Comprising a Warming Element

The present application is a National Phase entry of PCT Application No. PCT/EP2022/078486 filed Oct. 13, 2022, which claims priority to GB Application No. 2114648.5 filed Oct. 13, 2021, each of which is hereby incorporated by reference in their entirety.

The present invention relates to an aerosol provision device, an aerosol generating system and a method of generating an aerosol.

Electronic aerosol generating systems such as electronic cigarettes (e-cigarettes) generally contain a reservoir of a source liquid containing a formulation, typically including nicotine, from which an aerosol is generated e.g. through heat vaporization. An aerosol source for an aerosol provision system may thus comprise a heater having a heating element arranged to receive source liquid from the reservoir, for example through wicking or capillary action. While a user inhales on the device, electrical power is supplied to the heating element to vaporize source liquid in the vicinity of the heating element to generate an aerosol for inhalation by the user. Such devices are usually provided with one or more air inlet holes located away from a mouthpiece end of the system. When a user sucks on a mouthpiece connected to the mouthpiece end of the system, air is drawn in through the inlet holes and past the aerosol source. There is a flow path connecting between the aerosol source and an opening in the mouthpiece so that air drawn past the aerosol source continues along the flow path to the mouthpiece opening, carrying some of the aerosol from the aerosol source with it. The aerosol-carrying air exits the aerosol provision system through the mouthpiece opening for inhalation by the user.

Other aerosol provision devices generate aerosol from a solid material, such as tobacco or a tobacco derivative. Such devices operate in a broadly similar manner to the liquid-based systems described above, in that the solid tobacco material is heated to a vaporization temperature to generate an aerosol which is subsequently inhaled by a user.

In most aerosol provision devices, users seek consistent delivery on a puff-by-puff basis such that each puff tastes the same and/or provides the same desired effect. However, the devices described above are not always capable of providing consistent delivery.

It is desired to provide an aerosol provision device which delivers an improved delivery of aerosol and/or which provides a user with an improved sensorial experience.

According to an aspect there is provided an aerosol provision device for generating aerosol from aerosol generating material, the aerosol provision device comprising:

According to various embodiments a warming element is provided in order to prevent or at least substantially reduce the likelihood of aerosol generated from a planar aerosol generating article condensing within a heating chamber. The aerosol generating article may comprise a susceptor. Optionally, the susceptor comprises aluminum. Other embodiments are contemplated wherein the susceptor comprises an aluminum alloy. Optionally, the warming element and the susceptor may be spaced <4 mm apart in use. The warming element may comprise a plate or surface of ferritic material which may be heated to a temperature of e.g. 60-150° C. during a session of use. The warming element may be warmed by receiving a time varying magnetic field generated by one or more induction coils which may comprise the aerosol generator or heater. In alternative embodiments the warming element may be heated by a warming unit which may comprise either one or more resistive heaters and/or one or more inductive heaters which are separate from and distinct to the aerosol generator or heater. The warming elementmay comprise a thin plate, coating or foil which may have a thickness <25 μm. It is not essential that the aerosol generating article comprises a planar aerosol generating article and embodiments are contemplated wherein the reception region is arranged to receive a non-planar aerosol generating article. For example, the aerosol generating article may comprise a curved, corrugated or cylindrical substrate. Embodiments are contemplated wherein the aerosol generating article is cylindrical or has a circular or polygonal cross-sectional area.

According to various embodiments an aerosol provision device is provided comprising a warming element which helps to reduce or substantially prevent condensate forming on the walls of a reception region and/or elsewhere within the aerosol provision device.

According to various embodiments there is provided an aerosol provision device for generating aerosol from aerosol generating material, the aerosol provision device comprising at least one chamber having a warming element. The warming element may comprise ferritic material. The aerosol provision device may comprise a reception region arranged to receive an aerosol generating article comprising aerosol generating material. The aerosol generating article may comprise a planar aerosol generating article. The aerosol provision device may further comprise at least one aerosol generator arranged to cause aerosol to be generated from the aerosol generating material. The reception region may be located between the at least one aerosol generator and the at least one warming element.

Optionally, the aerosol generator comprises one or more first inductors.

Optionally, at least one of the one or more first inductors comprise a substantially planar inductor coil.

Optionally, the one or more first inductors are also arranged to warm the warming element in order to reduce the formation of condensation within the chamber.

Optionally, the aerosol generator comprises one or more first resistive heaters.

Optionally, the aerosol generator is arranged to warm the warming element to a temperature in the range 60-150° C. during a session of use. According to an embodiment the aerosol generator may be arranged to warm the warming element to a temperature in the range 60-70° C., 70-80° C., 80-90° C., 90-100° C., 100-110° C., 110-120° C., 120-130° C., 130-140° C. or 140-150° C.

Optionally, the aerosol provision device further comprises a warming unit arranged to warm the warming element in order to reduce the formation of condensation within the chamber.

Optionally, the warming unit comprises one or more second inductors.

Optionally, the warming unit comprises one or more second resistive heaters.

Optionally, the ferritic material comprises a coating or foil.

Optionally, the ferritic material has a thickness <25 μm. According to various embodiments the ferritic material may have a thickness <5 μm, 5-10 μm, 10-15 μm, 15-20 μm or 20-25 μm.

Optionally, the ferritic material may have a relative magnetic permeability selected from the range: (i) 100-200 μ/μ; (ii) 200-300 μ/μ; (iii) 300-400 μ/μ; (iv) 400-500 μ/μ; (v) 500-600 μ/μ; (vi) 600-700 μ/μ; (vii) 700-800 μ/μ; (viii) 800-900 μ/μ; (ix) 900-1000 μ/μ; (x) 1000-1100 μ/μ; (xi) 1100-1200μ/μ; (xii) 1200-1300 μ/μ; (xiii) 1300-1400 μ/μ; (xiv) 1400-1500 μ/μ; (xv) 1500-1600 μ/μ; (xvi) 1600-1700 μ/μ; (xvii) 1700-1800 μ/μ; (xviii) 1800-1900 μ/μ; (xix) 1900-2000 μ/μ; (xx) >2000 μ/μ.

Optionally, the warming element is planar. Alternatively, the warming element may be curved, concave, convex or dome shaped.

Optionally, the aerosol provision device comprises a plurality of aerosol generators, wherein at least some or each aerosol generator is arranged to cause aerosol to be generated from a different portion of the planar aerosol generating article.

Optionally, the aerosol provision device comprises a plurality of chambers, wherein at least some or each chamber is arranged to receive aerosol generated from a different portion of the planar aerosol generating article.

Optionally, at least some or each chamber comprises a warming element comprising ferritic material.

Optionally, the aerosol provision device is arranged to move, translate or rotate the planar aerosol generating article relative to the at least one aerosol generator during a session of use.

According to another aspect there is provided an aerosol generating system comprising: an aerosol provision device as described above; and

Optionally, the susceptor comprises a metallic foil. Other embodiments are contemplated wherein the susceptor comprises a metallic coating on a substrate.

Optionally, the susceptor comprises aluminum. Other embodiments are contemplated wherein the susceptor comprises an aluminum alloy.

In particular, the susceptor may comprise aluminum foil or an aluminum coating on a substrate. The substrate may provide a degree of rigidity to the planar aerosol generating article.

Optionally, the susceptor either has a relative magnetic permeability 1.0 μ/μor the susceptor has a relative magnetic permeability selected from the group consisting of: (i) <100 μ/μ; (ii) 100-200 μ/μ; (iii) 200-300 μ/μ; (iv) 300-400 μ/μ; (v) 400-500 μ/μ; (vi) 500-600 μ/μ; (vii) 600-700 μ/μ; (viii) 700-800 μ/μ; (ix) 800-900 μ/μ; (x) 900-1000 μ/μ; (xi) 1000-1100 μ/μ; (xii) 1100-1200 μ/μ; (xiii) 1200-1300 μ/μ; (xiv) 1300-1400 μ/μ; (xv) 1400-1500 μ/μ; (xvi) 1500-1600 μ/μ; (xvii) 1600-1700 μ/μ; (xviii) 1700-1800 μ/μ; (xix) 1800-1900 μ/μ; (xx) 1900-2000 μ/μ; and (xxi) >2000 μ/μ.

Optionally, the susceptor has a thickness <10 μm. According to various embodiments the susceptor may have a thickness <1 μm, 1-2 μm, 2-3 μm, 3-4 μm, 4-5 μm, 5-6 μm, 6-7 μm, 7-8 μm, 8-9 μm or 9-10 μm. Other embodiments are contemplated wherein the susceptor may comprise a plurality of layers and may have a total thickness >10 μm.

Optionally, the warming element and the susceptor may be spaced <4 mm apart. For example, according to various embodiments the spacing between the warming element and the susceptor may be <1 mm, 1-2 mm, 2-3 mm or 3-4 mm.

Optionally, the aerosol generator is arranged to heat the susceptor and/or the aerosol generating material to a temperature in the range 200-400° C. during a session of use. According to various embodiments the aerosol generator is arranged to heat the susceptor to a temperature in the range 200-220° C., 220-240° C., 240-260° C., 260-280° C., 280-300° C., 300-320° C., 320-340° C., 340-360° C., 360-380° C. or 380-400° C. during a session of use. According to various embodiments the aerosol generator is arranged to heat the aerosol generating material to a temperature in the range 200-220° C., 220-240° C., 240-260° C., 260-280° C., 280-300° C., 300-320° C., 320-340° C., 340-360° C., 360-380° C. or 380-400° C. during a session of use.

Optionally, the ferritic material has a magnetic permeability μand the susceptor has a magnetic permeability μand wherein the ratio μ/μis <100, 100-500, 500-1000, 1000-1500, 1500-2000, 2000-2500, 2500-3000, 3000-3500, 3500-4000, 4000-4500, 4500-5000 or >5000.

Optionally, the aerosol generator comprises one or more induction coils having a first surface area Ain a plane parallel with a planar surface of the susceptor and wherein the warming element has a second surface area Ain a plane parallel with the planar surface of the susceptor, wherein the ratio A/Ais in the range: (i) 0.7-0.8; (ii) 0.8-0.9; (iii) 0.9-1.0; (iv) 1.0-1.1; (v) 1.1-1.2; and (vi) 1.2-1.3.

According to another aspect there is provided a method of generating aerosol comprising:

Other embodiments are contemplated wherein the aerosol generating article may not necessarily comprise a planar aerosol generating article. For example, embodiments are contemplated wherein the aerosol generating article may comprise a curved, corrugated or non- planar substrate.

According to another aspect there is provided an aerosol provision device for generating aerosol from aerosol generating material, the aerosol provision device comprising:

Optionally, the reception region is located between the at least one aerosol generator and the at least one warming element.

Optionally, the reception region is arranged to receive a planar aerosol generating article comprising aerosol generating material.

According to another aspect there is provided an aerosol generating system comprising:

According to another aspect there is provided a method of generating aerosol comprising:

The method may further comprise activating the aerosol provision device.

While the invention is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description of the specific embodiments are not intended to limit the invention to the particular forms disclosed. On the contrary, the invention covers all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.

Aspects and features of certain examples and embodiments are discussed/described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed/described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

The present disclosure relates to aerosol provision systems, which may also be referred to as aerosol provision systems, such as e-cigarettes. Throughout the following description the term “e-cigarette” or “electronic cigarette” may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol provision system/device and electronic aerosol provision system/device. Furthermore, and as is common in the technical field, the terms “aerosol” and “vapor”, and related terms such as “vaporize”, “volatilize” and “aerosolize”, may generally be used interchangeably.

illustrates a schematic view of a portion of an aerosol provision device. The aerosol provision devicehas an aerosol generating articlearranged within a chamberof the aerosol provision device. The aerosol provision deviceincludes a reception regionwhich is arranged to receive the aerosol generating article. The aerosol generating articlecomprises aerosol generating materialwhich may be provided on a substrate.

According to various embodiments the aerosol generating materialmay be present on or in a support, to form a substrate. The support (or substrate) may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the aerosol generating material. In some alternative embodiments, the susceptor is on one or either side of the aerosol generating material.

According to various embodiments a susceptormay be provided upon the substrate. The susceptormay comprise aluminum foil. However, other embodiments are contemplated wherein no susceptor is provided upon the substrate. Yet further embodiments are contemplated wherein a susceptor made from a material other than aluminum is provided upon the substrate. According to various embodiments the substratemay comprise paper or card. Aerosol generating materialmay be arranged upon the susceptorwhich may comprise aluminum foil. The combination of the aerosol provision deviceand the aerosol generating articleform an aerosol provision system.