Field of the Disclosure

The present disclosure relates to an aerosol generation device having a baffle for retaining heated gases in a heating chamber. The disclosure is particularly applicable to a portable aerosol generation device, which may be self-contained and low temperature. Such devices may heat, rather than burn, tobacco or other suitable materials by conduction, convection, and/or radiation, to generate an aerosol for inhalation.

Background to the Disclosure

The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat or warm aerosolisable substances as opposed to burning tobacco in conventional tobacco products.

A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn device. Devices of this type generate an aerosol or vapour by heating an aerosol substrate that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range 100°C to 350°C. Heating an aerosol substrate, but not combusting or burning it, releases an aerosol that comprises the components sought by the user but less or no carcinogenic by-products of combustion and burning.

In general terms it is desirable to rapidly heat the aerosol substrate to, and to maintain the aerosol substrate at, a temperature at which an aerosol may be released therefrom without burning. It will be apparent that the aerosol released in the heating chamber from the aerosol substrate is delivered to the user when there is air flow passing through the aerosol substrate.

Aerosol generation devices of this type are portable devices and so energy consumption is an important design consideration. The present invention aims to address issues with existing devices and to provide an improved aerosol generation device and heating chamber therefor.

Summary of the Disclosure

According to a first aspect of the disclosure there is provided an aerosol generation device comprising: a heating chamber having a tubular wall extending around a central axis, the tubular wall defining an interior volume of the heating chamber, the heating chamber having an open end and being arranged to receive a substrate carrier comprising an aerosol substrate through the open end into the interior volume along the central axis; a heater extending around the heating chamber to supply heat to the heating chamber; and a baffle having a sealing surface facing out of the open end, the baffle being arranged to deform such that the sealing surface is deflected to face more towards the central axis and hence towards a side wall of the substrate carrier when the substrate carrier is inserted into the heating chamber.

The deflection of the sealing surface may allow an effective seal to be formed against the side wall of the substrate carrier. It will be appreciated that the deflection or folding of the sealing surface is typically towards the interior volume or away from the open end. The deflection or folding of the sealing surface may increase the surface area of the baffle that faces the central axis and hence the side wall of the substrate carrier. Moreover, when the sealing surface is not deflected, e.g. when the substrate carrier is not present, the baffle may extend across the open end of the heating chamber to a greater extent than when the side wall is deflected. For example, the open end may be a least partially blocked by the baffle, such that any aperture through the baffle is smaller than a cross-sectional extent, e.g. width, of the substrate carrier. The baffle in general, and specifically the deflected sealing surface in cooperation with the side wall of the substrate carrier when the substrate carrier has been inserted, may allow heated air to be retained in the heating chamber, which in turn can improve the efficiency of the aerosol generation device as energy expended in heating the air in the heating chamber is not wasted by allowing that air to escape the heating chamber.

The heater may be positioned externally of the heating chamber. The heater may be mounted on an external surface of the heating chamber or form a portion of the tubular wall of the heating chamber or be mounted on an internal surface of the tubular wall of the heating chamber. The heater may be mounted on a surface of the tubular wall facing away from the interior volume of the heating chamber. Heat from the externally positioned heater is transferred through the tubular wall to the interior volume. More specifically, heat is transferred from the externally positioned heater by conduction through the tubular wall to the interior volume. Heat may be transferred from the tubular wall directly to the aerosol substrate and/or from the tubular wall indirectly to the aerosol substrate by heating air that flows towards the aerosol substrate from the open end.

The heating chamber may have a base and the tubular wall may extend between the open end and the base. The base may be closed so that air is drawn exclusively into the heating chamber through the open end towards the aerosol substrate, and more specifically between an outer layer of the substrate carrier and the tubular wall towards the aerosol substrate.

Optionally, a distance between an innermost portion of the baffle and the central axis is less than a distance between an inner surface of the tubular wall and the central axis. That is, a distance between a portion of the baffle closest to the central axis and the central axis is less than a distance between an inner surface of the tubular wall and the central axis.

Optionally, the baffle is arranged proximate to the open end of the heating chamber. For example, the baffle is closer to the open end than to the opposite end of the heating chamber.

Optionally, the baffle is resiliently deformable.

Optionally, the baffle is a membrane comprising at least two portions defined by a slit therebetween, the portions being configured to be deformably partable to receive the substrate carrier into the heating chamber. In one example, the slit extends radially with respect to the tubular wall. In some examples, there are two or more slits, which may intersect with one another at the central axis.

Optionally, the baffle has at least one perforation configured to allow air flow therethrough.

Optionally, the baffle is arranged at least partially inside the heating chamber.

Optionally, the baffle is located outside the heating chamber, arranged adjacent or spaced away from the open end of the heating chamber.

Optionally, the baffle extends from the tubular wall.

Optionally, the baffle (completely) encircles a/the central axis.

Optionally, the baffle is made from a material having a first thermal conductivity and the tubular wall is made from a material having a second thermal conductivity, wherein the first thermal conductivity is less than the second thermal conductivity.

Optionally, the baffle has a taper in a direction away from the interior volume of the heating chamber such that the opening defined by the baffle for receiving the substrate carrier therethrough narrows towards the interior volume of the heating chamber.

Optionally, the baffle comprises a first baffle element and a second baffle element located concentrically and axially spaced apart from one another along a length of the tubular wall.

Optionally, the baffle comprises an elastomeric material. Optionally, the baffle is made of silicone rubber.

Optionally, the baffle is resiliently deformable from a sealing configuration into an inflow configuration upon suction through the substrate carrier by a user to permit air flow between the baffle and the substrate carrier into the interior volume of the heating chamber. The sealing configuration may be one in which the baffle is deformed to receive a substrate carrier, and the inflow configuration may be one in which an air gap is formed between the baffle and the substrate carrier to allow air to flow into the heating chamber.

Optionally, the baffle extends further towards the central axis in the sealing configuration than in the inflow configuration. Optionally, the baffle defines an opening for receiving the substrate carrier therethrough, wherein the opening has a width smaller than a width of the substrate carrier.

Optionally, the aerosol generation device further comprises an electrical power source; and control circuitry configured to control the supply of electrical power from the electrical power source to the heater.

Optionally, the heating chamber comprises a base arranged at the opposite end of the tubular wall to the open end, and further optionally wherein a distance between the baffle and the base of the heating chamber is approximately equal to a length of the aerosol substrate carried by the substrate carrier.

According to a second aspect of the disclosure there is provided an aerosol generation device comprising: a heating chamber having a tubular wall defining an interior volume of the heating chamber and having an open end, the heating chamber being arranged to receive a substrate carrier comprising an aerosol substrate through the open end into the interior volume of the heating chamber; the tubular wall being arranged to define an air gap being between the substrate carrier and the tubular wall when the substrate carrier is received in the heating chamber; a heater extending around the heating chamber to supply heat to the heating chamber; and a baffle being arranged for substantially sealing against the substrate carrier and for restricting air flow through the open end, wherein the baffle is deformable to receive the substrate carrier into the heating chamber.

Optionally, the baffle is resiliently deformable from a sealing configuration into an inflow configuration upon suction through the substrate carrier by a user to permit air flow between the baffle and the substrate carrier into the interior volume of the heating chamber. The sealing configuration may be one in which the baffle is deformed to receive a substrate carrier; the inflow configuration may be one in which an air gap is formed between the baffle and the substrate carrier to allow air to flow into the heating chamber.

Optionally, the substrate carrier is more rigid than the baffle. In the sealing configuration, the substrate carrier may therefore deform the baffle without itself being deformed by the baffle (when the substrate carrier is received in the heating chamber).

Optionally, the aerosol generation device of the second aspect may include the optional features described above in respect of the first aspect, in particular, those features relating to the size, position and function of the baffle of the first aspect.

Optionally in each of the above aspects, the baffle is deformable from a first configuration into a second configuration, wherein in the second configuration the substrate carrier is inserted into the heating chamber to allow the baffle to form a seal against the substrate carrier.

Optionally, the baffle is further deformable by air flow through the open end into the interior volume of the heating chamber. According to a third aspect of the disclosure there is provided an aerosol generation system comprising the aerosol generation device described above and the substrate carrier. In other words, the aerosol generation device and the substrate carrier may together form an aspect of the disclosure.

Embodiments of the disclosure are described below, by way of example only, with reference to the accompanying drawings.

Brief Description of the Drawings

Figure 1 is a schematic perspective view of an aerosol generation device according to a first embodiment of the disclosure.

Figure 2 is a schematic cross-sectional view from a side of the aerosol generation device of Figure 1.

Figure 3 is a schematic perspective view of the aerosol generation device of Figure 1 , shown with a substrate carrier of aerosol substrate being loaded into the aerosol generation device.

Figure 4 is a schematic cross-sectional view from the side of the aerosol generation device of Figure 1 , shown with the substrate carrier of aerosol substrate being loaded into the aerosol generation device.

Figure 5 is a schematic perspective view of the aerosol generation device of Figure 1 , shown with the substrate carrier of aerosol substrate loaded into the aerosol generation device.

Figure 6 is a schematic cross-sectional view from the side of the aerosol generation device of Figure 1, shown with the substrate carrier of aerosol substrate loaded into the aerosol generation device.

Figure 7 is a close-up schematic cross-sectional view of a portion of the aerosol generation device as shown in Figure 6.

Figure 8 is a schematic plan view of an aerosol generation device according to a second embodiment of the disclosure.

Figure 9 is a schematic cross-sectional view from the front of the aerosol generation device of Figure 8, shown with the substrate carrier of aerosol substrate loaded into the aerosol generation device.

Figure 10 is a schematic cross-sectional view from a side of the aerosol generation device of Figure 8, perpendicular to the view in Figure 9, shown with the substrate carrier of aerosol substrate loaded into the aerosol generation device.

Figure 11 is a schematic perspective view of an aerosol generation device according to a third embodiment of the disclosure having a baffle comprising perforations. Figure 12 is a detailed schematic cross-sectional view from the side of an aerosol generation device including the heating chamber of Figure 11 , shown with the substrate carrier of aerosol substrate loaded into the aerosol generation device.

Figure 13 is a schematic perspective view of an aerosol generation device according to a fourth embodiment of the disclosure having a baffle comprising a membrane.

Figure 14 is a schematic perspective view of the aerosol generation device of Figure 13, shown with the substrate carrier of aerosol substrate loaded into the aerosol generation device.

Figure 15 is a schematic cross-sectional view from the side of an aerosol generation device according to a fifth embodiment of the disclosure having an alternative air flow arrangement.

Figure 16 is a schematic cross-sectional view from the side of an aerosol generation device according to a sixth embodiment of the disclosure having a baffle arranged inside the heating chamber.

Figure 17 is a schematic cross-sectional view from the side of an aerosol generation device according to a seventh embodiment of the disclosure having a baffle arranged inside the heating chamber and spaced away from an open end.

Figure 18 is a schematic cross-sectional view from the side of an aerosol generation device according to an eighth embodiment of the disclosure having a baffle which is tapered in profile.

Figure 19 is a schematic cross-sectional view from the side of an aerosol generation device according to a ninth embodiment of the disclosure having a baffle with a first baffle element and a second baffle element.

Figure 20 is a schematic cross-sectional view from the side of an aerosol generation device according to a tenth embodiment of the disclosure, shown with a cap being loaded onto the aerosol generation device and a baffle arranged on the cap.

Figure 21 is a schematic cross-sectional view from the side of the aerosol generation device of Figure 20, shown with the cap loaded onto the aerosol generation device.

Figure 22 is a schematic cross-sectional view from the side of an aerosol generation device according to an eleventh embodiment of the disclosure.

Detailed Description of the Embodiments

First Embodiment

Referring to Figures 1 to 7, according to a first embodiment of the disclosure, an aerosol generation device 100 comprises an outer casing 102 housing various components of the aerosol generation device 100. In the first embodiment, the outer casing 102 has an irregular shape, but it will be appreciated that any shape is possible, so long as it is sized to fit the components described in the various embodiments set out herein.

A first end 104 of the aerosol generation device 100, shown towards the bottom of each of Figures 1 to 6, is described for convenience as a bottom, base or lower end of the aerosol generation device 100. A second end 106 of the aerosol generation device 100, shown towards the top of each of Figures 1 to 7, is described as the top or upper end of the aerosol generation device 100. During use, the user typically orients the aerosol generation device 100 with the first end 104 downward and/or in a distal position with respect to the user’s mouth and the second end 106 upward and/or in a proximate position with respect to the user’s mouth.

The aerosol generation device 100 has a heating chamber 108 located towards the second end 106 of the aerosol generation device 100. The heating chamber 108 is open towards the second end 106 of the aerosol generation device 100. In other words, the heating chamber 108 has an open first end 110 towards the second end 106 of the aerosol generation device 100. The heating chamber 108 has a side wall 114 extending between the open first end 110 and a base 112 (located at a second end of the heating chamber 108, opposite the open end 110). The side wall 114 and the base 112 are connected to one another. In some embodiments the side wall 114 and the base 112 are formed as a single piece. In the first embodiment, the side wall 114 is tubular. More specifically, it is cylindrical, extending around a central axis X. However, in other embodiments the side wall 114 has other suitable shapes, such as a tube with an elliptical or polygonal cross section, in each case extending around a central axis X. In yet further embodiments the side wall 114 is tapered. An aperture in the outer casing 102 at the second end 106 of the aerosol generation device 100 is aligned with the open end 110 to allow insertion of the substrate carrier 130. The heating chamber 108 is held spaced apart from an inner surface of the outer casing 102 to inhibit heat flow to the outer casing 102. In order to increase the thermal isolation of the heating chamber 108 further, the heating chamber 108 may be surrounded by insulation, for example a fibrous or foam material, such as cotton wool, aerogel or gas or in other examples vacuum insulation may be provided.

The heating chamber 108 is arranged to receive a substrate carrier 130, also known as a “consumable”, as illustrated in Figures 3 to 7. Typically, the substrate carrier 130 comprises a pre-packaged aerosol substrate 132, such as tobacco or another suitable aerosolisable material provided together with an aerosol collection region 134. Both the aerosol substrate 132 and the aerosol collection region 134 are wrapped in an outer layer 136, and abut one another part way along the substrate carrier 130 at a boundary. The aerosol substrate 132 is heatable to generate an aerosol for inhalation and is located towards the first end 138 (or “tip”) of the substrate carrier 130. The aerosol substrate 132 extends across the entire width of the substrate carrier 130 within the outer layer 136. In other embodiments the heating chamber 108 is arranged to receive the aerosol substrate 132 in other forms, such as loose shredded material or solid material packaged in other ways. The substrate carrier 130 is generally cylindrical. The aerosol substrate 132 is arranged along less than 50% of a length of the substrate carrier 130 (along the cylindrical axis), preferably between 20% and 40%, more preferably between 30% and 40%, for example around 36% (which is equivalent to around 20 mm of a 55 mm long substrate carrier 130). Although not shown in Figures 3 to 7, the substrate carrier 130 may further comprise a filter towards the second end 140.

In the first embodiment, the base 112 of the heating chamber 108 is closed, e.g. sealed or air-tight. That is, the heating chamber 108 is cup-shaped. This can ensure that air drawn from the open first end 110 is prevented by the base 112 from flowing out of the second end and is guided through the aerosol substrate 132 instead. It can also ensure a user inserts the substrate carrier 130 into the heating chamber 108 an intended distance and no further.

A heater 118 is mounted on an external surface of the heating chamber 108. That is to say, the heater 118 is mounted on a surface of the tubular side wall 114 facing away from an interior volume of the heating chamber 108. This can help to protect the heater 118 from damage as the substrate carrier 130 is inserted into the heating chamber 108. The heater 118 is usually electrically powered. In the first embodiment the heater 118 is a film heater comprising an electrically conductive (e.g. metal) track layered on a flexible, electrically insulating backing material (such as polyimide).

In the first embodiment, the aerosol generation device 100 is electrically powered. That is, it is arranged to heat the aerosol substrate 132 using electrical power. For this purpose, the aerosol generation device 100 has an electrical power source 120, e.g. a battery. The electrical power source 120 is coupled to control circuitry 122. The control circuitry 122 is in turn coupled to the heater 118. A user operates the aerosol generation device 100 using control means (not shown), arranged to cause coupling and uncoupling of the electrical power source 120 to the heater 118 via the control circuitry 122. This in turn causes the heater 118 to heat up and supply heat to the heating chamber 108. Where a substrate carrier 130 is present, the heat is transferred (usually primarily by conduction or convection) to the aerosol substrate 132, which releases vapours or aerosols for a user to inhale by sucking on the second end 140 of the substrate carrier 130.

The aerosol generation device 100 is shown without the substrate carrier 130 in Figures 1 and 2. In Figures 3 and 4, the substrate carrier 130 is shown above the aerosol generation device 100, but not loaded in the aerosol generation device 100. In Figures 5 to 7, the substrate carrier 130 is shown loaded in the aerosol generation device 100. As shown in Figures 1 to 7, the aerosol generation device 100 comprises a baffle 142. The baffle 142 is arranged towards the second end 106 of the aerosol generation device 100, between the aperture in the outer casing 102 and the open end 110 of the heating chamber 108. The baffle 142 may be mounted in place using any appropriate method, including for example: an interference fit; the baffle 142 being held in a groove; attachment with adhesive or other bonding methods; and clamping the baffle 142 in place using protrusions or flanges. As will be shown in the following embodiments, the baffle 142 may be arranged in different locations, such as on an internal surface of the tubular wall 114. In such cases, the mounting methods listed above, or any other suitable method may be used to position the baffle 142 in this location. In the first embodiment, the baffle 142 is an annular shape having an outer circular shape. The baffle 142 of the first embodiment comprises an inner circular shape having an inner circumference which defines a central aperture 144 for receiving the substrate carrier 130. Thus, the central aperture 144 has a circular shape.

Alternatively, the central aperture 144 is an elliptical or oval shape, such as the baffle 242 of the second embodiment. In other examples the central aperture 144 has other cross- sectional shapes e.g. square, triangular, star polygon, or is otherwise polygonal.

The baffle 142 and the central aperture 144 are centred about the central axis X such that a central region (e.g. the geometric centre or centroid) of the radial cross section of the baffle 142 is aligned with the central axis X. In other words the central aperture 144 encircles the central axis X. In the first embodiment, the central aperture 144 is circular and is centred on a point coinciding with the geometric centre of the interior volume defined by the tubular wall 114 of the heating chamber 108. Thus, the central aperture 144 is arranged concentrically with the tubular wall 114 of the heating chamber 108. The central aperture 144 has a width smaller than a width of the tubular wall 114. In the first embodiment, the central aperture 144 has a diameter smaller than a diameter of the tubular wall 114. In other examples, for example where the central aperture 144 is not circular, a smallest width of the central aperture 144 (as measured through the centroid of the central aperture 144) is smaller than a width of the tubular wall 114. The baffle 142 reduces the cross section of the space through which the substrate carrier 130 is received. This is achieved by providing the central aperture 144 with a width smaller than the width of the open end 110. This means that the substrate carrier 130 cannot be inserted into the heating chamber 108 through the central aperture 144 without contacting the baffle 142, and in particular the substrate carrier 130 contacts a sealing surface 143 located close to the central axis. When the substrate carrier 130 is inserted, the tip 138 of the substrate carrier 130 contacts the sealing surface 143 and pushes the sealing surface 143 downwards (towards the base 112 of the heating chamber 108). This downward force causes the baffle 142 to deform such that the sealing surface 143 is deflected from its original position (facing away from the base 112 and interior volume of the heating chamber 108) to a sealing position in which it faces more towards the central axis X and hence towards the outer surface of the substrate carrier 130. This allows the sealing surface 143 to form a seal with a side wall of the substrate carrier, where the sealing surface 143 contacts the substrate carrier 130.

The baffle 142 is deformable. In particular, the baffle 142 is made from a deformable material, for example a resiliently deformable material. In other words, the baffle 142 is made from a pliant or flexible material. The baffle 142 has material properties including being flexible, pliable, and/or bendable. The baffle 142 is resiliently deformable. For example, the baffle 142 is made from an elastomeric material, or rubber, or silicone. In particular, the baffle 142 is deformable to the extent that it is able to be deformed by a user inserting the substrate carrier 130 into the heating chamber 108, as described in more detail below.

This deformation may cause the baffle 142 to stretch to allow it to better conform to the surface of the substrate carrier 130 and thereby to form a seal. In addition, elastic or elastomeric materials usually have the property that they return to their original shape when the reason for their deformation is removed. In the present application, this property can help to prevent ingress of dirt, dust, water etc. into the heating chamber 108 when no substrate carrier 130 is present as the baffle 142 may return to a position in which the open end 110 is partially, substantially or even fully blocked, depending on the embodiment. The baffle 142 is also deformable such that the baffle 142 is not damaged by the deformation. That is, the substrate carrier 130 is pushed against the baffle 142, deforming the baffle 142 and allowing the substrate carrier 130 therethrough and into the heating chamber 108. This results in the baffle 142 deflecting and pressing against the substrate carrier 130 (when the substrate carrier is inserted) and forming a seal to retain heated air inside the heating chamber 108. The baffle 142 may be formed from a heat resistant material and/or a thermally insulating material, for example a heat resistant and/or thermally insulating material suitable for use in medical devices.

The baffle 142 extends further towards the central axis X than the tubular wall 114 extends. As a result, the baffle 142 comprises a lip portion that extends beyond the tubular wall 114 towards the central axis X. This narrows the cross-sectional area at the second end 106 relative to the cross-sectional area at the open end 110 defined by the tubular wall 114 of the heating chamber 108, which can help to provide a covering effect and keep the interior volume of the heating chamber 108 clean and free from dirt, dust, water, etc. even when no substrate carrier 130 is present.

Referring to Figures 1 to 4, when the substrate carrier 130 is not inserted into the heating chamber 108, the baffle 142 is in a first configuration. The first configuration involves the baffle 142 in a resting position, in a non-deformed state where it partially covers the open end 110 or an edge of the interior volume of the heating chamber 108 and defines a central aperture 144.

Referring to Figures 5 and 6, when the substrate carrier 130 is inserted into the heating chamber 108, the baffle 142 is deformed from the first configuration into a second, or sealing, configuration. In the second configuration the baffle 142 is in a deformed position, where the baffle 142 is deflected and bent to allow the substrate carrier 130 to be received into the heating chamber 108 through the central aperture 144. The sealing surface 143 is deflected to face more towards the central axis X than when the baffle 142 is not deflected (e.g. because a substrate carrier 130 is not inserted into the heating chamber 108). The baffle 142 forms a seal against the substrate carrier 130 in the second configuration. In the first embodiment, as the baffle 142 is annular and the central aperture 144 is circular, the baffle 142 (specifically the sealing surface 143) contacts and forms a complete seal around the circumference of the cylindrical substrate carrier 130. In other embodiments, the baffle 142 forms a partial seal against the substrate carrier 130 in the second configuration, such as for the elliptical baffle 242 of the second embodiment in which the baffle 242 contacts only a portion of the circumference of the substrate carrier 130 and makes only an intermittent seal against a circumference of the substrate carrier 130, or where perforations 346 are provided in the third embodiment, or where the baffle 442 seals against the entire circumference of the substrate carrier 130 with a slit membrane forming a valve in the fourth embodiment. In any case, the purpose of the baffle 142 in this and other embodiments is to form a seal to inhibit the flow of warmed air and vapours or aerosol generated by the heating (as described elsewhere in more detail) out of the heating chamber 108. This improves efficiency as energy used to heat the air and generate the vapours and aerosols is not wasted, nor is the vapour (or aerosol) itself, as it is blocked from egress by the baffle 142.

During use, air is able to flow into the heating chamber 108 from the environment around the aerosol generation device 100 to allow inhalation of aerosol, otherwise, no air is available to be inhaled through the aerosol substrate 132 to draw aerosol towards the user. Additionally, air enters the heating chamber 108 in order to be heated and subsequently heat and aerosolise the aerosol substrate 132 by convection. In the first embodiment, air can enter the heating chamber through the open end 110. However, when the substrate carrier 130 is loaded into the heating chamber 108 and the baffle 142 is deformed to form a seal, air is restricted from passing through the open end 110. In the first embodiment, such as shown in Figure 6, air is substantially prevented from flowing through the open end 110 in this position. The baffle 142 is in a second, sealing, configuration in this state.

When a user draws on the substrate carrier 130, the pressure within the heating chamber 108 is reduced to lower than the pressure of the environment external to the heating chamber 108. That is, there is a pressure differential across the seal formed between the baffle 142 and the substrate carrier 130. In the first embodiment, the application of a negative pressure is sufficient to further deform the baffle 142 from the second, sealing, configuration into a third, inflow, configuration. Referring to Figure 7, the baffle 142 is shown in the third, inflow, configuration. In the third configuration, the baffle 142 is pulled away from the substrate carrier 130 by air flow entering the open end 110 between the baffle 142 and the substrate carrier 130. That is, the baffle 142 further deforms towards the interior volume and the base 112 of the heating chamber 108. In particular, the baffle 142 further deforms away from the central axis X, and towards the tubular wall 114, causing the seal between the sealing surface 143 and the substrate carrier to be broken, thereby allowing air to flow in from the exterior of the aerosol generation device 100 to replenish the heated air sucked out through the substrate carrier 130 by the user. In other words the deformation further widens the central aperture 144 and allows the pressure differential to be equalised. In the third configuration, sufficient air can be supplied to the heating chamber 108 to be heated and cause vaporisation of the aerosol substrate 132. As a user sucks aerosol in the direction of Arrows A indicated in Figure 7, air is drawn into the heating chamber 108. The air flow between the baffle 142 and the substrate carrier 130 is indicated by Arrows B in Figure 7, as the baffle 142 is deformed into the third configuration to allow air flow into the heating chamber 108 as the user applies suction.

When the user ceases drawing on the substrate carrier 130, the pressure is no longer applied, and the baffle 142 resiliently returns to the second configuration. That is, the baffle 142 is resiliently deformable from the second configuration to the third configuration upon suction through the substrate carrier 130 by the user. This permits air flow temporarily through the open end 110 while the baffle 142 is in the third configuration when suction is applied. Therefore, when a user is not drawing on the substrate carrier 130, the baffle 142 maintains a seal against the substrate carrier 130, retaining heat and vapours in between inhalations (informally referred to as puffs), or while the aerosol generation device 100 is not in use and the substrate carrier 130 remains inserted. This can increase heat and vapour retention in between puffs, and can provide thermal insulation to provide faster initial heating.

In the second configuration, the baffle 142 points towards the base 112 of the heating chamber 108 (such as shown in Figure 6). For example, when the baffle 142 returns to the second configuration, this arrangement of the baffle 142 helps prevent backflow (e.g. flow of air, gas, vapour, and/or aerosol) out of the open end 110. This can help resist positive pressure differentials in which the inside of the heating chamber 108 is at a higher pressure than the pressure of the environment external of the aerosol generation device 100. For example, positive pressure differentials may occur when fresh cool air is drawn in from the exterior of the aerosol generation device 100 and subsequently heated thereby increasing the pressure.

Therefore, the baffle 142 restricts unwanted air flow of aerosol out of the heating chamber 108, while allowing air flow into the heating chamber 108 under suction from a user. This creates a one-way valve openable by a user drawing on the aerosol generation device 100. The degree of deformability or flexibility of the baffle 142 is chosen as a compromise between ensuring an adequate seal to inhibit aerosol from escaping and allowing sufficient air flow to enter the heating chamber 108 with sufficient ease that a user does not need to strain to achieve the effects set out herein, or to insert the substrate carrier 130 into the heating chamber 108.

Additionally, the draw resistance is a property that affects user satisfaction. Draw resistance is the amount of suction required to provide sufficient inhalation of aerosol. If the draw resistance is too great, it will be difficult to inhale and will not be pleasant for the user. It is desired to emulate the draw resistance of a cigarette to provide a comfortable and familiar experience.

The draw resistance may be adjusted by varying the degree of flexibility of the baffle 142 and selecting the pressure drop required to deform the baffle 142 away from the substrate carrier 130 to the third configuration to permit air flow. Preferentially, the pressure drop is selected to be in the range of 20 to 120 mm water column and more preferably between 60 to 100 mm water column. In units of pascals, the pressure drop is preferably selected to be in the range of approximately 200 to 1200 Pa and more preferably between approximately 600 to 1000 Pa.

The substrate carrier 130 is inserted into the heating chamber 108 oriented such that the first end 138 of the substrate carrier 130, towards which the aerosol substrate 132 is located, enters the heating chamber 108. The substrate carrier 130 is inserted into the heating chamber 108 until the first end 138 of the substrate carrier 130 rests against the base 112 of the heating chamber 108; that is, until the substrate carrier 130 can be inserted into the heating chamber 108 no further. In other embodiments, the first end 138 of the substrate carrier 130 does not rest against the base 112. This enables air flow between the base 112 and the first end 138. In one embodiment such as the eleventh embodiment, the first end 138 rests of a platform 1180 in the base 112 which is raised to contact a central portion of the first end 138 of the substrate carrier 130, such that air can flow into part of the first end 138.

It will be seen from Figures 5 to 7 that when the substrate carrier 130 has been inserted into the heating chamber 108 as far as it will go, only a part of the length of the substrate carrier 130 is inside the heating chamber 108. A remainder of the length of the substrate carrier 130 protrudes from the heating chamber 108. At least a part of the remainder of the length of the substrate carrier 130 also protrudes from the second end 106 of the aerosol generation device 100. In other embodiments all, or substantially all, of the substrate carrier 130 may be received in the aerosol generation device 100, such that none or substantially none of the substrate carrier 130 protrudes from the aerosol generation device 100.

With the substrate carrier 130 inserted into the heating chamber 108, the aerosol substrate 132 within the substrate carrier 130 is arranged at least partially within the heating chamber 108. In the first embodiment, the aerosol substrate 132 is wholly within the heating chamber 108. This ensures that the entirety of the aerosol substrate 132 can be heated. In the first embodiment, the aerosol substrate 132 is arranged to extend a height longer than the heater 118. That is, the entire length of the heater 118 along the axial length of the heating chamber 108 is overlapped with the aerosol substrate 132. In some embodiments, the pre-packaged amount of the aerosol substrate 132 in the substrate carrier 130 is arranged to extend along the substrate carrier 130 from the first end 138 of the substrate carrier 130 by a distance that is approximately (or even exactly) equal to an internal height of the heating chamber 108 from the base 112 to the open end 110 of the heating chamber 108. This is effectively the same as the length of the tubular wall 114 of the heating chamber 108, inside the heating chamber 108. For example, the boundary between the aerosol substrate 132 and the aerosol collection region 134 may be substantially radially aligned with the baffle 142 when the substrate carrier 130 is inserted into the heating chamber 108. That is, the seal between the baffle 142 and the substrate carrier 130 is aligned with the edge of the aerosol substrate 132. This can provide additional heat and vapour retention within the heating chamber 108 where it is desired e.g. within the aerosol substrate 132.

With the substrate carrier 130 loaded in the aerosol generation device 100, the user switches the aerosol generation device 100 on using the user-operable button 126. This causes electrical power from the electrical power source 120 to be supplied to the heater 118 via (and under the control of) the control circuitry 122. The heater 118 causes heat to be conducted via the tubular wall 114 of the heating chamber 108 into the aerosol substrate 132, causing heating of at least parts of the aerosol substrate 132 to a temperature at which it can begin to release aerosol or vapour.

Once heated to a temperature at which aerosols begin to be generated from the aerosol substrate 132, the user may inhale the vapour by sucking the vapour through the second end 140 of the substrate carrier 130. The user may be alerted that vapour has been formed through use of e.g. a visual or audio cue. Such cues may be determined by e.g. temperature or time measurements. That is, the vapour is generated from the aerosol substrate 132 located at the first end 138 of the substrate carrier 130 in the heating chamber 108 and drawn along the length of the substrate carrier 130, through the aerosol collection region 134 in the substrate carrier 130, to the second end 140 of the substrate carrier 130, where it enters the user’s mouth. This flow of aerosol is illustrated by Arrows A in Figure 7.

It will be appreciated that, as a user sucks air and/or vapour in the direction of Arrows A in Figure 7, air or a mixture of air and vapour flows from the vicinity of the aerosol substrate 132 in the heating chamber 108 through the substrate carrier 130. This action also draws ambient air into the heating chamber 108 (via flow paths indicated by Arrows B in Figure 7) from the environment surrounding the aerosol generation device 100 and between the substrate carrier 130 and parts of the baffle 142. The air drawn into the heating chamber 108 is then heated, and drawn into the substrate carrier 130. The heated air heats the aerosol substrate 132 to cause generation of aerosol by convection. More specifically, in the first embodiment, air enters the heating chamber 108 through a space provided between the tubular wall 114 of the heating chamber 108 and the outer layer 136 of the substrate carrier 130. An outer diameter of the substrate carrier 130 is less than an inner diameter of the heating chamber 108, for this purpose. More specifically, in the first embodiment, the heating chamber 108 has an internal diameter of 10 mm or less, preferably 8 mm or less and most preferably approximately 7.6 mm. This allows the substrate carrier 130 to have a diameter of approximately 7.0 mm (± 0.1 mm). This corresponds to an outer circumference of 21 mm to 22 mm, or more preferably 21.75 mm. In other words, the space between the substrate carrier 130 and the tubular wall 114 of the heating chamber 108 is most preferably approximately 0.1 mm. In other variations, the space is at least 0.2 mm, and in some examples it is up to 0.3 mm. It is noted that Figures 1 to 7 are not necessarily to scale. In some examples, the space between the substrate carrier 130 and the tubular wall 114 may be larger than this to allow space for deformation of the baffle 142. In other examples, the width of the tubular wall 114 is wider towards the open end 110 to provide a recess or a taper to allow the baffle 142 to deform downwards into the interior volume of the heating chamber 108. In such examples, the tubular wall 114 is narrower towards the interior volume of the heating chamber 108 or towards the base 112 to provide more efficient heating of the aerosol substrate 132.

A single inhalation by the user is generally referred to a “puff. In some scenarios, it is desirable to emulate a cigarette smoking experience, which means that the aerosol generation device 100 is typically capable of holding sufficient aerosol substrate 132 to provide a predetermined number of puffs, for example ten to fifteen puffs.

It can be appreciated from Figures 1 to 7 and the accompanying description that, according to the first embodiment, there is provided an aerosol generation device 100 comprising a heating chamber 108 having a tubular wall 114 extending around a central axis X. The tubular wall 114 defines an interior volume of the heating chamber 108 and the heating chamber 108 has an open end 110 and is arranged to receive a substrate carrier 130 comprising an aerosol substrate 132 through the open end 110 into the interior volume along the central axis X. A heater 118 extends around the heating chamber 108 to supply heat to the heating chamber 108. A baffle 142 is provided having a sealing surface 143 facing out of the open end 110, the baffle 142 being arranged to deform such that the sealing surface 143 is deflected to face more towards the central axis X and hence towards a side wall of the substrate carrier 130 when the substrate carrier 130 is inserted into the heating chamber 108. The sealing surface 143 deflecting in this way presses the sealing surface 143 against the substrate carrier 130 to form a seal. This seal can retain heated air in the heating chamber 108 which in turn can improve the efficiency of the aerosol generation device 100 as energy expended in heating the air in the heating chamber 108 is not wasted by allowing that air to escape the heating chamber 108. The baffle 142 is configured to restrict air flow through the open end 110 of the heating chamber 108. When the substrate carrier 130 is inserted into the heating chamber 108 as described above, the baffle 142 is deformed to allow the substrate carrier 130 to be inserted. The baffle 142 remains deformed while the substrate carrier 130 is held in the heating chamber 108. Although the baffle 142 is resiliently deformable, it is not sufficiently resiliently deformable to push the substrate carrier 130 back out of the heating chamber 108 when a user stops pushing the substrate carrier 130 into the heating chamber 108.

When the substrate carrier 130 is inserted into the heating chamber 108 and the baffle 142 is deformed, the baffle 142 restricts air flow through the open end 110 of the heating chamber 108. The baffle 142 forms at least a partial seal with the substrate carrier 130. In the first embodiment, the central aperture 144 of the baffle 142 is a complementary shape to the substrate carrier 130 (i.e. circular) such that a complete seal is formed around the circumference of the substrate carrier 130. Different shaped apertures 144 can be used to adapt the aerosol generation device 100 to differently shaped substrate carriers 130.

In addition, the elastic force from the baffle 142 provides a centring effect in the sense that the substrate carrier 130 is held in the centre of the aperture 144 due to the forces from opposing sides of the deformed baffle 142 cancelling. Where the central aperture 144 is itself located centrally with respect to the central axis X, the net effect is to hold the substrate carrier 130 centrally within the heating chamber 108. This results in an air gap between the substrate carrier 130 and the tubular wall 114 which is approximately constant all the way around the substrate carrier, which can help to ensure that the substrate carrier 130 is evenly heated, and to ensure that the draw resistance is predictable and constant.

When a user has finished using the substrate carrier 130, the substrate carrier 130 is removed from the aerosol generation device 100, for example after: a predetermined number of puffs have been taken, a user determines the aerosol substrate 132 has been expended, or the aerosol generation device 100 determines that the substrate carrier 130 has been consumed. The baffle 142 is deformable to allow the substrate carrier 130 to be removed from the heating chamber 108. Thus, the baffle 142 is resiliently deformable. The baffle 142 is deformable to return to the original non-deformed position (i.e. the first configuration) when the substrate carrier 130 is removed, returning to the original position. The baffle 142 is configured to allow the substrate carrier 130 to be removed without altering the substrate carrier 130. That is, the baffle 142 does not tear the outer layer 136 of the substrate carrier, or cause aerosol substrate 132 to be removed from the substrate carrier 130. Additionally, the deformation does not damage the baffle 142 and the baffle 142 returns to the original position (e.g. as in Figure 2) when the substrate carrier 130 is removed.

Second Embodiment

An aerosol generation device 100 according to a second embodiment is now described with reference to Figures 8 to 10 which respectively show plan and first and second elevation views of an aerosol generation device 100. The aerosol generation device 100 of the second embodiment is identical to the aerosol generation device 100 of the first embodiment described with reference to Figures 1 to 7, except where explained below, and the same reference numerals are used to refer to similar features. Figures 8 to 10 show an aerosol generation device 100 which is identical to the aerosol generation device 100 of the first embodiment, except where explained below.

The baffle 242 of the second embodiment is different to the baffle 142 of the first embodiment, as can be seen in Figure 8. The baffle 242 of the second embodiment has a stadium shaped central aperture 244 instead of the circular shape in the first embodiment. A sealing surface 243 is located on an outwardly facing part of the baffle 242. In the second embodiment, the baffle 242 is a substantially annular shape having an outer circular shape with an outer circumference in contact with the inner surface of the outer casing 102. The baffle 242 of the second embodiment comprises an inner stadium shape having an inner perimeter which defines a central aperture 244. Thus, the central aperture 244 has a stadium shape. In other examples, the central aperture 244 is an ellipse, and in particular an ellipse with an eccentricity of close to zero. In such a case, the central aperture 244 is substantially circular, but the perimeter deviates from an exact circular shape, with some parts being closer to the central axis X than other parts.

Alternatively, the central aperture 244 is an oval shape. In other embodiments, the baffle 242 may be an elliptical annulus having an inner elliptical shape and an outer elliptical shape. In such an example, the outer casing 102 may also be elliptical in cross section to conform to the baffle 242. In some embodiments, the baffle 242 has a narrow portion 242a and a wide portion 242b, which each respectively define a smallest dimension and a largest dimension of the central aperture 244 (wherein each diameter is measured through the centroid of the central aperture 244). The narrow portion 242a extends towards the central axis X substantially along an axis Y illustrated in Figure 8. The axis Y is perpendicular to the central axis X, and is arranged parallel to the width of the baffle 242, which in the second embodiment is also arranged parallel to the base 112. The wide portion 242b extends towards the central axis X substantially along an axis Z illustrated in Figure 8. The axis Z is perpendicular to both the central axis X and the axis Y, and is arranged parallel to the width of the baffle 242, which in the second embodiment is also arranged parallel to the base 112.

In use, as described below, the narrow portion 242a is configured to contact the substrate carrier 130 as the substrate carrier 130 is inserted into the heating chamber 108, while as shown the wide portion 242b does not contact the substrate carrier 130. This can be achieved, for example, by providing a baffle having a narrow portion 242a which is narrower than the substrate carrier 130. As the substrate carrier 130 is inserted into the heating chamber 108, the sealing surface 243, in particular the outwardly facing portion of the baffle 242, is contacted by the tip 134 which forces the sealing surface downwards and deforms the baffle 242 so that the sealing surface faces towards the substrate carrier 130 (and hence towards the central axis X) and forms a seal against the substrate carrier 130.

As shown in Figure 8, a space is provided between parts of the baffle 242 and the substrate carrier 130 to permit air flow therethrough into the heating chamber 108. In Figure 8, the difference in size between the narrow portion 242a and the wide portion 242b is exaggerated to emphasise this effect. By providing a narrow portion 242a and a wide portion 242b, a partial seal can be provided (at the narrow portion 242a) between the baffle 242 and the substrate carrier 130, as described in more detail below. In some cases, both the narrow portion 242a and the wide portion 242b may contact and form a seal against the substrate carrier 130, but the sealing strength and degree of local deflection of the baffle 242 may be different at the narrow portion 242a compared to the wide portion 242b.

In an alternative embodiment, the baffle 242 may have a square-shaped central aperture 244 to receive a circular cross section substrate carrier 130, for example contacting and sealing with the substrate carrier 130 at the sides of the square, while providing a space and an air flow path at the corners of the square. Thus, the dimension between opposite sides of the square corresponds to the narrow portion 242a and the dimension between diagonally opposite corners of the square corresponds to the wide portion 242b. In other examples, the baffle 242 may have a rectangular-shaped central aperture 244, optionally with rounded corners. For example, the baffle 242 may have an elliptical central aperture 244. Figure 9 shows a cross section of the aerosol generation device 100 of the second embodiment in the plane formed by the axis X and the axis Y, showing the narrow portion 242a of the baffle 242 deformed by the substrate carrier 130. In some examples, the wide portion 242b is configured to not contact the substrate carrier 130. As such, the wide portion 242b is not directly deformed by the substrate carrier 130. However, the tension within the baffle 242 from the narrow portion 242a deforming causes the wide portion 242b to also be deformed, but this may be to a lesser extent. Thus, in some examples of the second embodiment, the whole interior perimeter of the baffle 242 may be deformed.

Figure 10 shows a cross section of the baffle 242 in the plane formed by the axis X and the axis Z, showing the wide portion 242b of the baffle 242 which does not contact the substrate carrier 130. Thus, the baffle 242 does not form a seal with the substrate carrier 130 at the wide portion 242b. Overall, the baffle 242 forms a partial seal with the substrate carrier 130. That is, the baffle 242 is sealed at the narrow portion 242a, but is not sealed at the wide portion 242b.

The partial seal is formed due to the narrow portion 242a of the baffle 242 contacting and being deformed by the substrate carrier 130 such that a seal is formed between the narrow portion 242a and the surface of the substrate carrier 130, while the wide portion 242b of the baffle 242 is not in contact with the substrate carrier 130 and provides a space between the baffle 242 and the substrate carrier 130. This is a result of providing an elliptical central aperture 244 and a cylindrical substrate carrier 130. The gaps in the partial seal are configured to provide an air flow path from outside the aerosol generation device 100 into the heating chamber 108 between the baffle 242 and the substrate carrier 130. The air flow paths are indicated by Arrows B in Figure 10.

Providing parts of the baffle 242 to seal against the substrate carrier 130 can improve heat and vapour retention within the heating chamber 108, while the air flow paths allow air into the heating chamber 108 for inhalation. The shape and size of the central aperture 244 may thus be chosen to adjust the size of the space present between parts of the baffle 242 and the substrate carrier 130 to balance heat and vapour retention against ease of drawing fresh air into the heating chamber 108.

Providing a partial seal instead of a complete seal also means that air flow can be provided into the heating chamber 108 without further deforming the baffle 242 to the third configuration such as in the first embodiment. This means that the baffle 242 may be made from a less deformable material.

Third Embodiment

An aerosol generation device according to a third embodiment is now described with reference to Figures 11 and 12. The aerosol generation device 100 of the third embodiment is identical to the aerosol generation device 100 of the first embodiment described with reference to Figures 1 to 7, except where explained below, and the same reference numerals are used to refer to similar features. In particular, Figures 11 and 12 show a detailed view of the heating chamber 108. The aerosol generation device 100 of the third embodiment has an alternative baffle 342 that is different to the baffle 142; 242 of the first and second embodiments.

In more detail, referring to Figures 11 and 12, the baffle 342 is similar to the baffle 142 of the first embodiment, but instead it comprises four perforations 346 and comprises a rim 348. Other variants of the third embodiment may have other numbers of perforations 342, for example one or more, including two, three, five, six, seven, or eight perforations 346, or perhaps more. The perforations 346 may also be referred to as holes, apertures, or gaps. In the third embodiment, the perforations 346 have a circular cross section, although other shapes are envisaged such as a square cross section, and different perforations 346 may have different shaped cross sections.

The baffle 342 has an annular shape and a rim 348 is arranged around an outer circumference of the baffle 342. The rim 348 is an annulus which co-operates with the outer casing 102. That is, an outer circumference of the rim 348 is equal to the inner circumference of the outer casing 102. The rim 348 has an inner circumference which is attached to the baffle 342. A sealing surface 343 is located towards an inner edge of the baffle 342.

The rim 348 provides additional support to the baffle 342 and may allow for a thinner and more flexible baffle 342 while maintaining structure. The rim 348 is made from a sturdy material to support the baffle 342 and maintain the heating chamber 108 in co-operation with the outer casing 102. The baffle 342 may be more flexible than the rim 348 to allow deformation such as described above with reference to the first and second embodiments. In some embodiments, the baffle 342 having perforations 346 may be provided without a rim 348, for example replacing the baffle 242 of the second embodiment. It should also be appreciated that the rim 348 may be provided with baffles of other embodiments, such as a baffle 142 having no perforations according to the first embodiment.

In the third embodiment, the baffle 342 is arranged to extend from the rim 348 towards the central axis X. In the third embodiment, the baffle 342 extends towards the central axis X by the same amount as in the first embodiment. Thus, the total width of the annulus of the baffle 342 is less than the baffle 142 of the first embodiment. The boundary between the baffle 342 and the rim 348 is arranged to axially align with the tubular wall 114 such that the baffle 342 covers part of the interior volume of the heating chamber 108 at the open end 110. Thus, the rim 348 does not overlap the interior volume of the heating chamber 108. The perforations 346 extend through the entirety of the thickness of the baffle 342, allowing air to flow through the baffle 342 in a controlled way.

The perforations 346 are arranged around the annulus of the baffle 342. In the third embodiment, the perforations 346 are arranged evenly-distributed around the annulus of the baffle 342 such that there is an equal separation between each adjacent perforation 346. Providing even separation between perforations 346 enables uniform air flow around the substrate carrier 130, as described below. The perforations 346 have a diameter less than a distance between the inner diameter of the baffle 342 closest to the central axis X and the tubular wall 114. The baffle 342 also comprises a central aperture 344 similar to the central aperture 144 of the first embodiment. The perforations 346 are arranged towards the inner circumference of the annular baffle 342; that is, towards the central aperture 344. As the baffle 342 is arranged closer to the central axis X than the tubular wall 114 is towards the central axis X, the perforations 346 are arranged closer to the central axis X than the tubular wall 114 is towards the central axis X. By this, it is meant that the perforations 346 are arranged radially between the tubular wall 114 and the central axis X. As a result, the perforations 346 are arranged at a position coincident in an axial direction with the interior volume of the heating chamber 108. Therefore, a distance between opposing perforations 346 on opposing sides of the baffle 342 is less than a width of the tubular wall 114. This means that the perforations 346 are arranged to provide fluid communication between the interior volume of the heating chamber 108 through the open end 110 and an outside environment beyond the second end 106 of the aerosol generation device 100. In other words, the perforations 346 provide further apertures between the interior volume of the heating chamber 108 and the outside environment in addition to the central aperture 344. In cases where the baffle 342 has a wider outer diameter than the tubular wall 114, such as the baffle 142 in the first embodiment, the perforations 346 are arranged in a portion of the baffle 342 which is between the tubular wall 114 and the central axis X, as described above, to enable fluid communication with the interior volume of the heating chamber 108 and the outside environment.

Referring to Figure 12, when a user inserts the substrate carrier 130 into the heating chamber 108, the tip 134 contacts the sealing surface 343 and causes the baffle 342 to deform to form a seal against the substrate carrier 130. This results in the sealing surface deflecting to face more towards the substrate carrier 130. This may be regarded as the second configuration, as described above in the first embodiment. In the third embodiment, the perforations 346 are configured to remain open throughout the deformation such that they provide fluid communication between the interior volume of the heating chamber 108 and the outside environment, even when the central aperture 344 is sealed by the substrate carrier 130. As shown in Figure 12, the perforations 346 provide apertures and hence an air flow path through the open end 110 when a substrate carrier 130 is inserted and the baffle 342 otherwise forms a seal. As a user sucks aerosol in the direction of Arrows A in Figure 12, this draws air into the heating chamber 108. The air flow through the perforations 346 in the baffle 342 is indicated by Arrows B in Figure 12. In this manner, the baffle 342 need not be deformable to the third configuration like in the first embodiment to permit air flow, as air flow is instead provided through the perforations 346.

The perforations 346 can alter the draw resistance. This means that more air can be drawn into the heating chamber 108 more easily. The size, number, and positioning of the perforations 346 can be selected to balance the draw resistance and the potential heat loss or vapour loss associated with having such perforations 346. Preferentially, the pressure drop is selected to be in the range of 20 to 120 mm water column and more preferably between 60 to 100 mm water column. In units of pascals, the pressure drop is preferably selected to be in the range of approximately 200 to 1200 Pa and more preferably between approximately 600 to 1000 Pa.

In the third embodiment, the perforations 346 are holes that have a constant diameter through the thickness of the baffle 342. That is, the perforation 346 at an upper surface of the baffle 342 which is arranged nearest to the second end 106 of the aerosol generation device 100 is the same size as at a lower surface of the baffle 342 which is arranged on the opposing side of the baffle 342 nearest to the base 112 of the heating chamber 108. In other embodiments, the perforations 346 have a varying width through the thickness of the baffle 342. As the baffle 342 is deformed into the second configuration, in some examples the size of the perforation 346 is reduced, particularly at the lower surface of the baffle 342, restricting air flow through the perforations 346 if the part of the baffle 342 comprising the perforations 346 is significantly deformed. In some embodiments, the perforations 346 are sized to ensure that even when the baffle 342 is deformed to the second configuration by receiving the substrate carrier 130, the perforations 346 are still sufficiently open to permit air flow. In some embodiments, this involves providing the perforations 346 spaced away from the central aperture 344 to prevent significant deformation of the parts of the baffle 342 comprising the perforations 346, or in alternative embodiments, it involves providing a wide enough perforation 346 to prevent closure of the perforation 346 when deformed, including providing a wider perforation 346 at the lower surface of the baffle 342 which is constricted when deformed, for example.

Furthermore, in some embodiments the baffle 342 is deformable to the third configuration in the same way as in the second embodiment, where the perforations 346 further improve the draw resistance in addition to breaking the seal temporarily in the third configuration as a user applies suction. In some examples of the third embodiment, the perforations 346 can be fitted with one way flow valves such as rubber slit valves or artificial variants of the one-way flow valves found in human veins. This may further aid in retaining heat and aerosol within the heating chamber 108.

While only shown as the heating chamber 108 in Figures 11 and 12, the third embodiment can readily be formed as part of the full aerosol generation device 100, for example replacing heating chamber 108 in Figure 2.

It is to be understood that the perforations 346 in the baffle 342 in the third embodiment can be readily applied to other embodiments, for instance to embodiments having alternative baffles such as the baffle 442 of the fourth embodiment.

Fourth Embodiment

A fourth embodiment is now described with reference to Figures 13 and 14. The aerosol generation device 100 of the fourth embodiment is identical to the aerosol generation device 100 of the first embodiment described with reference to Figures 1 to 7, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the fourth embodiment has an alternative baffle 442 that is different to the baffle 142 of the first embodiment.

In more detail, Figures 13 and 14 show a detailed schematic perspective view of a heating chamber 108 highlighting the baffle 442. Referring to Figure 13, the baffle 442 has a rim 448, wherein the baffle 442 is attached to an inner circumference of the rim 448. The baffle 442 is shown in a first configuration where the baffle 442 is not deformed and a substrate carrier 130 has not been loaded into the heating chamber 108. The baffle 442 comprises a membrane. Alternatively, the baffle 442 may be regarded as a septum or a valve, separating the interior volume of the heating chamber 108 from the outside environment.

The rim 448 is identical to the rim 342 of the third embodiment. The rim 448 has an inner circumference which is attached to the baffle 442. In some embodiments, the baffle 442 of the fourth embodiment having segments 450 as described below may be provided without a rim 448, for example replacing the baffle 142 of the first embodiment. It should also be appreciated that the rim 448 may be provided with baffles of other embodiments, such as a baffle 142 according to the first embodiment. For instance, the baffle 442 may extend to the outer casing 102 such as the baffle 142 in the first embodiment, or the outer circumference of the baffle 442 may be attached to the tubular wall 114, such as in the sixth or seventh embodiments where the baffle 642, 742 is arranged inside the heating chamber 108. The baffle 442 is centred about the central axis X. The baffle 442 comprises a plurality of segments 450 such that the membrane of the baffle 442 is divided into a plurality of segments 450. Referring to Figure 13, the baffle 442 comprises four segments 450. Each segment 450 is approximately a circular sector shape. A circular sector is defined as a portion of a solid circle (i.e. a disk) enclosed by two radial sides separated at the centre of the circle by an angle, the sector having an arc length being a portion of the circumference of the circle between the two radii. In the fourth embodiment, each segment 450 comprises two sides, each defining a boundary of the segment 450. Each of these sides approximately forms a radius of the baffle 442, but may have a length slightly shorter than the radius, as shown in Figure 13. The baffle 442 is divided into four equal-sized circular sector shaped segments 450, with each segment 450 being approximately a quarter-circle. That is, the central angle between the two radial sides of each segment 450 is approximately 90°. This shape is often geometrically referred to as a quadrant. It is to be understood that this embodiment can readily be extrapolated to alternative numbers of segments 450, for instance having six segments 450, each having a central angle of approximately 60°, and so on.

A portion of each segment 450 towards the centre of the baffle 442 is a triangular shape. The shape of the segment 450 may be described as a petaline, leaflet or cuspid shape. The baffle 442 may be described as tetracuspid or quad-cuspid, having four cuspid segments 450. The segments 450 may otherwise be described as flaps, while the membrane of the baffle 442 as a whole is described as a cover.

The segments 450 extend towards the central axis X. Each segment 450 is a circular sector shape with an outer end defining an arc attached to the rim 448, wherein the segment 450 narrows in a triangular shape towards the central axis X, reaching a point at the central axis X. Each segment 450 extends substantially to a point intersecting the central axis X such that each segment 450 meets at the central axis X, which coincides with the geometric centre of the baffle 442. A sealing surface 443 of the baffle 442 is located on the triangular parts of each flap.

The segments 450 are attached to the rim 448 at the outer circumference of the baffle 442. In the fourth embodiment, the segments 450 are joined to one another towards the outer circumference. That is, they are contiguous. The segments 450 are therefore joined to the rim 448 around the entire outer circumference. In other embodiments, the segments 450 are not joined together, and the segments 450 are separate, distinct, and optionally are spaced apart around the rim 448 and are not contiguous with one another, such that the segments 450 are not joined to the rim 448 around the entire outer circumference. The baffle 442 comprises a slit 452 arranged between the segments 450. Referring to Figure 13, the slit 452 is arranged in a cross shape, thereby dividing the baffle 442 into the four individual segments 450. In more detail, the slit 452 is formed from two intersecting slits, intersecting at the centre of the baffle 442. The slit 452 extends through the entire height (or thickness) of the baffle 442. The slit 452 partially separates each segment 450 from one another. In particular, the slit 452 is arranged between radial sides of adjacent segments 450. The slit 452 extends from the centre of the circular membrane of the baffle 442 (i.e. at the central axis X) along each radial side of each segment 450 towards the outer circumference. However, the slit 452 does not extend entirely towards the outer circumference of the membrane of the baffle 442. That is, the slit 452 defines a separation between adjacent segments 450 from the central axis X along part of the radius of the baffle 442. As such, adjacent segments 450 are joined together towards the outer circumference where the slit 452 does not extend to. Therefore, the segments 450 are contiguous towards the outside circumference but are not contiguous towards the centre of the baffle 442.

Overall, the segments 450 can be considered to be attached together at their respective arc lengths, while separated at their radial sides. Therefore, the segments 450 are independently movable at locations where separated from one another by the slit 452. As the baffle 442 is deformable, each segment 450 is deformable and not constrained by being attached to other segments 450. This allows each segment 450 to deform and deflect individually when receiving a substrate carrier 130 as described below.

In the fourth embodiment, the slit 452 is configured to separate the segments 450, but not to provide a significant gap between when no substrate carrier 130 is present. The segments 450 are arranged to touch adjacent segments 450 even though they are not joined together. Additionally, where the points of the segments 450 meet in the centre of the baffle 442, the segments 450 touch each other. The baffle 442 therefore provides a complete cover in the first configuration, and can assist in preventing dirt from entering the heating chamber 108 when the aerosol generation device 100 is not in use. The fourth embodiment therefore provides a seal (e.g. an airtight seal) even in the first configuration where a substrate carrier 130 has not been inserted. However, in some examples, due to the manufacturing process, the slit 452 may have a width large enough to prevent adjacent segments 450 from touching, e.g. where material is cut away to form the slit 452.

As the segments 450 meet but are not joined at the centre of the baffle 442, there is no central aperture defined by the baffle 442, unlike the central aperture 144 in the first embodiment. Thus, there is no aperture or gap between the segments 450 at the central axis X. It is noted that in some cases there may be a small gap where the segments 450 meet due to manufacturing tolerances. However, it is desired that the segments 450 meet in order to provide a baffle 442 which covers the circular area of the baffle 442. Preferably, there is no aperture between the segments 450 at the centre. Any aperture is less than a width of the substrate carrier 130. The ability to provide a baffle 442 with no aperture improves the covering effect of the baffle 442, and helps to keep the interior of the heating chamber 108 clean and free from dirt, dust, moisture etc. when a substrate carrier 130 is not inserted into the heating chamber 108.

In other embodiments, the segments 450 overlap towards the central axis X. In other embodiments, the segments 450 extend to a point close to the central axis X, but do not extend entirely to the central axis X. For example, this would result in a small central aperture between the segments 450 at the centre of the baffle 442. For example, in some embodiments, the points of the segments 450 are rounded at the centre such that the segments 450 do not extend entirely to the centre. In other embodiments, the segments 450 are arranged overlapping adjacent segments 450 to ensure a more complete covering. This would involve the segments 450 extending beyond the central axis X such that the segments 450 overlap in the centre to ensure there is no aperture.

In some examples, the membrane of the baffle 442 is thinner than the annular baffle 142 of the first embodiment. In some examples, the membrane of the baffle 442 is more flexible than the baffle 142 of the first embodiments.

Referring to Figure 14, the substrate carrier 130 can be inserted into the heating chamber 108 when the user wishes to use the aerosol generation device 100. To insert the substrate carrier 130 into the heating chamber 108, the tip 134 of the substrate carrier 130 is pressed against the sealing surface 443, causing the segments 450 to be pushed downwards, deforming the baffle 442 and causing the sealing surface 443 to face more towards the central axis X, and to form a seal against the outer surface of the substrate carrier 130. Continued exertion of a force causes the substrate carrier 130 to be inserted through the baffle 442.

As the baffle 442 comprises no aperture between the segments 450, the substrate carrier 130 must contact the segments 450 of the baffle 442 in order to be inserted into the heating chamber 108. The segments 450 are deformed by the substrate carrier 130 as the substrate carrier 130 is inserted. Therefore, the baffle 442, and in particular, the segments 450 are deformable under the force of the user inserting the substrate carrier 130. The segments 450 are deformable such that as the substrate carrier 130 is inserted through the centre of the baffle 442 towards the heating chamber 108, the segments 450 deform towards the base 112 of the heating chamber 108. The segments 450 are pushed into the interior volume of the heating chamber 108 towards the base 112. In particular, the segments 450 bend about the arc length at the outer diameter arranged between adjacent radial sides defined by the slit 452 such that the segment 450 bends out of the plane of the baffle 442, such that the point(s) on each segment closest to the central axis X in the first configuration are bent towards the base 112. The segments 450 are maintained in the deformed position in the second configuration by the substrate carrier 130 when the substrate carrier 130 is held loaded into the aerosol generation device 100.

The insertion of the substrate carrier 130 involves the segments 450 of the baffle 442 deforming to expose a central aperture 444 which the substrate carrier 130 fills. Thus, the central aperture 444 is defined by the gaps between adjacent segments 442 resulting from the bending of the segments 450. It is noted that although a central aperture 444 is formed by the separation of the segments 450, the central aperture 444 is at least partially filled by the substrate carrier 130 as it is inserted. The segments 450 are deformed until the central aperture 444 is approximately the same width as the width of the substrate carrier 130. As such, the baffle 442 extends less far towards the central axis X when it is deformed by the substrate carrier 130 in order to allow the substrate carrier 130 to be inserted, compared to when it is not deformed. The segments 450 will be bent sufficiently to allow the substrate carrier 130 to be inserted. In some embodiments, the radial side and hence slit 452 along each segment 450 are at least greater than a radius of the substrate carrier 130. That is, a radius of the baffle 442 corresponding to the radius of the substrate carrier 130 is configured to deflect upon insertion of the substrate carrier 130. In some examples, this is less than the size of the slit 452 such that part of the slit exposes part of the central aperture 444 which is not filled by the substrate carrier 130. This can improve air flow as discussed below. In other embodiments where the diameter of the slit 452 is smaller than the diameter of the substrate carrier 130, a portion of the baffle 442 arranged between the outer circumference of the baffle 442 and the slit 452 is also configured to be deformed by the substrate carrier 130, in order to allow the substrate carrier 130 to be inserted.

When the substrate carrier 130 is inserted into the heating chamber 108 and the baffle 442 is deformed, the baffle 442 restricts air flow through the open end 110 of the heating chamber 108. The baffle 442 forms at least a partial seal with the outer layer 136 of the substrate carrier 130. In the fourth embodiment, the segments 450 defining the central aperture 444 of the baffle 442 form a partial seal against the outer layer 136 of the substrate carrier 130. This is because the baffle 442 is deformed to receive the substrate carrier 130 and is under tension from the substrate carrier 130. In the fourth embodiment, the baffle 442 deforms such that the segments 450 separate and are pressed against the substrate carrier 130. However, this is not a complementary shape to the substrate carrier 130 and a complete seal is not formed around the entire circumference of the substrate carrier 130, and instead only a partial seal is formed, with gaps being present particularly between adjacent segments 450, especially where the radius of the slit 452 is greater than the radius of the substrate carrier 130. In one embodiment, the radius of the segments 450 and hence the radius of the slit 452 is the same or less than as the radius of the substrate carrier 130. Therefore, the entire segment 450 is deformed by the insertion of the substrate carrier 130 and the substrate carrier 130 forms a seal against the outer portion of the baffle 442 contiguous around the outer diameter. In this embodiment, the substrate carrier 130 forms a seal in a similar way to the first embodiment, where a seal is formed around the entire circumference of the substrate carrier 130. In such cases, it may be preferable to include perforations in the baffle 442, such as perforations 346 of the third embodiment in order to provide air flow. Advantageously, friction between the segments 450 and the substrate carrier 130 can help in retaining the substrate carrier 130 within the heating chamber 108.

When the substrate carrier 130 is not inserted into the heating chamber 108, the baffle 442 is in the first configuration. Referring to Figure 13, the baffle 442 is shown in the first configuration. In the first configuration, the segments 450 are arranged to touch and the baffle 442 covers the open end 110 or an edge of the interior volume of the heating chamber 108. When the substrate carrier 130 is inserted into the heating chamber 108, the segments 450 of the baffle 442 are deformed from the first configuration into a second configuration. Referring to Figure 14, the baffle 442 is shown in the second configuration. The second configuration involves the baffle 442 in a deformed position, where the segments 450 are deflected and bent to allow the substrate carrier 130 to be received into the heating chamber 108 through the central aperture 444. The baffle 442 forms a partial seal against the substrate carrier 130 in the second configuration.

The partial seal provides advantages of heat retention as described with reference to the first embodiment, while also providing gaps between the substrate carrier 130 and the baffle 442. In particular, the segments 450 will not contact the substrate carrier 130 around the entire circumference of the substrate carrier 130. There is not a complete seal at a point between adjacent segments 450. This provides apertures through which air can flow between the interior volume of the heating chamber 108 and the outside environment. This can improve the draw resistance. In some embodiments, this means that perforations in the baffle such as in the third embodiment are not required, making manufacturing easier. In other embodiments, perforations are also provided in the baffle 442 to further improve draw resistance.

In some embodiments, the segments 450 are arranged to be positioned axially away from the aerosol substrate 132 in the substrate carrier 130 along the central axis X when the substrate carrier 130 is loaded into the heating chamber 108. In particular, the segments 450 may impede heat transfer from the heater 118 to the aerosol substrate 132, especially in examples where the segments 450 are made from a low thermal conductivity material. In one embodiment, the length and/or area of each segment 450 is limited to reduce the interference with heating the aerosol substrate 132. In another embodiment, the baffle 442 is positioned spaced away from the aerosol substrate 132 located within the substrate carrier 130. For example, the baffle 442 may be positioned outside the heating chamber 108 such as in the first, second, fifth, tenth, eleventh or twelfth embodiments.

Similarly to the first embodiment, the baffle 442 is resiliently deformable such that as the substrate carrier 130 is removed, the segments 450 are configured to resiliently move back to the first configuration. This provides a seal when the substrate carrier 130 is removed. This is beneficial where several substrate carriers 130 are used in succession in a relatively short period of time because heat and vapours can be retained better within the heating chamber 108.

In some embodiments, the portions of the slit 452 furthest from the central axis X are provided with means for preventing the slit from tearing the baffle further, for example if a user uses too much force to insert the substrate carrier 130. These means may include a larger perforation or cut-out at the outer part of the slit 452, whereby the increased radius reduces the force concentration. These may also double as perforations, such as perforations 346 of the fourth embodiment. In some cases, they may be made from a tougher material (e.g. thicker) or comprising a hole with a rim (e.g. made from plastic or metal to improve structural support and prevent tearing).

While only shown as the heating chamber 108 in Figures 13 and 14, the fourth embodiment can readily be formed as part of the full aerosol generation device 100, for example replacing heating chamber 108 in Figure 2.

It is to be understood that the baffle 442 comprising segments 450 in the fourth embodiment can be readily applied to other embodiments, for instance to embodiments having the baffle arranged inside the heating chamber such as the baffle 642 of the sixth embodiment.

Fifth Embodiment

A fifth embodiment is now described with reference to Figure 15. The aerosol generation device 100 of the fifth embodiment is identical to the aerosol generation device 100 of the first embodiment described with reference to Figures 1 to 7, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the fifth embodiment has an alternative air flow path to the air flow path of the first embodiment.

In more detail, referring to Figure 15, the aerosol generation device 100 of the fifth embodiment comprises an air inlet 554 in the outer casing 102. The air inlet 554 is arranged in a side wall of the outer casing 102 between the heating chamber 108 and the first end 104 of the aerosol generation device 100. In other embodiments, the air inlet 554 may be arranged in the outer casing 102 at the base, towards the first end 104. In the fifth embodiment, the air inlet 554 is arranged proximate the base 112 of the heating chamber 108. The air inlet 554 provides fluid communication between the outside environment and the interior of the outer casing 102. In some examples, the electrical power source 120 and the control circuitry 122 within the outer casing 102 are isolated from the air flow pathway. For example, in some embodiments, a pipe is provided connected to the air inlet 554 to prevent air flow from interfering with the control circuitry 122 and the electrical power source 120. In some embodiments, the electrical connections 124 are additionally routed around the air flow path to prevent interference or damage.

The heating chamber 108 also comprises an air inlet 558. The air inlet 558 is arranged in the base 112, but in other examples may be provided in the tubular wall 114. The air inlet 558 is arranged in the centre of the base 112, although other positions are envisaged. The air inlet 558 extends through the base 112. The air inlet 558 is configured to provide fluid communication between the interior volume of the heating chamber 108 and the air inlet 554 in the outer casing 102. Therefore, the outside environment is in fluid communication with the interior volume of the heating chamber 108 through the air inlet 554 in the outer casing 102 and through the air inlet 558 in the base 112 of the heating chamber 108.

This air flow pathway provides a path for air to flow from the outside into the heating chamber 108. This is useful in combination with a baffle 542, which is similar to the baffle 142 of the first embodiment, except where explained below, specifically in the sense that insertion of the substrate carrier 130 includes the tip 134 contacting the sealing surface 543 and forcing it downwards to deform the baffle 542 and deflect the sealing surface 543 to face more towards the central axis X to form a seal against the outer surface of the substrate carrier 130. This is beneficial because the baffle 542 can provide a more secure seal when air is not required to be sucked in through the air flow pathway from outside through the open end 110 into the heating chamber 108 between the baffle 542 and the substrate carrier 130 (illustrated by Arrow B in Figure 7). Instead, the alternative air flow pathway from outside through the base 112 into the heating chamber 108 removes the need to provide a baffle 542 which is deformable to allow airflow between the baffle 542 and the substrate carrier 130. Instead, a complete seal can be achieved between the baffle 542 and the substrate carrier 130, improving the efficiency of heat retention, while air flow is achieved from underneath. For example, to achieve a better seal, the flexibility of the baffle 542 can be reduced or the deformability can be reduced. In alternative embodiments, to achieve a better seal the baffle 542 extends further towards the central axis X than in the first embodiment. However, in other embodiments, the baffle 542 is also deformable to the third configuration to allow for more air flow into the heating chamber 108 to improve the draw resistance. When a user applies suction to the substrate carrier 130 in a direction indicated by Arrow A in Figure 15, air can be drawn from the outside through the air inlet 554 in the outer casing 102, in a direction indicated by Arrow C in Figure 15, and through the air inlet 558 in the base 112 into the heating chamber 108, in a direction indicated by Arrow D in Figure 15. The air is generally heated as it enters the heating chamber 108, such that the air assists in transferring heat to the aerosol substrate 132 by convection.

It will be appreciated that the air flow path through the heating chamber 108 is generally linear in the fifth embodiment; that is from the base 112 of the heating chamber 108 to the open end 110 of the heating chamber 108. The arrangement of the fifth embodiment also allows the gap between the tubular wall 114 of the heating chamber 108 and the substrate carrier 130 to be reduced. Indeed, in the fifth embodiment, the diameter of the heating chamber 108 is less than 7.6 mm, and the space between the substrate carrier 130, having a diameter of 7.4 mm, and the tubular wall 114 of the heating chamber 108 is less than 1 mm. It is noted that Figure 15 is not to scale.

In other embodiments, the air inlet 554 in the outer casing 102 is located at the first end 104 of the aerosol generation device 100. This allows the passage of air through the entire aerosol generation device 100 to be broadly linear, e.g. with air entering the aerosol generation device 100 at the first end 104, which is typically oriented distal to the user during use, flowing through (or over, past, etc.) the aerosol substrate 132 within the aerosol generation device 100 and out into the user’s mouth at the second end 140 of the substrate carrier 130, which is typically oriented proximal to the user during use, e.g. in the user’s mouth.

Because air flow into the heating chamber 108 can be achieved entirely by using the air inlets 554, 558, the inlets 554, 558 can be sized, shaped, and positioned appropriately to achieve the desired effects. More specifically, the air inlets 554, 558 can be sized to allow a desired draw resistance, and optionally further to balance this draw resistance with heat losses through the inlets 554, 558. In some examples, the air inlets 554, 558 can be provided with a one-way flow valve to reduce heat leakage. In some examples, the air inlets 558 may be located elsewhere on the heating chamber 108, for example on the tubular wall 114. In such cases, multiple air inlets 554 may be located distributed around and/or along the tubular wall 114.

It is to be understood that the alternative air flow pathway of the fifth embodiment can be readily applied to other embodiments, for instance to embodiments having an alternative baffle such as the baffle 442 of the fourth embodiment. Sixth Embodiment

A sixth embodiment is now described with reference to Figure 16. The aerosol generation device 100 of the sixth embodiment is identical to the aerosol generation device 100 of the first embodiment described with reference to Figures 1 to 7, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the sixth embodiment has an alternative baffle 642 that is different to the baffle 142 of the first embodiment.

In more detail, referring to Figure 16, the baffle 642 is arranged inside the heating chamber 108. In particular, the baffle 642 is attached to the internal surface of the tubular wall 114. The baffle 642 extends from the tubular wall 114 towards the central axis X. The baffle 642 is arranged proximal to the open end 110 of the heating chamber 108 in the axial direction. In the sixth embodiment, the baffle 642 is arranged inside the heating chamber 108 and arranged such that an upper surface of the baffle 642 nearest the second end 106 of the aerosol generation device 100 is substantially aligned with the open end 110. In other embodiments, the baffle 642 is spaced away from the open end 110 towards the base 112 such as in the seventh embodiment.

An outer circumference of the baffle 642 is thus in contact and attached to the tubular wall 114. For example, the baffle 642 is fixed to the tubular wall 114 with adhesive. Alternatively, the baffle 642 is received into a recess or ledge within the tubular wall 114 of the heating chamber 108. In other embodiments, the tubular wall 114 is crimped or bent over the upper surface of the baffle 642 to further secure the baffle 642.

In the sixth embodiment, the baffle 642 is annular and has a similar shape to the baffle 142 of the first embodiment. As the outer circumference of the baffle 642 abuts the tubular wall 114, the baffle 642 of the sixth embodiment is thus smaller than the baffle 142 of the first embodiment. The baffle 642 comprises a central aperture 644 defined by an inner diameter of the annulus of the baffle 642. A width of the central aperture 644 is hence smaller than the width of the tubular wall 114. In the sixth embodiment, the central aperture 644 is the same width as the central aperture 144 of the first embodiment. Therefore, the baffle 642 of the sixth embodiment extends from the tubular wall 114 towards the central axis X by the same amount than the baffle 142 of the first embodiment extends beyond the tubular wall 114 towards the central axis X. Therefore, the sixth embodiment provides an alternative arrangement that provides a similarly-sized central aperture 644 when compared with the central aperture 144 of the first embodiment. Thus the annular width of the baffle 642 between the inner and outer diameters is less than the first embodiment. The width of the baffle 642 may be the same as the width of the baffle 342 of the third embodiment.

In other embodiments, the central aperture 644 is smaller than the central aperture 144 in the first embodiment. As a result, this requires more deformation of the baffle 642 by the substrate carrier 130 but provides a tighter seal. As in the first embodiment, insertion of the substrate carrier 130 includes the tip 134 contacting the sealing surface 643 and forcing it downwards to deform the baffle 642 and deflect the sealing surface 643 to face more towards the central axis X to form a seal against the outer surface of the substrate carrier 130.

It is to be understood that the baffle 642 inside the heating chamber 108 in the sixth embodiment can be readily applied to other embodiments, for instance to embodiments having alternative baffles such as the baffle 442 of the fourth embodiment, or having perforations 346 of the third embodiment.

Seventh Embodiment

A seventh embodiment is now described with reference to Figure 17. The aerosol generation device 100 of the seventh embodiment is identical to the aerosol generation device 100 of the sixth embodiment described with reference to Figure 16, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the seventh embodiment has a baffle 742 that is positioned differently to the baffle 642 of the sixth embodiment.

In more detail, referring to Figure 17, the baffle 742 is positioned inside the heating chamber 108 and is identical to the baffle 642 of the sixth embodiment, except that the baffle 742 of the seventh embodiment is arranged spaced away from the open end 110 and is positioned further towards the base 112 than the baffle 642 of the sixth embodiment.

Positioning the baffle 742 further from the open end 110 can restrict the interior volume available between the baffle 742 and the base 112 and between the substrate carrier 130 and the tubular wall 114 in which air can be heated. This may be desirable where a small volume of air is desired to be heated to a high temperature, and a larger volume would require a high power to heat to the required temperature, or would take a long time to reach the temperature. By providing a smaller volume, quicker heating and a shorter time to first puff can be achieved. However, it is preferable to ensure sufficient volume to collect and heat air within the heating chamber 108, and thus in some examples, the baffle 742 is positioned towards the open end 110 sufficient to provide the required volume within the heating chamber 108.

In some embodiments, it is desirable that the baffle 742 is not positioned to overlap with the aerosol substrate 132. That is, the baffle 742 is not positioned at an axial position closer to the base 112 than a boundary between the aerosol substrate 132 and the aerosol collection region 134 in which no aerosol substrate 132 is located towards the second end 140 of the substrate carrier 130. That is, the baffle 742 is positioned such that the aerosol substrate 132 is arranged between the baffle 742 and the base 112. If the baffle 742 is positioned between part of the aerosol substrate 132 and the interior volume of the heating chamber 108, then this part of the aerosol substrate 132 will experience a reduction in heating. Therefore, in some cases the entire aerosol substrate 132 is positioned between the baffle 742 and the base 112 of the heating chamber 108, such as shown in Figure 7 of the first embodiment. This can also be applied to other embodiments. Therefore, in the seventh embodiment, the distance the baffle 742 is positioned away from the open end 110 is chosen as a balance between improving heat retention and time to first puff, while ensuring that the aerosol substrate 132 is contained within the sealed portion of the heating chamber 108 and adequately heated. As in the first embodiment, insertion of the substrate carrier 130 includes the tip 134 contacting the sealing surface 743 and forcing it downwards to deform the baffle 742 and deflect the sealing surface 743 to face more towards the central axis X to form a seal against the outer surface of the substrate carrier 130.

In other embodiments, it may be suitable to arrange the baffle 742 to be aligned with the boundary between the aerosol substrate 132 and the aerosol collection region 134 in order to help provide a seal at this location to retain heat within the aerosol substrate 132.

It is to be understood that the variability of the position of the baffle 742 relative to the open end 110 of the heating chamber 108 in the seventh embodiment can be readily applied to other embodiments, for instance to embodiments having alternative baffles such as the baffle 442 of the fourth embodiment.

Eighth Embodiment

An eighth embodiment is now described with reference to Figure 18. The aerosol generation device 100 of the eighth embodiment is identical to the aerosol generation device 100 of the sixth embodiment described with reference to Figure 16, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the eighth embodiment has a baffle 842 that is different to the baffle 642 of the sixth embodiment.

In more detail, referring to Figure 18, the baffle 842 is arranged inside the heating chamber 108 similarly to the baffle 642 of the sixth embodiment. The baffle 842 is identical to the baffle 642 of the sixth embodiment, except that the baffle 842 of the eighth embodiment comprises a tapered portion 860. That is, the baffle 842 has a profile which tapers. More specifically, the baffle 842 tapers in a radial direction. The baffle 842 also defines a central aperture 844. An upper surface of the baffle 842 is tapered towards the open end 110 away from the base 112. The tapered portion 860 increases a width of the central aperture 844 towards the open end 110 away from the base 112. That is, the width of the central aperture 844 is smaller at a point of the baffle 842 closest to the base 112, and is wider at a point of the baffle 842 furthest from the base 112. As a result, the inner diameter of the baffle 842 increases from the lower surface of the baffle 842 arranged closest to the base 112 towards the upper surface of the baffle 842 arranged furthest from the base 112 in the axial direction. In the eighth embodiment, the increase in diameter of the tapered portion 860 is linear. That is, the tapered portion 860 is straight and the diameter increases smoothly at a constant rate. In the eighth embodiment, the sloped tapered surface 860 also acts as a sealing surface 843. As in the first embodiment, insertion of the substrate carrier 130 includes the tip 134 contacting the sealing surface 843 and forcing it downwards to deform the baffle 842 and deflect the sealing surface 843 to face more towards the central axis X to form a seal against the outer surface of the substrate carrier 130.

The tapered portion 860 provides a decreasing width of the central aperture 844 for the substrate carrier 130 to be inserted into. Thus, the tapered portion 860 provides a guide for receiving the substrate carrier 130 and may assist in loading the substrate carrier 130 into the heating chamber 108. Additionally, by providing a tapered portion 860 which gradually increases, the force needed to deform the baffle 842 to insert the substrate carrier 130 is reduced, and there is a smaller risk of damaging the substrate carrier 130 as it is inserted (e.g. tearing the paper of the outer layer 136 and exposing the aerosol substrate 132). The innermost part of the baffle 842 (closest to the central axis X) is thinnest and therefore is the most flexible, which may improve the seal formed against the substrate carrier 130.

In some examples, the baffle 842 comprises a tapered portion 860 and also comprises a constant thickness portion between the central axis X and the tubular wall 114. For example, an annulus around the tapered portion 860 extends to the tubular wall 114 with a constant thickness.

In other embodiments, the tapered portion 860 increases in diameter non-linearly. For example, the slope may not be a constant gradient, for example increasing or decreasing gradient towards the base 112. In one example, the slope gradient decreases towards the base 112 to reduce the force to insert the substrate carrier 130 initially, but to also provide an effective seal. Other shape profiles are possible, other than the tapering design shown in Figure 18. For example rounded profiles, profiles where the widest point is the midpoint of the baffle 842, etc. are also envisaged.

It is to be understood that the tapered portion 860 in the eighth embodiment can be readily applied to other embodiments, for instance to embodiments having a baffle arranged outside the heating chamber such as the baffle 142 of the first embodiment.

Ninth Embodiment

A ninth embodiment is now described with reference to Figure 19. The aerosol generation device 100 of the ninth embodiment is identical to the aerosol generation device 100 of the sixth embodiment described with reference to Figure 16, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the ninth embodiment has a baffle 942 that is different to the baffle 642 of the sixth embodiment.

In more detail, referring to Figure 19, the baffle 942 is arranged inside the heating chamber 108 similarly to the baffle 642 of the sixth embodiment, but the baffle 942 comprises a first baffle element 942c and a second baffle element 942d. In the ninth embodiment, the first baffle element 942c and the second baffle element 942d are each identical to the baffle 642 of the sixth embodiment. That is, the first baffle element 942c and the second baffle element 942d are annular, arranged inside the heating chamber 108 and are configured to deform upon insertion of the substrate carrier 130 in the manner described herein. The first baffle element 942c is arranged proximate to the open end 110 in the same position as the baffle 642 in the sixth embodiment, while the second baffle element 942d is arranged spaced away from the open end 110 towards the base 112 such as in the seventh embodiment. By providing two baffle elements 942c and 942d spaced axially apart along the tubular wall 114, heat and vapour retention can be further improved. The outermost surface of the first baffle element 942c also acts as a sealing surface. As in the first embodiment, insertion of the substrate carrier 130 includes the tip 134 contacting the sealing surface 943 and forcing it downwards to deform the baffle 942 and deflect the sealing surface 943 to face more towards the central axis X to form a seal against the outer surface of the substrate carrier 130.

Each of the baffle elements 942c, 942d can be the baffles of any embodiments disclosed herein. For instance, at least one of the first baffle element 942c and the second baffle element 942d may comprise a tapered portion such as in the eighth embodiment, or may comprise segments such as in the fourth embodiment. In some examples, the baffle elements 942c and 942d are the same, but in other examples they may be different. For example, the first baffle element 942c may be identical to the baffle 442 of the fourth embodiment comprising segments 450 to form a cover at the open end 110 to prevent dust entering the heating chamber 108 when the aerosol generation device 100 is not in use, while the second baffle element 942d may be identical to the baffle 642 of the sixth embodiment to provide a more secure seal within the heating chamber 108.

It is to be understood that the baffle 942 may further comprise additional baffle elements. For example, there may be at least three baffle elements positioned at different positions along the length of the tubular wall 114. Additionally, one or more baffle elements may be positioned outside the heating chamber 108 in addition to baffle element(s) inside the heating chamber 108. It is to be understood that the first baffle element 942c and the second baffle element 942d of the ninth embodiment can be readily applied to other embodiments, for instance to embodiments having alternative baffles such as the baffle 442 of the fourth embodiment. Indeed, the first and second baffle elements 942c, 942d can have different shapes and/or sizes, e.g. one can be the baffle 642 of the sixth embodiment and the other can be the tapered profile baffle 842 of the eighth embodiment.

Tenth Embodiment

A tenth embodiment is now described with reference to Figures 20 and 21. The aerosol generation device 100 of the tenth embodiment is identical to the aerosol generation device 100 of the first embodiment described with reference to Figures 1 to 7, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the tenth embodiment has a baffle 1042 that is different to the baffle 142 of the first embodiment.

In more detail, referring to Figure 20, the aerosol generation device 100 comprises a cap 1062 configured to be inserted onto the second end 106 of the aerosol generation device 100. The cap 1062 comprises a first wall 1064 having a cylindrical shape. The first wall 1064 is the outermost wall of the cap 1062. The first wall 1064 is arranged to be inserted onto the second end 106 such that a lower portion of the first wall 1064 slides into a corresponding recess 1063.

The cap 1062 comprises a second wall 1066 having a cylindrical shape. A diameter of the second wall 1066 is smaller than the diameter of the first wall 1064. The first wall 1064 and the second wall 1066 are arranged concentrically and both are arranged centred about the central axis X. In some examples, the diameter of the second wall 1066 is similar to the diameter of the tubular wall 114.

The first wall 1064 is connected to the second wall 1066 at a top of the cap 1062, wherein the top of the cap 1062 is furthest away from the first end 104 of the aerosol generation device 100 when the cap 1062 is loaded onto the aerosol generation device 100. The cap 1064 therefore forms a U-shape cross section, and is arranged to fit into the recess 1063 in the outer casing 102 of the aerosol generation device 100, and the recess can ensure that the cap is correctly positioned with respect to the aperture in the outer casing 102. Referring to Figure 21 , when the cap 1062 is positioned on the aerosol generation device 100, the second wall 1066 extends to a point towards the second end 106 of the aerosol generation device 100, proximate to the open end 110 of the heating chamber 108.

The cap 1062 comprises a baffle 1042 arranged on the second wall 1066. In the tenth embodiment, the baffle 1042 is arranged extending from an end of the second wall 1066 arranged to be proximate to the open end 110 and having a sealing surface facing outwardly of the cap. The baffle 1042 is arranged extending towards the central axis X. When the cap 1062 is inserted onto the aerosol generation device 100, the baffle 1042 covers the aperture in the outer casing 102, to allow the substrate carrier 130 to be inserted through the aperture while engaging with the baffle 1042, as described above. In the tenth embodiment, the baffle 1042 is arranged between the heating chamber 108 and the second wall 1066 of the cap 1062. In other embodiments, the baffle 1042 is arranged inside the inner diameter of the second wall 1066 in a similar manner to the baffle 642 of the sixth embodiment. Furthermore, the baffle 1042 may be arranged spaced away from the open end 110, for example located inside the inner diameter of the second wall 1066 and arranged further away from the second end 106 of the aerosol generation device 100. As in the first embodiment, insertion of the substrate carrier 130 includes the tip 134 contacting the sealing surface 1043 and forcing it downwards to deform the baffle 1042 and deflect the sealing surface 1043 to face more towards the central axis X to form a seal against the outer surface of the substrate carrier 130.

The tenth embodiment allows the baffle 1042 to be detachable from the heating chamber 108 and the aerosol generation device 100. This may allow for easier cleaning of the heating chamber 108 by removing the baffle 1042 such that it does not obstruct entry of a cleaning implement into the heating chamber 108. Furthermore, this may allow the baffle 1042 itself to be cleaned, separately from the heating chamber 108. In alternative embodiments, the heating chamber 108 is itself removable from the aerosol generation device 100. In addition, the use of a cap 1062 having a baffle 1042 can provide the opportunity to retrofit legacy devices with a baffle, for example by attaching the cap to the casing using clips, straps, adhesive, etc.

The cap 1062 may taper away from the second end 106 or otherwise be shaped to provide a comfortable mouthpiece for a user, for example in such cases where the substrate carrier 130 does not extend further away from the second end 106 than the cap 1062 does.

It is to be understood that the cap 1062 of the tenth embodiment can be readily applied to other embodiments, for instance to embodiments having alternative baffles such as the baffle 442 of the fourth embodiment.

Eleventh Embodiment

An eleventh embodiment is now described with reference to Figure 22. The aerosol generation device 100 of the eleventh embodiment is identical to the aerosol generation device 100 of the first embodiment described with reference to Figures 1 to 7, except where explained below, and the same reference numerals are used to refer to similar features. The aerosol generation device 100 of the eleventh embodiment has a heating chamber 1108 different to the heating chamber 108 of the first embodiment. Overall, the eleventh embodiment is provided as an example system in which the previous embodiments described herein may be implemented in practice. In particular, the baffle of any previous embodiment may be implemented in the aerosol generation device 100 of the eleventh embodiment.

In more detail, referring to Figure 22, the aerosol generation device 100 comprises a heating chamber 108 having a generally cup shape, similar to the heating chamber 108 of the first embodiment, and having similar dimensions, except as described below. The heating chamber 108 is arranged for receiving the substrate carrier 130. A baffle 1142 is arranged towards the second end 106 of the aerosol generation device 100 with a sealing surface 1143 facing outwardly. The baffle 1142 is identical to the baffle 142 of the first embodiment, and is configured to deform to receive the substrate carrier 130 into the heating chamber 108. As in the first embodiment, insertion of the substrate carrier 130 includes the tip 134 contacting the sealing surface 1143 and forcing it downwards to deform the baffle 1142 and deflect the sealing surface 1143 to face more towards the central axis X to form a seal against the outer surface of the substrate carrier 130.

A plurality of protrusions 1174 are formed in the inner surface of the tubular wall 114. The protrusions 1174 are indents in the tubular wall 114 extending towards the central axis X. The protrusions 1174 reduce the effective diameter of the tubular wall 114 where they are present. The protrusions 1174 are formed by crimping or otherwise indenting the tubular wall 114. The width of the protrusions 1174 around the perimeter of the tubular wall 114 is small relative to their length, their length being parallel to the central axis X (or broadly in a direction from the base 112 to the open end 110 of the heating chamber 108). In this embodiment, there are four protrusions 1174, although only two can be seen in the cross section of Figure 22. Four is a suitable number of protrusions 1174 for holding a substrate carrier 130 in a central position within the heating chamber 108 by applying a pressure on opposing sides of the substrate carrier 130. Other numbers of protrusions 1174 are envisaged, for example two, six, eight or more.

The protrusions 1174 are arranged around the circumference of the tubular wall 114, and are spaced evenly around the tubular wall 1174. Providing the protrusions 1174 evenly- spaced around the tubular wall 114 and having the same indent depth into the interior of the heating chamber 108 towards the central axis X, means that the substrate carrier 130 can be held in a central position in the heating chamber 108.

The protrusions 1174 have a variety of purposes and the exact form of the protrusions 1174 (and corresponding indentations on an outer surface of the tubular wall 114) is chosen based on the desired effect. In any case, the protrusions 1174 extend towards and engage the substrate carrier 130, and so are sometimes referred to as engagement elements. Indeed, the terms “protrusion” and “engagement element” are used interchangeably herein. Similarly, where the protrusions 1174 are provided by pressing the tubular wall 114 from the outside, for example by hydroforming or pressing, etc., the term “indentation” is also used interchangeably with the terms “protrusion” and “engagement element”. Forming the protrusions 1174 by indenting the tubular wall 114 has the advantage that they are unitary with the tubular wall 114 so have a minimal effect on heat flow. In addition, the protrusions 1174 do not add any thermal mass, as would be the case if an extra element were to be added to the inner surface of the tubular wall 114 of the heating chamber 108. Lastly, indenting the tubular wall 114 as described increases the strength of the tubular wall 114 by introducing portions extending transverse to the tubular wall 114, so providing resistance to bending of the tubular wall 114, and allowing the tubular wall 114 to be made thinner, thereby increasing thermal conduction across its thickness.

The aerosol generation device 100 works by both conduction and convection. Heat is conducted from the surface of protrusions 1174 that engage against the outer layer 136 of substrate carrier 130. Convection is achieved by heating air in an air gap between the inner surface of the tubular wall 114 and the outer layer 136 of the substrate carrier 130. That is, there is convective heating of the aerosol substrate 132 as heated air is drawn through the aerosol substrate 132 when a user sucks on the aerosol generation device 100. The width and height (i.e. the distance that each protrusion 1174 extends into the heating chamber 108) increases the surface area of the tubular wall 114 that conveys heat to the air, so allowing the aerosol generation device 100 to reach an effective temperature quicker.

The protrusions 1174 interact with the substrate carrier 130 such that a portion of the aerosol substrate 132 is compressed along the length of the protrusions 1174. Referring to Figure 22, the substrate carrier 130 is compressed to be received into the heating chamber 108 past the protrusions 1174. Compression of the aerosol substrate 132 improves conduction within the aerosol substrate 132 and can cause more efficient and even heating, particularly of central regions. Each protrusion 1174 comprises an upper end arranged towards the second end 106 where the protrusion 1174 meets the tubular wall 114. In the eleventh embodiment, the upper end is an angled taper shape smoothly increasing the diameter of the tubular wall 114 to the protrusion 1174.

The combination of providing protrusions 1174 and a baffle 1142 around the substrate carrier 130 can help align the substrate carrier 130 with the centre of the heating chamber 108, providing more even heating of the aerosol substrate 132 and more uniform air flow around the substrate carrier 130. Furthermore, the protrusions 1174 reduce the interior volume of the heating chamber 108 to provide better heating efficiency along with providing a seal at the open end 110 by the baffle 1168.

The heating chamber 108 further comprises a platform 1180 in the base 112. The platform 1180 raises the first end 138 of the substrate carrier 130 relative to the base 112 such that air can enter the first end 138 around the platform 1180. Thus, the platform 1180 has a smaller width than the first end 138. Air in the heating chamber 108 can then be drawn by a user through the first end 1138, indicated by Arrows A in Figure 22.

The combination of providing a platform 1180 in the base 112 of the heating chamber 108 to improve air flow through the first end 138 of the substrate carrier 130 with providing an air flow path indicated by Arrows B in Figure 22 can provide an optimum air flow balancing air supply for aerosolisation of the aerosol substrate 132 and draw resistance. In some embodiments, the baffle 1142 is configured to be further deformed to a third configuration such as the baffle 1142 of the first embodiment to permit airflow between the baffle 1142 and the substrate carrier 130 when a user applies suction to the second end 140. In other examples, the baffle 1142 is provides with perforations such as the baffle 342 of the third embodiment to provide air flow into the heating chamber 108.

Definitions and Alternative Embodiments

It will be appreciated from the description above that many features of the different embodiments are interchangeable with one another. The disclosure extends to further embodiments comprising features from different embodiments combined together in ways not specifically mentioned. For example any of the baffle arrangements set out herein may be used with either air flow path (first and second embodiments). Similarly, the protrusions described in the eleventh embodiment may be incorporated into any of the baffle designs. The cap may be included with any of the other designs. In some cases, the cap may be simply a mouthpiece, while in other cases it may provide an additional baffle, for example to improve heat and vapour retention.

The term “heater” should be understood to mean any device for outputting thermal energy sufficient to form an aerosol from the aerosol substrate. The transfer of heat energy from the heater to the aerosol substrate may be conductive, convective, radiative or any combination of these means. As non-limiting examples, conductive heaters may directly contact and press the aerosol substrate, or they may contact a separate component which itself causes heating of the aerosol substrate by conduction, convection, and/or radiation. Convective heating may include heating a liquid or gas which consequently transfers heat energy (directly or indirectly) to the aerosol substrate.

Radiative heating includes, but is not limited to, transferring energy to an aerosol substrate by emitting electromagnetic radiation in the ultraviolet, visible, infrared, microwave or radio parts of the electromagnetic spectrum. Radiation emitted in this way may be absorbed directly by the aerosol substrate to cause heating, or the radiation may be absorbed by another material such as a susceptor or a fluorescent material which results in radiation being re-emitted with a different wavelength or spectral weighting. In some cases, the radiation may be absorbed by a material which then transfers the heat to the aerosol substrate by any combination of conduction, convection and/or radiation.

Heaters may be electrically powered, powered by combustion, or by any other suitable means. Electrically powered heaters may include resistive track elements (optionally including insulating packaging), induction heating systems (e.g. including an electromagnet and high frequency oscillator), etc. The heater may be arranged around the outside of the aerosol substrate, it may penetrate part way or fully into the aerosol substrate, or any combination of these.

The term “temperature sensor” is used to describe an element which is capable of determining an absolute or relative temperature of a part of the aerosol generation device. This can include thermocouples, thermopiles, thermistors and the like. The temperature sensor may be provided as part of another component, or it may be a separate component. In some examples, more than one temperature sensor may be provided, for example to monitor heating of different parts of the aerosol generation device, e.g. to determine thermal profiles.

With reference to the above-described embodiments, aerosol substrate includes tobacco, for example in dried or cured form, in some cases with additional ingredients for flavouring or producing a smoother or otherwise more pleasurable experience. In some examples, the aerosol substrate such as tobacco may be treated with a vaporising agent. The vaporising agent may improve the generation of aerosol from the aerosol substrate. The vaporising agent may include, for example, a polyol such as glycerol, or a glycol such as propylene glycol. In some cases, the aerosol substrate may contain no tobacco, or even no nicotine, but instead may contain naturally or artificially derived ingredients for flavouring, volatilisation, improving smoothness, and/or providing other pleasurable effects. The aerosol substrate may be provided as a solid or paste type material in shredded, pelletised, powdered, granulated, strip or sheet form, optionally a combination of these. Equally, the aerosol substrate may be a liquid or gel. Indeed, some examples may include both solid and liquid/gel parts.

Consequently, the aerosol generation device could equally be referred to as a “heated tobacco device”, a “heat-not-burn tobacco device”, a “device for vaporising tobacco products”, and the like, with this being interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices which are designed to vaporise any aerosol substrate.

The embodiments of the aerosol generation device are described as being arranged to receive the aerosol substrate in a pre-packaged substrate carrier. The substrate carrier may broadly resemble a cigarette, having a tubular region with an aerosol substrate arranged in a suitable manner. Filters, aerosol collection regions, cooling regions, and other structure may also be included in some designs. An outer layer of paper or other flexible planar material such as foil may also be provided, for example to hold the aerosol substrate in place, to further the resemblance of a cigarette, etc.

As used herein, the term “fluid” shall be construed as generically describing non-solid materials of the type that are capable of flowing, including, but not limited to, liquids, pastes, gels, powders and the like. “Fluidized materials” shall be construed accordingly as materials which are inherently, or have been modified to behave as, fluids. Fluidization may include, but is not limited to, powdering, dissolving in a solvent, gelling, thickening, thinning and the like.

As used herein, the term “volatile” means a substance capable of readily changing from the solid or liquid state to the gaseous state. As a non-limiting example, a volatile substance may be one which has a boiling or sublimation temperature close to room temperature at ambient pressure. Accordingly “volatilize” or “volatilise” shall be construed as meaning to render (a material) volatile and/or to cause to evaporate or disperse in vapour.

As used herein, the term “vapour” (or “vapor”) means: (i) the form into which liquids are naturally converted by the action of a sufficient degree of heat; or (ii) particles of liquid/moisture that are suspended in the atmosphere and visible as clouds of steam/smoke; or (iii) a fluid that fills a space like a gas but, being below its critical temperature, can be liquefied by pressure alone.

Consistently with this definition the term “vaporise” (or “vaporize”) means: (i) to change, or cause the change into vapour; and (ii) where the particles change physical state (i.e. from liquid or solid into the gaseous state).

As used herein, the term “atomise” (or “atomize”) shall mean: (i) to turn (a substance, especially a liquid) into very small particles or droplets; and (ii) where the particles remain in the same physical state (liquid or solid) as they were prior to atomization.

As used herein, the term “aerosol” shall mean a system of particles dispersed in the air or in a gas, such as mist, fog, or smoke. Accordingly the term “aerosolise” (or “aerosolize”) means to make into an aerosol and/or to disperse as an aerosol. Note that the meaning of aerosol/aerosolise is consistent with each of volatilise, atomise and vaporise as defined above. For the avoidance of doubt, aerosol is used to consistently describe mists or droplets comprising atomised, volatilised or vaporised particles. Aerosol also includes mists or droplets comprising any combination of atomised, volatilised or vaporised particles.