Technical Field

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

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles that burn tobacco by creating products that release compounds without burning. Examples of such products are heating devices which release compounds by heating, but not burning, the material. The material may be for example tobacco or other non-tobacco products, which may or may not contain nicotine.

Summary

In accordance with some embodiments described herein, there is provided an aerosol provision device for generating aerosol from an aerosol-generating material, the device comprising a heating assembly comprising a heating zone configured to receive at least a portion of an article comprising aerosol generating material, the heating zone defining a longitudinal axis along which at least a portion of an article comprising aerosol generating material is extendable, a heating element array comprising at least three heating elements, wherein the at least three heating elements are distributed around the longitudinal axis to surround the heating zone, wherein the heating element array is adjustable between a clamped condition and an unclamped condition in which at least one of the at least three heating elements is moved relative to at least one other of the at least three heating elements.

The at least three heating elements may be arranged to be equally spaced in the clamped condition.

The at least three heating elements may be equally radially distributed about the longitudinal axis.

In the clamped condition, the at least one of the at least three heating elements of the heating element array which is arranged to be moved may be configured to be brought into contact with an article received in the heating zone. In the clamped condition, the heating element array may be arranged to be free from compressing at least part of an article received in the heating zone.

The clamped condition may be a compression condition in which the heating element array compresses at least part of an article.

The array of elements may define the heating zone.

The at least one of the at least three heating elements may be moved radially.

The device may comprise an engaging mechanism arranged to move the heating element array between the clamped and unclamped conditions.

The engaging mechanism may be arranged to move at least two of the heating elements.

The engaging mechanism may be arranged to move each of the heating elements of the heating element array.

The heating elements may comprise a contact surface. The contact surface of each of the heating elements may be planar.

The heating elements may be resistive heating elements. The heating elements may be ceramic.

The heating element array may comprise at least four heating elements.

The heating elements may be resiliently deformable.

The heating elements may protrude axially and parallel to the axis of the device.

At least two of the heating elements may be moved radially with respect to each other and the device. Each element of the heating element array may be moved radially with respect to each other and the device.

The device may comprise a body. The body may comprise the engaging mechanism. The engaging mechanism comprises a drive member. The drive member may be rotatable. The drive member may be user operable. The engaging mechanism may comprise a cam to act on the at least one moveable heating element. The engaging mechanism may provide a wedge action to move the heating element array.

In the unclamped condition, movement of the article may be unrestricted.

At least one of the at least three heating elements may be biased radially towards the heating zone. In accordance with some embodiments described herein, there is provided an aerosol provision system comprising the aerosol provision device as described above, and an article comprising aerosol generating material, the article configured for at least partial receipt in the heating chamber, such that in use, the article is clamped within the heating chamber.

The article may have a circumferential exterior surface.

In the clamped condition, the at least one of the at least three heating elements of the heating element array which is arranged to be moved may be configured to be brought into contact with the article.

The clamped condition may be a compression condition in which the heating element array compresses an article.

The radial distance from the longitudinal axis to each of the heating elements in the clamped condition may correspond to the radius of the circumferential exterior surface of the article. The heating element array may be adjustable into the compression condition in which the heating element array compresses an article.

In the clamped condition, the heating element array may be arranged to be free from compressing at least part of an article received in the heating zone. The radial distance from the longitudinal axis to each of the heating elements in the compressed condition may be smaller than the radius of the circumferential exterior surface of the article in an uncompressed state.

The radial distance from the longitudinal axis to the moveable heating element in the unclamped condition may be greater than the radius of the circumferential exterior surface.

The article may be cylindrical.

In the unclamped condition, at least one of the at least three heating elements may be radially spaced from the article.

In the unclamped condition, two of the at least three heating elements may be at an equal radial distance from the article, and at least one of the at least three heating elements may be at a greater radial distance from the article than the other heating elements. In the unclamped condition, all of the at least three heating elements may be at an equal radial distance from the article.

In the clamped condition, the at least three heating elements may be at an equal radial distance from the axis.

The article may be compressed such as to provide a larger contact surface with the heating elements.

Brief Description of the Drawings

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

Figure 1 shows a perspective view of an aerosol provision system;

Figures 2a and 2b show a perspective view of the aerosol provision system of Figure 1 , in an unclamped and clamped condition respectively with some internal components visible; and

Figures 3a and 3b show sectional perspective views of the aerosol provision system of Figure 1 , in an unclamped and clamped condition respectively with some internal components visible.

Detailed Description

As used herein, the term “aerosol-generating material” is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. Aerosol-generating material may include any plant based material, such as tobaccocontaining material and may, for example, include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Aerosolgenerating material also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. Aerosol-generating material may for example be in the form of a solid, a liquid, a gel, a wax or the like. Aerosol-generating material may for example also be a combination or a blend of materials. Aerosolgenerating material may also be known as “smokable material”.

The aerosol-generating material may comprise a binder and an aerosol former.

Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosolgenerating material is substantially free from botanical material. In some embodiments, the aerosol-generating material is substantially tobacco free.

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

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

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

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

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

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

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

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

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

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

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

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

An aerosol generating device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article. Figure 1 shows an aerosol provision system 101 including an aerosol provision device 100 for generating aerosol from an aerosol generating material and an article 102. The device 100 may be used to heat the replaceable article 102 comprising the aerosol generating material, to generate aerosol or other inhalable medium which is inhaled by a user of the device 100.

The device 100 comprises a body 110. The body 110 surrounds and houses various components of the device 100. An opening 160 is formed in one end of the body 110, through which the article 102 may be inserted for heating by an aerosol generator 111 (refer to Figure 2). In use, the article may be fully or partially inserted into the heating zone 112 where it may be heated by one or more components of the aerosol generator 111. The aerosol generator 111 comprises a heating assembly 113.

The body 110 comprises a first body portion 140 and a second body portion 150. The first body portion 140 is mounted with to the second body portion 150. It will be understood that the number of body portions may vary. The first body portion 140 and the second body portion 150 are axially aligned with respect to each other and a longitudinal axis 107 of the device 100. The first body portion 140 acts as a first housing, and the second body portion 150 acts as a second housing. Together they define a device housing.

The device 100 may also include a user-operable control element (not shown), such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device by operating the switch.

The end of the device 100 closest to the opening 160 may be known as the proximal end (or mouth end) 105 of the device 100 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 102 into the opening 160, operates the aerosol generator 111 to begin heating the aerosol generating material, and draws on the aerosol generated in the device 100. This causes aerosol to flow through the device 100 along a flow path towards the proximal end 105 of the device 100.

The other end of the device furthest away from the opening 160 may be known as the distal end 106 of the device 100 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device, the aerosol flows in a direction towards the proximal end 105 of the device 100. The terms proximal and distal as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the longitudinal axis 107.

Figures 2a and 2b show a perspective view of the system 101 with the heating assembly 113 of the device 100 visible through the second housing 150. Figures 3a and 3b show a section perspective view of the system 101 through the second housing 150 to show the heating assembly 113.

The first and second body portions 140, 150 are movably attached to one another. The first and second body portions 140, 150 are axially aligned along the longitudinal axis 107. The first body portion 140 houses an electronics assembly (not shown). The heating assembly 113 extends in the second body portion 150. The arrangement may differ, for example the second body portion 150 may be omitted, with the heating assembly in the body. The second body portion 150 rotates relative to the first body 140 around the longitudinal axis 107. The second body portion 150 forms part of an engaging mechanism, as described below. The second body portion 150 acts as an actuator. In embodiments, the second body portion is omitted or forms a one-piece component with the first body portion. The second body portion may not act as the actuator. Other actuator mechanisms may be used, for example the actuator in embodiments comprises a different manual actuation arrangement, such as a button, switch. Other actuation arrangements include a motor. The actuator may comprise a portion of the body 110, or a portion of at least one of the first or second body portions 140, 150. In embodiments, the actuator comprises a component separate to body 110. The actuator may comprise the first body portion 140.

The second body portion 150 surrounds the heating assembly 113. The second body portion 150 attaches to the first body portion 140 at a mount 116. The attachment point 116 allows for relative rotation between the first and second body portions 140, 150.

The heating assembly 113 comprises a heating element array 120. The heating element array 120 comprises three heating elements 122a, 122b, 122c. The heating element array 120 may comprise more than three heating elements 122, for example, four heating elements. The heating elements 122 are mounted to a base 115 of the first body portion 140. The heating elements 122 protrude axially from the base 115 and parallel to the longitudinal axis 107. The heating element array 120 defines a heating zone 112. The heating elements 122 surround the heating zone 112. The heating elements 122 are distributed around the longitudinal axis 107. The article 102 is received in the heating zone 112. The article 102 extends through the device 100 along the longitudinal axis 107. The heating elements are resistive heating elements. The heating elements in embodiments are ceramic heating elements. Other heating arrangements are envisaged, for example inductive.

The heating element array 120 is movable between a clamped and an unclamped condition. The unclamped condition is shown in Figures 2a and 3a. The clamped condition is shown in Figures 2b and 3b. In the unclamped condition, the article 102 is inserted into the heating zone 122. In the clamped condition, the heating elements 122 contact the article 102 to retain the article 102 within the heating zone 112.

The heating elements 122 are moveable relative to each other to contact the article 102 in the clamped condition. The heating element array 120 retains the article 102 in the heating zone 112. In the clamped condition, the article 102 is contacted and compressed by all of the heating elements 122. The article 102 is evenly contacted and compressed by all of the heating elements 122. The article 102 is compressed by the heating element array 120 in the clamped condition. As used herein the term “clamped” is used to indicate that a feature is held between at least two components such that the feature is at least partially retained by the at least two components. As used herein the term “compression” is used to indicate that any portion of the article significantly distorts from its initial uncompressed state. There is a predetermined substantive change to the shape or size of any portion of the article. That is at least some deformation occurs. It will be understood that by the clamping nature of the configuration some small/minimal compressive force will occur, both in general and due to slight tolerances in manufacture of the article. In a clamped but non-compressed state the article is held by the clamping action without any portion of the article significantly distorting from its initial unclamped state.

The three heating elements 122a, 122b, 122c move to contact the article in the clamped condition. In the clamped condition, the heating elements 122 are arranged to be equally spaced from each other to evenly contact the article 102. The heating elements 122 may be equally circumferentially distributed around the heating zone 112 in the clamped condition. Each heating element 122 is spaced at an equal radial distance from the longitudinal axis 107 in the clamped condition. In the unclamped condition, the heating elements 122a, 122b, 122c are of equal radial distance from the longitudinal axis 107. The heating elements 122a, 122b, 122c apply equal pressure to compress the article.

In embodiments, at least one of the heating elements is moved relative to the other heating elements to contact the article 102 in the clamped condition. One or two of the heating elements may be moved. At least one of the heating elements may be fixed relative to the device 100. In embodiments, at least one of the heating elements 122 moves radially with respect to the longitudinal axis to contact the article 102 in the clamped condition. Two or more of the heating elements 122 may be movable to contact the article 102 in the clamped condition. Two or more of the heating elements 122 may be moved radially to contact the article 102 in the clamped condition. One or more heating elements may move a greater radial distance than the other heating elements to contact the article. In embodiments, in the unclamped condition, the heating elements 122 may be of unequal radial distances from the longitudinal axis 107. In the unclamped condition, the heating elements 122 may be unequally spaced from one another.

The heating elements 122 comprise contact surfaces 124. Each heating element 122a, 122b, 122c has a corresponding contact surface 124a, 124b, 124c which contacts the article 102 in the clamped condition. Each contact surface 124 is planar. The planar surface allows for ease of manufacture of the heating element. The article 102 is substantially cylindrical. The exterior surface 103 of the article contacts each contact surface 124 of the heating elements 122. The contact surfaces 124 contact the article 102 at evenly spaced points around its circumference to compress the article 102.

The area of the article 102 which is contact by the contact surfaces 124 is increased by the compression of the exterior surface 103. This provides a large contact area for heat transfer. The area of contact on the exterior surface 103 is equal to the size of the contact surface 124. The compression of the article 102 allows for more efficient heating of the article 102 as the contact area is larger between the heating elements 122 and the article 102. Multiple heating elements provide even compression and heating of the article 102 by the contact surfaces 124, and a larger overall contact area on the article 102.

The article is radially compressed such that the contact surfaces 124 flatten the exterior surface 103 of the article 102 by compression. This compression increases the contact area between the contact surfaces and the exterior surface 103. The heating elements 122 do not contact the entire exterior surface 103 of the article 102. In the clamped condition, axial portions of the exterior surface 103 of the article 102 remain unclamped and therefore uncompressed. Axial portions of the exterior surface 103 are contacted and compressed by each contact surface 124 of the heating elements 122. The number of compressed sections of the article corresponds to the number of contact surfaces and therefore heating elements. The number of compressed sections on the article may be three or more.

In the unclamped condition, the article 102 is inserted into the device 100 through the opening 160. The article 102 is inserted such that the exterior surface contacts the contact surfaces 124 of the heating elements 122 which are not movable. One or more of the heating elements 122 may be fixed in position and unmovable relative to the article 102 and other heating elements 122. All of the heating elements 122 may be movable. In the unclamped condition, the article may be spaced from contact surfaces 124 of the heating elements 122 which are movable. When the device 100 is moved to the unclamped condition, at least one of the heating elements 122 is moved axially inward towards the article 102. At least one of the heating elements 122 may be biased radially towards the heating zone 112.

The movable heating elements 122 may move to contact the article 102 and compress the exterior surface 103. The movable heating elements 122 may move the article 102 to contact the remaining heating elements 122. In the clamped condition, the movable heating elements 122 are radially spaced from the article 102. At least one of the heating elements 122 is at a greater radial distance from the article than the other heating elements 122. In the case where two of the at least three heating elements 122 are at an equal radial distance from the article 102, at least one of the heating elements is at a greater radial distance from the article 102.

The clamped condition is a compression condition. In the clamped condition, the radial distance from the longitudinal axis 107 to each of the contact surfaces 124 of the heating elements 122 corresponds to the radius R1 of the exterior surface 103 of the article 102 at the point where the contact surfaces 124 and the exterior surface 103 meet. The radial distance from the longitudinal axis 107 to each of the contact surfaces 124 of the heating elements in the clamped condition is smaller than the radius of the exterior surface 103 of the article 102 in an uncompressed, unclamped condition. The radial distance from the longitudinal axis 107 to each of the at least one movable heating elements 122 in the unclamped condition is greater than the radius of the exterior surface 103 of the article 102 in an uncompressed, unclamped condition. In the clamped condition, the radius R1 of the compressed portion of the exterior surface 103 contacted by the contact surface 124 is smaller than the radius R2 of the uncompressed portion of the exterior surface 103 which is not contacted by the heating elements 122. In the unclamped condition, the radius of the exterior surface 103 of the article 102 is constant.

The second body portion 150 is rotatable around the longitudinal axis 107 relative to the first body portion 140 and the heating assembly 113. The second body portion 150 comprises an engaging mechanism 130. The engaging mechanism 130 comprises an engaging member 131 on the movable heating elements 122 and a corresponding body member (not shown) on the interior of the second body portion 150. Each movable heating element 122 may comprise a corresponding engaging member 131. The body member acts on the engaging member 131 to move the heating element array 120 into a clamped condition. The engaging mechanism 130 is arranged to move the movable heating elements 122 into the clamped condition to clamp the article 102. The engaging mechanism 130 moves the three heating elements 122a, 122b, 122c between an unclamped and clamped condition.

The engaging mechanism 130 is arranged to move the heating element array 120 between a clamped and an unclamped condition. In the clamped condition, the heating element array 120 compresses the article 102. The engaging mechanism 130 may comprise a drive member. The drive member may be rotatable. The drive member may be user operable. The engaging mechanism 130 may comprise a cam to act on the movable heating elements 122. The engaging mechanism 130 may provide a wedge action to move the movable heating elements 122. In embodiments, the engaging mechanism 130 moves at least one of the heating elements 122. The engaging mechanism 130 may move two or more of the heating elements. The engaging mechanism 130 may act on only the movable heating elements. The engaging mechanism may not act on any fixed heating elements.

The heating element array 120 is biased towards an unclamped condition. In embodiments, the heating element array 120 is biased towards a clamped condition and the engaging mechanism moves the heating element array towards an unclamped condition to receive the article 102. In embodiments, in the clamped condition, the heating element array is arranged to be free from compressing at least part of the article 102. The article 102 may be frictionally restrained within the heating zone 112 by the heating element array 120. The radial distance between the heating elements in this clamped condition correspond to the radius of the exterior of the article 102. In embodiments, the article may not be compressed. The airflow pathway and heating profile of the uncompressed and compressed articles differ

In use, the device 100 is also moved from a clamped condition to an unclamped condition to remove the article 102 when the article 102 is required to be removed at the end of its life. The second body portion 150 is moved relative to the first body portion 140 to disengage the engaging mechanism 130 and move the heating element array 120 into an unclamped condition. The article 102 is spaced from at least one of the heating elements 122 and can therefore be easily removed from the device 100. The heating element array 120 is biased in the unclamped condition such that when the engaging mechanism is disengaged, the heating elements 122 are spaced from the article 102 to allow removal of the article 102 from the device 100. In embodiments, the engaging mechanism may be driven between a clamped and unclamped condition such that the device must be driven into an unclamped condition to release the article 102. In embodiments, the engaging mechanism comprises a cam operable to move the heating element array between the clamped and unclamped position.

An electronics assembly is in the body 110. The electronics assembly is housed in the first body portion 140. The electronics assembly comprises a power source. The power source may be, for example, a battery, such as a rechargeable battery or a non- rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the heating assembly to supply electrical power when required and under control of a controller to heat the aerosol generating material. The electronics assembly comprises an electronics module. The electronics module may comprise a printed circuit board assembly (PCBA). The PCBA may comprise, for example, a printed circuit board (PCB) that supports at least one controller, such as a processor, and memory. The PCB may also comprise one or more electrical tracks to electrically connect together various electronic components. The battery terminals may be electrically connected to the PCB so that power can be distributed throughout the device 100. The heating assembly is connected to the electronics assembly at the base 115. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.