A NON-COMBUSTIBLE AEROSOL PROVISION DEVICE

TECHNICAL FIELD

The present invention relates to a non-combustible aerosol provision device.

BACKGROUND

There is a drive toward increasing the recyclability and sustainability of consumer products to reduce harm to the environment. Manufacturers and suppliers may also benefit from recycling as manufacturing costs can be reduced by reusing recycled components.

There is often a difficulty in engaging consumers with recycling, particularly where the act of recycling imposes an additional burden on them, such as sorting their waste into different recyclable categories.

SUMMARY

In accordance with some embodiments described herein, in a first aspect there is provided a non-combustible aerosol provision device, the device being configured to generate an aerosol by heating a consumable, the device comprising means to engage a component of the consumable when the consumable is inserted into the device, so that, when a portion of the consumable is removed from the device, the component is retained by said means to separate the component from the portion of the consumable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a non-combustible aerosol provision device;

FIG. 2 is a schematic illustration of a system comprising the non-combustible aerosol provision device of FIG. 1 and a consumable;

FIG. 3 is a schematic illustration of an article comprising a heating element for use with the non-combustible aerosol provision device of FIG. 1;

FIG. 4 is a schematic detail view of features of the device of FIG. 1;

FIG. 5 is a schematic detail view of features of the device of FIG. 1;

FIG. 6 is a schematic illustration of an article comprising a heating element for use with the non-combustible aerosol provision device of FIG. 1;

FIG. 7 is a schematic illustration of a non-combustible aerosol provision device;

FIG. 8 is an isometric illustration of an article comprising a heating element for use with the non-combustible aerosol provision device of FIG. 7;

FIG. 9 is a schematic illustration of the article of FIG. 8; and

FIG. 10 is an isometric illustration of an article comprising a heating element for use with a non-combustible aerosol provision device.

DETAILED DESCRIPTION

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 aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

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

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

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

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be 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 device may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

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

In some embodiments, the substance to be delivered comprises an active substance.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

In some embodiments, the substance to be delivered comprises a flavor.

As used herein, the terms “flavor” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

In some embodiments, the flavor may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

An 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 semi-solid (such as a gel) which may or may not contain an active substance and/or flavorants.

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

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

The aerosol-generating material may comprise or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as active substances, to form a slurry and then heating the slurry to volatilize at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt %, 70 wt %, 80 wt %, 85 wt % or 90 wt % of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such an arrangement of discrete portions of film on a support. The aerosol-generating film may be substantially tobacco free.

The aerosol-generating material may comprise one or more active substances and/or flavors, one or more aerosol-former materials, and optionally one or more other functional material.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may comprise one or more of pH regulators, coloring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

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

A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use.

The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavor, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavorant, a colorant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components.

A non-combustible aerosol provision device 20 (herein referred to simply as the ‘device 20’) is shown schematically in FIG. 1. The device 20 comprises a wall 21 that defines a rod shaped consumable receiving space 22 (herein referred to simply as ‘receiving space 22’); and a heater 23 configured to heat the consumable receiving space 22.

The device further comprises a power source 24 and a control unit 25 which are configured to power and control the heater 23, respectively. The power source 24 may be, for example, a battery 24, 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 various components of the device, including the heater 23, receiving space 22, battery 24 and control unit 25 are retained within a housing 26.

The device 20 is of the approximate size and shape to allow a user to hold the device 20 in a single hand. In use, a consumable 1 comprising an aerosol generating material 5 is inserted into the receiving space 22 and heated by the heater 23. The heat causes one or more volatiles from the aerosol-generating material 5 to form an aerosol. A mouth end 12 of the consumable protrudes from the device as illustrated by FIG. 2. To inhale the aerosol generated by the heated consumable 1, a user draws on the mouth end 12 of the consumable 1, in the manner of a conventional cigarette.

The device further comprises an inlet 27 as shown in FIG. 1. When a user draws on the consumable 1, air is drawn from the inlet 27 and through the consumable.

The device 20 further comprises a first activation button 28 to allow a user to turn the device 20 on or off, and a second activation button 29 to activate the heater 23. To use the device 20, a user draws on the mouth end 12 of the consumable 1 while simultaneously pressing the second activation button 29 to cause the heater 23 to heat the consumable 1 and generate an aerosol.

The inlet 27 may comprise a pressure sensor (not shown) which acts as a ‘puff sensor’. The puff sensor is configured to detect a drop in pressure at the air inlet 27 which indicates that a user is drawing on a consumable 1 located within the receiving space 22. The device 20 is thereby configured to activate the heater 23 in response to a drop in pressure detected at the air inlet 27.

The control unit 25 is configured to direct electrical energy from the battery 24 to activate the heater 23 in response to an input signal.

In one example, the input signal is generated when the second activation button 29 is pressed by the user. In another embodiment, the input signal is generated when a pressure drop is detected at the inlet 27 by a pressure sensor.

The heater 23 may be an inductive heating assembly 23 and comprise various components to heat the consumable receiving space via an inductive heating process. Induction heating is a process of heating an electrically conducting object (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive heater and the susceptor, allowing for enhanced freedom in construction and application.

In the example illustrated by FIG. 1, the inductive heating assembly comprises an inductor coil 201. The inductor coil 201 is made from an electrically conducting material. For example, the inductor coil 201 may be made from Litz wire/cable which is wound in a helical fashion about the wall 21. Litz wire comprises a plurality of individual wires which are individually insulated and are twisted together to form a single wire. Litz wires are designed to reduce the skin effect losses in a conductor. The inductor coil 201 is made from copper Litz wire which has a rectangular cross section. In other examples the Litz wire can have other shape cross sections, such as circular. The inductor coil 201 is configured to generate a varying magnetic field for heating a susceptor.

FIG. 3 shows an article 1 that, in some embodiments, form part of a non-combustible aerosol provision system comprising the article 1 and the non-combustible aerosol provision device 20. The article 1 is rod shaped and comprises a mouth end 12 and a distal end 12′, opposite the mouth end 12.

The article 1 comprises an aerosol generating section 2 circumscribed by a wrapper 3. In the illustrated embodiment, a heating element 4 extends axially within the aerosol generating section 2. The heating element 4 is a susceptor comprising a material configured for heating by induction.

Therefore, when the article 1 is inserted into the non-combustible aerosol provision device 20, the heating element 4 is inductively heated by the heater 23 of the device 20 to heat the aerosol generating section 2. Heat from the heating element 4 is transferred from the heating element 4 to aerosol generating material 5 of the aerosol generating section 2 to generate an aerosol for inhalation by a user.

The article of FIG. 1 further comprises a filter plug 6 arranged in coaxial alignment with the aerosol generating section 2 and attached thereto by a paper wrapper 8 that circumscribes the length of the article 1. The filter plug 6 may additionally be wrapped in a plug wrap 7 disposed in between the filter plug 6 and the paper wrapper 8. Such articles 1 are typically discarded following use. There is an environmental benefit if consumer participation of recycling can be encouraged.

The heating element 4 may be made from any material suitable for induction heating. In the present example, the heating element is made from a ferrous material, such as steel. Such materials must be separated from the aerosol generating section 2 for recycling.

Referring again to FIG. 1, the device 20 comprises means 202 to engage a component of the consumable 1 when the consumable 1 is inserted into the device 20, so that, when a portion of the consumable 1 is removed from the device 20, the component is retained by said means 202 to separate the component from the portion of the consumable 1. In particular, the device 20 comprises means 202 to engage the heating element 4 of the consumable 1 when the consumable 1 is inserted into the receiving space 22. Said means 202 are configured to retain the heating element 4 in the device 20 when a portion of the consumable 1 is removed from the device 20.

Therefore, the heating element 4 is separated from the portion of the consumable 1 for recycling. It will be appreciated that ‘portion of the consumable 1’ herein means that part of the consumable that is not retained by said means.

The means 202 are configured to engage a portion of the heating element at the distal end 12′ of the consumable 1. FIGS. 4 and 5 are a detailed schematic illustration showing part of the receiving space 23, the means 202 to engage the heating element 4 and a disposal chamber 203. In the illustrated embodiments, the means 202 comprise an engaging portion 204 that upstand from a base 205 of the receiving space 22.

The engaging portion 204 illustrated by FIG. 4 is configured for embodiments in which the heating element 4 comprises a magnetic material. The engaging portion 204 comprises a tine 206 that penetrates an axial end of the consumable 1 when the consumable is inserted into the receiving space 22. The tine 206 is disposed to locate adjacent the heating element 4. The engaging portion 204 comprises an electromagnet 207 that, when activated, magnetises the tine 206 and attracts the heating element 4. The electromagnet 207 comprises a coil 208 that is connected to the power source 24. The coil 208 is provided at a lower end of the tine 206. That is, an end of the tine 206 that is not configured for insertion into the consumable 1. When a current is provided to the coil 208 the tine 206 is magnetised to draw a heating element in proximity to the tine 206 toward the tine 206.

The engaging portion illustrated by FIG. 5 comprises a pair of tines 209 that penetrate an axial end of the consumable 1 when the consumable 1 is inserted into the receiving space 22. The pair of tines 209 are positioned within the receiving space 22 so that the tines 209 locate either side a portion of the heating element 4. The engaging portion 204 comprises an actuator 210 to effect movement of the tines 209 toward each other. When a current is provided to the actuator 210, the tines 209 move toward each other, trapping the heating element 4 between the tines 209. In the illustrated embodiment, the tines 209 further comprise a barb 211 provided on one of the tines 209 to engage the heating element 4. The bard extends in a direction of movement of the tine 209. The barb 211 may be configured to penetrate the heating element 4, or to engage an aperture in the heating element 4.

A consumable sensor 212 is provided that relays the presence of a consumable to the control unit 25 when the consumable 1 is inserted into the receiving space 22. The control unit 25 may distribute power to the engaging portion 204 following receipt of a signal from the consumable sensor 212 indicating the presence of a consumable 1. Therefore, the engaging portion 204 is activated on insertion of the consumable 1. When a user removes the consumable 1, the consumable sensor 212 ceases to relay the presence of the consumable 1 to the control unit 25.

The control unit 25 is configured to deactivate the engaging portion 204 only after a predetermined period of time from the end of the signal indicating the presence of the consumable 1. This allows a user to completely remove a portion of the consumable 1 while the engaging portion 204 remains active. Therefore, the heating element 4 remains attached to the engaging portion 204 as the portion of the consumable 1 is removed.

In the particular embodiment of FIG. 4, the consumable sensor 212 relays the presence of the consumable 1 to the control unit 25, which then distributes power to the electromagnet 207.

Therefore, the electromagnet 207 is activated on insertion of the consumable 1. When a user removes a portion of the consumable 1, the consumable sensor 212 ceases to relay the presence of the portion of the consumable 1 to the control unit 25. The control unit 25 is configured to deactivate the electromagnet 207 only after a predetermined period of time from the end of the signal indicating the presence of the portion of the consumable 1. This allows a user to completely remove the portion of the consumable 1 while the electromagnet 207 remains active. Therefore, the heating element 4 remains attached to the tine 206 due to the electromagnetic force induced by the electromagnet 207 as the portion of the consumable 1 is removed.

In the particular embodiment of FIG. 5, the consumable sensor 212 relays the presence of the consumable 1 to the control unit 25 which then distributes power to the actuator 210. Therefore, the tines 209 are moved toward each other on insertion of the consumable 1 to grip the heating element 4. When a user removes a portion of the consumable 1, the consumable sensor 212 ceases to relay the presence of the portion of the consumable 1 to the control unit 25. The control unit 25 is configured to activate the actuator 210 to move the tines apart, releasing their grip on the heating element 4, only after a predetermined period of time from the end of the signal indicating the presence of the portion of the consumable 1. This allows a user to completely remove the portion of the consumable 1 while the heating element 4 is retained by the tines 209.

The disposal chamber 203 is provided for used heating elements 4. By ‘used heating elements 4’ it is meant heating elements 4 that have been removed from the portion of the consumable 1 by means 202 and retained within the device 20. The disposal chamber 203 is disposed below the receiving space 22. That is to say, the disposal chamber 203 is disposed below the receiving space 22 when the device 20 is oriented as shown in FIG. 2, with the consumable 1 protruding from an upmost face of the device 20. Therefore, when the engaging portion 204 is deactivated, the heating element 4 may fall through into the disposal chamber 203 under gravity. The disposal chamber 203 collects heating elements 4 as consumables 1 pass through the device 20. Although not shown, the disposal chamber 203 may comprise a tray that can be removed to allow emptying of the disposal chamber 203. For example, a portion of the disposal chamber 203 may be removable from the device 20, said portion comprising the tray and being configured for holding the used heating elements 4.

A trap door 213 is provided to selectively open or close the disposal chamber 203. When the trap door 213 is open, the receiving space 22 communicates with the disposal chamber 203. When the trap door 213 is closed, the receiving space 22 is closed off form the disposal chamber 203. The trap door 213 is electronically actuated. In one embodiment, the control unit 25 distributes power to the trap door 213 to selectively open or close the trap door 213. The control unit 25 may send a signal to the trap door 213 to open the trap door 213 following a predetermined period from when the consumable sensor 212 ceases to relay the presence of the consumable 1 to the control unit 25. Therefore, the trapdoor 213 is opened only after the consumable 1 has been removed. Preferably, the trap door 213 is opened at the same time that the engaging portion 204 is deactivated so that the heating element 4 is released by the engaging portion 204 to drop the heating element 4 into the disposal chamber 203. The control unit 25 may be configured to close the trap door 213 on receipt of a signal from the consumable sensor 212 indicating the presence of a consumable 1.

In another embodiment illustrated by FIG. 6, in which like features retain the same reference numbers, the heating element 4 extends beyond an axial end of the consumable 1 to protrude from the consumable 1. In such an embodiment, it is not a requirement that the engaging portion 204 penetrates the axial end of the consumable 1. Instead, the receiving space 22 may be configured so that the axial end of the consumable is supported spaced from the base 205 of the receiving space 22. This may be achieved, for example, by a narrowing of the receiving space 22 near the base 205, or by a ledge (not shown) extending into the receiving space to support the axial end of the consumable 1. In such examples, the an extended part 9 of the heating element 4 makes contact with the engaging portion 204 without the consumable 1 being pushed all the way to the base of the receiving space 22. This may be useful, for example, where the axial end of the consumable 1 is less suitable for penetration by the engaging portion 204. In the example, of FIG. 6, the axial end of the consumable 1 is provided with a distal end plug 14. The distal end plug 14 will be less easily penetrated than a distal end of aerosol generating material 5. The distal end plug 14 is provided to prevent condensate from seeping out of the distal end 12′ of the article 1 and into the receiving space 22 of the aerosol provision device 20 during use. The distal end plug 14 is provided with its own plug wrap 15 and is adjoined to a distal end 12′ of the aerosol generating section 2 by the paper wrapper 3. The heating element 4 extends through the distal end plug 14 and out of the distal end 12′ of the article 1, terminating at the extended portion 9. The paper wrapper 3 is adhered to the plug wrap 15 to ensure the distal end plug 14 remains in place throughout use of the article 1, including during removal of the heating element 4.

The consumable 1 may be provided with any additional segments required. The example of FIG. 6 shows a cooling segment 10 and an expansion segment 11 arranged in coaxial alignment with the aerosol generating section 2 and filter plug 7 and attached thereto by a series of overlapping wrapping materials. The cooling segment 10 and the expansion segment 11 are disposed between the aerosol generating section 2 and the filter plug 7. The cooling segment 10 is directly adjacent the aerosol generating section 2. The expansion segment 11 is disposed between the cooling segment 10 and the filter plug 7 and is directly adjacent to both. A wrapping material 13 extends over both segments 10, 11 and is disposed in between the segments 10, 11 and the paper wrapper 8.

The aerosol generating material 5 of the aerosol generating section 2 may comprise a solid aerosol-forming substrate, the solid aerosol-forming substrate may comprise one or more of: powder, granules, pellets, shreds, spaghetti strands, strips or sheets containing one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco. The solid aerosol-forming substrate may be in loose form. The aerosol-forming substrate may comprise a plug of solid aerosol-forming substrate.

In the embodiments illustrated by FIGS. 3 and 6, the aerosol generating material 5 comprises one or more sheets of homogenized tobacco material that has been gathered into a rod, circumscribed by the wrapper 3, and cut to provide the aerosol generating section 2. Preferably, the homogenized tobacco material comprises a crimped and gathered sheet of homogenized tobacco material. Preferably, folds formed in the crimped and gathered sheet extend in an axial direction through the aerosol generating section 2. Therefore, the crimped and gathered sheet of homogenized tobacco material does not obstruct axial movement of the heating element 4 when it is removed. The homogenized tobacco material may comprise at least one of fibers, binder and aerosol former.

Preferably, the sheet of homogenized tobacco material is a cast leaf. Cast leaf is a form of reconstituted tobacco that is formed from a slurry including tobacco particles, fiber particles, aerosol former, and binder. The cast leaf may additionally comprise one or more flavors.

In the embodiments illustrated by FIGS. 3 and 6, it is therefore preferable that the heating element 4 comprises a smooth outer surface so as to slide from the aerosol generating section 2 without catching on aerosol generating material 5 of the aerosol generating section 2. The heating element 4 may be a cuboid, a rod or any other suitable shape. In some embodiments the heating element 4 may comprise a flat profile. By ‘flat profile’ it is meant that the heating element 4 is a cuboid having a thickness significantly smaller than a width or length of the heating element 4. Therefore, the heating element 4 resembles a thin, flat strip.

FIGS. 7 to 9 illustrate alternative embodiments of an aerosol provision system comprising a non-combustible aerosol provision device 30 and a consumable 50 for use with the device.

FIG. 7 is a cross-sectional view through a schematic representation of the aerosol provision device 30. FIGS. 8 and 9 show the consumable 40 for use in the device 30. The aerosol provision device 30 comprises an outer housing 31, a power source 32, control circuitry 33, a plurality of aerosol generating components 34, a receptacle or aerosol forming chamber 35, a mouthpiece end 36, an air inlet 37, an air outlet 38, an activation button 39 and an inhalation sensor 40. The outer housing 31 is arranged such that the power source 32, control circuitry 33, aerosol generating components 34, receptacle 35 and inhalation sensor 40 are located within the outer housing 31. The outer housing 31 also defines the air inlet 37 and air outlet 38, described in more detail below. The activation button 29 is located on the exterior of the outer housing 31.

The power source 32 is configured to provide operating power to the aerosol provision device 30. The power source 32 may be any suitable power source, such as a battery. For example, the power source 32 may comprise a rechargeable battery, such as a lithium ion battery. The control circuitry 33 is suitably configured or programmed to control the operation of the aerosol provision device 30 and distribute power from the power source 32 to other components of the device 30.

FIGS. 8 and 9 illustrate the consumable 50. The consumable 50 (also herein referred to as article 50) comprises a carrier material 51, a heating element 52 and aerosol generating material 53 disposed on the heating element 52. In the present example, the carrier material 51 is made of card and is the main structural component of the article 50, providing the article 50 with sufficient rigidity to maintain its shape in normal handling, such as inserting and removing the article 50 from the aerosol provision device 30. The carrier material 51 is broadly cuboidal in shape and comprises a substantially flat profile. By ‘flat profile’ it is meant that the thickness of the carrier material 51 is less than its width and length. By way of a concrete example, the length of the carrier material 51 may be 30 to 80 mm, the width may be 7 to 25 mm, and the thickness may be between 0.2 to 1 mm. However, it should be appreciated that the above are exemplary dimensions of the carrier material 51, and in other implementations the carrier material 51 may have different dimensions as appropriate.

The heating element 52 is adhered to the carrier material 51. The heating element 52 comprises a thin strip of material that is suitable for inductive heating. In the illustrated embodiments, the heating element 52 has substantially the same length and width as the carrier material 51 so that the heating element 52 can be superimposed on top of the carrier material 51 and adhered thereto.

FIG. 9 shows a cross section through the article 50. An adhesive layer 54 is provided between the heating element 52 and carrier material 51 to adhere the heating element 52 and the carrier material 51 to each other. Part of the heating element 52 is not adhered to the carrier material 51, thereby providing a tab 55 of the heating element 52 that is free for a user to lift away from the carrier material 51. Therefore a user can peel back the heating element 52 from the carrier material 51, separating the heating element 52 from the carrier material 51 for recycling. In the illustrated embodiment, a region between the carrier material 51 and heating element 52 is free of adhesive to provide the tab 55. However, it will be appreciated that in other embodiments the carrier material 51 and the heating element 52 may be adhered to each other over the entire area of overlap between the carrier material 51 and heating element 52. In such embodiments, the tab 55 may instead be provided by extension of the heating element 52 beyond the carrier material 51. The adhesive used in the adhesive layer 54 is selected so as to have a bond strength that prevents separation of the heating element 52 from the carrier material 51 during insertion and removal of the article 50 from the device 30, but is weak enough to enable a user of normal dexterity to peel the heating element 52 away from the carrier material 51 when required.

A plurality of discreet portions of the aerosol generating material 53 are provided directly on the heating element 52. Although three circular portions of aerosol generating material 53 are provided, it will be appreciated that any number may be provided as required. For example, in another implementation, a two by three array of discreet portions of aerosol generating material 53 are provided. Importantly, the number and spacing of aerosol generating portions 53 matches the number and spacing of aerosol generating components 34 in the device 30 so that, when the article 50 is correctly installed in the receptacle 35, the aerosol generating portions 53 are disposed directly above the aerosol generating components 34.

Although not shown in FIG. 7, the device 30 may comprise a lid portion and a base portion which are configured to engage with one another to secure an article 50 within the receptacle 35. Various configurations for the lid and base portions are considered, for example, although not shown in FIG. 7, the device 30 may comprise a hinged door or removable part of the outer housing 31 to permit access to the receptacle 35 such that a user may insert and/or remove the article 50 from the receptacle 35. The hinged door or removable part of the outer housing 31 may also act to retain the article 50 within the receptacle 35 when closed.

In the described implementation, the aerosol generating material 53 comprises a gelling agent (sometimes referred to as a binder) and an aerosol former material (which might comprise glycerol, for example). Optionally, the aerosol generating material may comprise one or more of the following: an active substance (which may include a tobacco extract), a flavorant, an acid, and a filler. Other components may also be present as desired.

In the described implementation, the aerosol generating components 34 are inductive heaters configured to generate a varying magnetic field to induce eddy currents in the heating element 52 immediately below the discreet portions of aerosol generating material 53.

The device 30 further comprises means 202 to engage a component of the consumable 50 when the consumable 50 is inserted into the device 30, so that, when a portion of the consumable 50 is removed from the device 30, the component is retained by said means 202 to separate the component from the portion of the consumable 50. In particular, the device 30 comprises means 202 to engage the carrier material 51 of the consumable 50 when the consumable 50 is inserted into the receptacle 35 of the device 30. Said means 202 are configured to retain the carrier material 51 in the device 30 when the portion of the consumable 50 is removed from the device 30. Therefore, the carrier material 51 is separated from the portion of the consumable 50 for separate disposal.

In the illustrated implementation, said means 202 comprise suction cups 41. The suction cups 41 are disc shaped resilient diaphragms that are configured to generate a partial vacuum between a planar lower surface of the carrier material 51 and the diaphragm when activated, as will be described further below.

To use the device 30, an article 50 is inserted into the receptacle 35 and the device 30 is switched on by way of a sensor (not shown) determining that the article 50 is present in the receptacle 35. Alternatively, the device 30 may be switched on by user interaction with the activation button 39. In either event, a signal is sent to the control circuitry 33 to indicate the presence of the article 50.

The control circuitry then distributes power to an actuator 42 of the suction cups 41. The actuator displaces the diaphragm of each suction cup 41 from a flat state to a conical state, thereby generating a partial vacuum between the diaphragms and the lower surface of the carrier material 51 to fixedly hold the article 50 within the receptacle 35.

With the article 50 installed in the receptacle 35, a user may then draw on the mouth end 36 of the device 30. When the user draws on the mouth end 36 of the device 30, a flow of air is induced through the inlet 37, into the receptacle 35 and out through the outlet 38 for inhalation. The inhalation sensor 40 determines a pressure drop at the inlet 37 and generates a signal which is transmitted to the control circuitry 33. In turn, the control circuitry 33 distributes power from the power source 32 to the aerosol generating components 34 which heat the heating element 52 as described. Heat from the heating element 52 vaporizes volatile elements of the discreet portions of aerosol generating material 53 which are entrained into the flow of air through the device 30 for inhalation. The control circuitry 33 may be configured to distribute power to all of the aerosol generating components 34 at once or, more preferably, in sequence. Therefore, each portion of aerosol generating material 53 is heated at a different time. Preferably, each portion of aerosol generating material 53 is heated for a predetermined time, or for a predetermined number of puffs, before the adjacent portion of aerosol generating material 53 is heated. Once each portion of aerosol generating material 53 has been heated for predetermined time, or predetermined number of puffs, the device indicates to the user that the article 50 is due to be replaced. This may be determined, for example, by the control circuitry 33. The control circuitry 33 sends a signal to an end of use indicator 43 to indicate to the user that the article 50 is to be removed. The end of use indicator 43 may be a light or any other suitable indication device. The suction cups 41 remain in the conical state to retain the carrier material in the receptacle 35 as the user removes a portion of the article 50. In particular, the user lifts and grips the tab 55 to peel the back the heating element 52 from the carrier material 51. The heating element 52 is therefore separated from the carrier material 51 for separate recycling. After a further predetermined period, the control circuitry 33 distributes power to the actuator 42 of the suction cups 41. The actuator displaces the diaphragm of each suction cup 41 from the conical state to the flat state, thereby releasing the partial vacuum between the diaphragms and the lower surface of the carrier material 51, allowing the carrier material 51 to be removed from the receptacle 35. The device is further provided with a second indicator 44 to indicate to a user that the carrier material 51 is no longer retained by the suction cups 41. In other words, after the further predetermined period, the control circuitry 33 sends a signal to the second indicator 44 to indicate to a user that the carrier material 51 may be removed from receptacle 35 for separate disposal.

While the illustrated implementation of said means 202 comprises suction cups 41, it will be appreciated that the device 30 may be configured to engage the carrier material 51 in any other suitable way. For example, in another implementation, the carrier material 51 extends beyond the heating element 52 to provide a portion 56 of the carrier material 51 for clamping. An article 50 according to this implementation is illustrated by FIG. 10, with like features retaining the same reference numbers. In such an implementation, said means 202 comprises a clamp to clamp the extended portion of the carrier material 51. The clamp is electronically actuated. As above, when an article 50 is inserted into the device 30, a signal is sent to the control circuitry 33 to indicate the presence of the article 50. The control circuitry 33 is configured to distribute power to the clamp to clamp the extended portion of the carrier material 51 on receipt of said signal. When the article 50 is due to be replaced, the carrier material 51 remains clamped to retain the carrier material 51 in the receptacle 35 as the user removes a portion of the article 50. In particular, the user lifts and grips the tab 55 to peel the back the heating element 52 from the carrier material 51. The heating element 52 is therefore separated from the carrier material 51 for separate recycling. After a period, the control circuitry 33 distributes power to the clamp to unclamp the carrier material 51, allowing the carrier material 51 to be removed from the receptacle 35. The control circuitry 33 then sends a signal to the second indicator 44 to indicate to a user that the carrier material 51 may be removed from receptacle 35 for separate disposal.

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 utilized 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.

A NON-COMBUSTIBLE AEROSOL PROVISION DEVICE

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