AEROSOL GENERATING DEVICE

TECHNICAL FIELD

The present invention relates to an aerosol generating device for generating an aerosol from aerosol-generating material. The present invention also relates to a system comprising an aerosol generating device and an article comprising aerosol-generating material.

BACKGROUND OF THE INVENTION

Methods of, and devices for, extraction of compounds from materials have long been used to provide users with the pleasurable or medicinal benefits of the inhalation of such compounds. Attempts have been made to provide 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, for example, contain nicotine.

SUMMARY OF THE INVENTION

In accordance with some embodiments described herein, there is provided an aerosol generating device for generating an aerosol from aerosol-generating material comprising:

- a receptacle comprising a peripheral wall defining a heating zone for receiving at least a portion of an article containing aerosol-generating material;
- an elongate rib protruding into the heating zone, the elongate rib comprising an article locating face arranged to space at least a portion of an article received in the heating zone from the peripheral wall to provide an airflow path between the article and the peripheral wall;
- wherein the elongate rib extends at least partially circumferentially about the peripheral wall.

The elongate rib may form an at least partially helical path around the peripheral wall of the receptacle.

The elongate rib may form a complete helical path around the peripheral wall of the receptacle in contact with the article.

The elongate rib may comprise a discontinuity.

The elongate rib may comprise at least two turns of a helical path, wherein each turn comprises a discontinuity.

Each of the at least two discontinuities of the at least two turns of the helical path of the elongate rib may be at the same circumferential angular position on the peripheral wall of the receptacle.

Each of the at least two discontinuities on of the at least two turns of the helical path of the elongate rib may be at different circumferential angular positions on the peripheral wall of the receptacle.

The elongate rib may extend discontinuously in only a circumferential direction around the peripheral wall of the receptacle.

The cross-sectional shape of the elongate rib may be trapezoidal. The shorter of the two parallel sides of the trapezoidal cross-section of the elongate rib may form the article locating face.

The cross-sectional shape of the elongate rib may be rectangular. The corners of the article locating face of the rectangular cross-section of the rib may be rounded. The cross-sectional shape of the elongate rib may be elliptical. The cross-sectional shape of the elongate rib may be triangular. The triangular cross-section of the elongate rib may have rounded apexes.

The elongate rib may be truncated.

The elongate rib may be configured to partially deform the article.

The elongate rib may be one of a plurality of elongate ribs.

Each of the plurality of elongate ribs may extend at least partially circumferentially about the peripheral wall.

The plurality of peripheral ribs may define a helical path about the peripheral wall.

Adjacent peripheral ribs of the plurality of peripheral ribs may be spaced from each other in a circumferential direction. Adjacent peripheral ribs of the plurality of peripheral ribs may be spaced from each other in an axial direction. An axial flow path may be defined along the heating zone by at least some of the peripheral ribs.

The receptacle and the elongate rib may be integrally formed.

The receptacle and elongate rib may be a one piece component.

The aerosol generating device may comprise a heating element configured to heat the article.

The receptacle may comprise the heating element.

The receptacle may be a tubular member.

The heating element may comprise a material heatable by penetration with a magnetic field.

The heating element may comprise a material configured to heat under application of an electric current therethrough.

The elongate rib or plurality of elongate ribs may form part of the heating element.

The heating element may upstand in the receptacle.

In accordance with some embodiments described herein, there is provided an aerosol generating device for generating an aerosol from aerosol-generating material comprising:

- a receptacle comprising a peripheral wall defining a heating zone for receiving at least a portion of an article containing aerosol-generating material;
- an elongate rib comprising at least one article locating face protruding in the heating zone, the article locating face having a circumferential length greater than an axial length with respect to a longitudinal axis of the heating zone.

In accordance with some embodiments described herein, there is provided an aerosol generating device system comprising the aerosol generating device of any those described above and an article containing aerosol generating material, in which the article is at least partially receivable in the heating zone of the aerosol generating device.

The article may be tubular and may comprise a circular cross section.

In accordance with some embodiments described herein, there is provided an aerosol generating device for generating an aerosol from aerosol-generating material, the device comprising a heating zone for receiving at least a portion of an article containing aerosol-generating material and a heating arrangement comprising a heating element arranged to heat the heating zone, and a threaded arrangement in the heating zone configured to threadingly engage with the article.

The threaded arrangement may comprise an internal thread arranged to threadingly engage with an outer side of the article.

The threaded arrangement may comprise an external thread arranged to threadingly engage in the article.

The heating element may comprise the threaded arrangement.

The heating element may at least partially encircle the heating zone.

The heating element may form at least part of a receptacle defining the heating zone.

The heating element may comprise a tubular member and the threaded arrangement may comprise a thread on an inner side of the tubular member.

The heating element may protrude in the heating zone.

The threaded arrangement may comprise a shaft and a thread on the shaft.

The shaft may be tapered.

The thread may extend from a free end of the shaft.

The thread may have a constant pitch along the length of the shaft.

The thread may comprise a heat conductive material.

The thread may be heatable by penetration with the varying magnetic field in the heating zone.

The aerosol generating device may comprise an actuating mechanism configured to rotate the threaded arrangement in the heating zone.

The actuating mechanism may comprise an actuator.

The actuator may comprise an electric motor.

The actuating mechanism may be configured to rotate the threaded arrangement in the heating zone in response to insertion of an article into the heating zone.

The aerosol generating device may comprise a receptacle defining the heating zone, wherein the receptacle comprises the threaded arrangement.

The heating element may protrude in the heating zone.

The heating element may comprise a planar peripheral side.

The aerosol generating device may comprise a field generator including an inductor coil configured to generate a varying magnetic field.

The heating element may be heatable by penetration with the varying magnetic field in the heating zone.

The heating element may comprise part of a resistive heating arrangement.

In accordance with some embodiments described herein, there is provided a heating element for heating an article containing aerosol-generating material received in a heating zone of an aerosol generating device, the heating element comprising a threaded arrangement arranged to threadingly engage with an article containing aerosol-generating material.

The heating element may comprise material heatable by penetration with a varying magnetic field.

The heating element may be a resistive heating element.

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

The article may comprise an article thread configured to interact with the threaded arrangement of the device.

The article thread of the article may be an internal threaded bore.

The article thread of the article may be on an outer side of the article.

The article may comprise a pre-formed bore configured to receive the heating element.

The threaded arrangement may be configured to engage with a face of the bore.

The article may comprise an engaging feature configured to engage with the threaded arrangement.

The engaging feature may be at least one of a bore, a collar, a shoulder, a ridge, a protrusion, a recess, a lip, a chamfer, a region of increased thickness, a region of reduced thickness, a face, and an edge.

The threaded arrangement may be configured to engage with a relatively more resilient engaging feature of the article.

The threaded arrangement may be configured to engage with a relatively less resilient engaging feature of the article.

The article may comprise an outer side of the article, and the threaded arrangement may be configured to at least one of deform and distend an outer side of the article when the article is received in the heating zone.

The threaded arrangement may be configured to compress the article.

The threaded arrangement may be configured to form an indent in the outer side of the article

The article may comprise an outer side, and the threaded arrangement may be configured to at least one of deform and distend the outer side of the article when the article is received in the heating zone. Insertion of the article may be configured to deform the threaded arrangement.

The article may be a consumable.

The heating element may be removable from the heating zone. The heating element may be interchangeable.

The heating element may upstand from the base. The heating element may comprise a sharp edge or point at a free end. The heating element may be a pin. The heating element may be configured to pierce the article received by the heating zone.

The heating element and receptacle may be co-axial.

The apparatus of this aspect can include one or more, or all, of the features described above, as appropriate.

The aerosol generating device may be a non-combustible aerosol generating device.

The device may be a tobacco heating device, also known as a heat-not-burn device.

The aerosol generating material may be non-liquid aerosol generating material.

The article may be dimensioned to be at least partially received within the heating zone.

In accordance with some embodiments described herein, there is provided an aerosol generating device for generating an aerosol from aerosol-generating material comprising: a receptacle defining a heating zone configured to receive at least a portion of an article comprising aerosol-generating material, and a heating element arranged to heat the heating zone.

In accordance with some embodiments described herein, there is provided an aerosol-generating system comprising an article comprising aerosol-generating material; an aerosol generating device for heating aerosol-generating material comprising a heating zone configured to receive at least a portion of the article; and a heating element.

The apparatus of these aspects can include one or more, or all, of the features described above, as appropriate.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 shows a front perspective view of an aerosol generating system with an aerosol generating device and an article inserted into the device;

FIG. 2 shows schematically the aerosol generating system of FIG. 1;

FIG. 3 shows schematically the aerosol generating system of FIG. 1 with a threaded arrangement on an inner surface of the heating zone;

FIG. 3a shows schematically an example of an article for use with the aerosol generating system of FIG. 3;

FIG. 3b shows schematically an example of an externally threaded article for use with the aerosol generating system of FIG. 3;

FIG. 4 shows schematically another aerosol generating system where the threaded arrangement is formed on the inner surface of a receptacle of the device;

FIG. 4a shows schematically an article with a preformed bore for use with the aerosol generating system of FIG. 4 or 5;

FIG. 5 shows schematically another aerosol generating system of FIG. 1 where an inner heating element is provided with a thread;

FIG. 5a shows schematically an internally threaded article for use with the aerosol generating system of FIG. 5; and

FIG. 6 shows schematically another aerosol generating system of claim 1 where the device according to FIG. 5, comprises an actuation mechanism for rotating at least one of the receptacle and heating element.

FIG. 7 shows schematically a receptacle provided with an elongate rib for use with the aerosol generating system of FIG. 1 or 2.

FIGS. 8A and 8B show schematically the receptacle of FIG. 7, with an article inserted therein.

FIG. 9 shows schematically the receptacle of FIG. 7, with discontinuities in the elongate rib around the circumference of the receptacle.

FIG. 10A shows schematically a triangular cross-section elongate rib for use with the receptacle of FIG. 7.

FIG. 10B shows schematically a rectangular cross-section elongate rib for use with the receptacle of FIG. 7.

FIG. 10C shows schematically an elliptical cross-section elongate rib for use with the receptacle of FIG. 7.

FIGS. 11A and 11B show schematically a receptacle according to FIG. 7, with a triangular rib according to FIG. 10A, with an article inserted in the receptacle.

DETAILED DESCRIPTION OF THE DRAWINGS

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

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

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

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

Apparatus is known that heats aerosol generating material to volatilize at least one component of the aerosol generating material, typically to form an aerosol which can be inhaled, without burning or combusting the aerosol generating material. Such apparatus is sometimes described as an “aerosol generating device”, an “aerosol provision device”, a “heat-not-burn device”, a “tobacco heating product device” or a “tobacco heating device” or similar. Similarly, there are also so-called e-cigarette devices, which typically vaporize an aerosol generating material in the form of a liquid, which may or may not contain nicotine. The aerosol generating material may be in the form of or be provided as part of a rod, cartridge or cassette or the like which can be inserted into the apparatus. A heater for heating and volatilising the aerosol generating material may be provided as a “permanent” part of the apparatus.

An aerosol generating device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilize the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol provision 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.

FIG. 1 shows an example of an aerosol generating system 100. The system 100 comprises an aerosol generating device 101 for generating aerosol from an aerosol generating material, and a replaceable article 110 comprising the aerosol generating material. The device 101 can be used to heat the replaceable article 110 comprising the aerosol generating material, to generate an aerosol or other inhalable material which can be inhaled by a user of the device 101.

The device 101 comprises a housing 103 which surrounds and houses various components of the device 101. The housing 103 is elongate. The device 101 has an opening 104 in one end, through which the article 110 can be inserted for heating by the device 101. The article 110 may be fully or partially inserted into the device 101 for heating by the device 101.

The device 101 may comprise a user-operable control element 106, such as a button or switch, which operates the device 101 when operated, e.g. pressed. For example, a user may activate the device 101 by pressing the switch 106.

The device 101 defines a longitudinal axis 102, along which an article 110 may extend when inserted into the device 101. The opening 104 is aligned on the longitudinal axis 102.

FIG. 2 is a schematic illustration of the aerosol generating system 100 of FIG. 1, showing various components of the device 101. It will be appreciated that the device 101 may include other components not shown in FIG. 2 and that some components shown in FIG. 2 may not be present in some embodiments.

As shown in FIG. 2, the device 101 includes an apparatus for heating aerosol-generating material 200. The apparatus 200 includes a heating assembly 201, a controller (control circuit) 202, and a power source 204. The apparatus 200 comprises a body assembly 210. The body assembly 210 may include a chassis and other components forming part of the device. The heating assembly 201 is configured to heat the aerosol-generating material of an article 110 inserted into the device 101, such that an aerosol is generated from the aerosol generating material. The power source 204 supplies electrical power to the heating assembly 201, and the heating assembly 201 converts the supplied electrical energy into heat energy for heating the aerosol-generating material.

The power source 204 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 power source 204 may be electrically coupled to the heating assembly 201 to supply electrical power when required and under control of the controller 202 to heat the aerosol generating material. The control circuit 202 may be configured to activate and deactivate the heating assembly 201 based on a user operating the control element 106. For example, the controller 202 may activate the heating assembly 201 in response to a user operating the switch 106.

The end of the device 101 closest to the opening 104 may be known as the proximal end (or mouth end) 107 of the device 101 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 110 into the opening 104, operates the user control 106 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the article 110 along a flow path towards the proximal end of the device 101.

The other end of the device furthest away from the opening 104 may be known as the distal end 108 of the device 101 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 of the device 101. The terms proximal and distal as applied to features of the device 101 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the axis 102.

The heating assembly 201 may comprise various components to heat the aerosol generating material of the article 110 via an inductive heating process or a resistive heating process, for example. Induction heating is a process of heating an electrically conducting heating element (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 element and the susceptor, allowing for enhanced freedom in construction and application. Resistive heating instead utilises utilizes the Joule heating effect arising from the electrical resistance of a material in response to application of a current directly therethrough.

The apparatus 200 includes a heating chamber 211 configured and dimensioned to receive the article 110 to be heated. The heating chamber 211 defines a heating zone 215. In the present example, the article 110 is generally cylindrical, and the heating chamber 211 is correspondingly generally cylindrical in shape. However, other shapes would be possible. The heating chamber 211 is formed by a receptacle 212. The receptacle 212 includes an end wall 213 and a peripheral wall 214. The end wall 213 acts as a base of the receptacle 212. The receptacle 212 in embodiments is a one-piece component. As used herein, the term ‘one-piece component’ is intended to mean that the features are formed together such that no joints are defined therebetween. In other embodiments the receptacle 212 comprises two or more components.

The heating chamber 211 is defined by the inner surfaces of the receptacle 212. The receptacle 212 acts as a support member. The receptacle 212 comprises a generally tubular member. The receptacle 212 extends along and around and substantially coaxial with the longitudinal axis 102 of the device 101. However, other shapes would be possible. The receptacle 212 (and so heating zone 215) is open at its proximal end such that an article 110 inserted into the opening 104 of the device 101 can be received by the heating chamber 211 therethrough. The receptacle 212 is closed at its distal end by the end wall 213. The receptacle 212 may comprise one or more conduits that form part of an air path. In use, the distal end of the article 110 may be positioned in proximity or engagement with the end of the heating chamber 211. Air may pass through the one or more conduits forming part of the air path, into the heating chamber 211, and flow through the article 110 towards the proximal end of the device 101.

The receptacle 212 may be formed from an insulating material. For example, the receptacle 212 may be formed from a plastic, such as polyether ether ketone (PEEK). Other suitable materials are possible. The receptacle 212 may be formed from such materials ensure that the assembly remains rigid/solid when the heating assembly 201 is operated. Using a non-metallic material for the receptacle 212 may assist with restricting heating of other components of the device 101. The receptacle 212 may be formed from a rigid material to aid support of other components.

Other arrangements for the receptacle 212 would be possible. For example, in an embodiment the end wall 213 is defined by part of the heating assembly 201. In embodiments, the receptacle 212 comprises material that is heatable by penetration with a varying magnetic field. In some embodiments, the receptacle 212 comprises a material heatable by resistive Joule heating.

As illustrated in FIG. 3, the heating assembly 201 may comprise a heating element 320 positioned surrounding the heating zone 215. In such an arrangement, the heating element 320 forms the receptacle 212. The heating element 320 defines the peripheral wall 214. The heating element 320 is configured to heat the heating zone 215. The heating zone 215 is defined in the heating chamber 211. In embodiments the heating chamber 211 defines a portion of the heating zone 215 or the extent of the heating zone 215.

The heating element 320 is heatable to heat the heating zone 215. The heating element 320 may be an induction heating element or a resistive heating element. That is, the heating element 320 may comprise a susceptor that is heatable by penetration with a varying magnetic field or a resistive material heatable by passing a current directly therethrough from a power source. If the heating member 320 comprises a susceptor, the susceptor comprises electrically conducting material suitable for heating by electromagnetic induction. For example, the susceptor may be formed from a carbon steel. It will be understood that other suitable materials may be used, for example a ferromagnetic material such as iron, nickel or cobalt.

As shown in FIG. 2, the heating assembly 201 comprises a magnetic field generator 250. The magnetic field generator 250 is configured to generate one or more varying magnetic fields that penetrate the heating element 320 so as to cause heating in the heating element 320. The magnetic field generator 250 includes an inductor coil arrangement 251. The inductor coil arrangement comprises an inductor coil 252, acting as an inductor element. The inductor coil 252 may be a helical coil, however other arrangements are envisaged. In embodiments, the inductor coil arrangement 251 comprises two or more inductor coils. The two or more inductor coils in embodiments are disposed adjacent to each other and may be aligned co-axially along the axis.

In some examples, in use, the magnetic field generator 250 is configured to heat the heating element 320 to a temperature of between about 200° C. and about 350° C., such as between about 240° C. and about 300° C., or between about 250° C. and about 280° C. In examples where the heating element is a resistive heating element, similar or the same temperatures may be reached by resistive heating therein.

The inductor coil 252 may be a helical coil comprising electrically-conductive material, such as copper. The coil is formed from wire, such as Litz wire, which is wound helically around a support member (not shown). The support member is formed by the receptacle 212 or by another component. In embodiments, the support member is omitted. The support member is tubular. The coil 252 defines a generally tubular shape. The inductor coil has a generally circular profile. In other embodiments, the inductor coil may have a different shape, such as generally square, rectangular or elliptical. The coil width may increase or decrease along its length.

Other types of inductor coil may be used, for example a flat spiral coil. With a helical coil it is possible to define an elongate inductor zone in which to receive a susceptor, which provides an elongate length of susceptor to be received in the elongate inductor zone. The length of susceptor subjected to varying magnetic field may be maximized. By providing an enclosed inductor zone with a helical coil arrangement it is possible to aid the flux concentration of the magnetic field.

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. Other wire types could be used, such as solid. The configuration of the helical inductor coil may vary along its axial length. For example, the inductor coil, or each inductor coil, may have substantially the same or different values of inductance, axial lengths, radii, pitches, numbers of turns, etc. In embodiments, such as that shown in FIGS. 4 and 5, the heating element 420 extends in the heating zone 215. The heating element 420, acting as a protruding element, protrudes in the heating zone 215. The heating element 420 upstands from the base. The heating element 420 is spaced from the peripheral wall 214. The heating assembly 201 is configured such that when an article 110 is received by the heating chamber 211, the heating element 420 extends into a distal end of the article 110. The heating element 420 is positioned, in use, within the article 110. The heating element 420 is configured to heat aerosol generating material of an article 110 from within, and for this reason is referred to as an inner heating element.

The heating element 420 extends into the heating chamber 211 from the distal end of the heating chamber 211 along the longitudinal axis 102 of the device (in the axial direction). In embodiments the heating element 420 extends into the heating chamber 211 spaced from the axis 102. The heating element 420 may be off-axis or non-parallel to the axis 102. Although one heating element 420 is shown, it will be understood that in embodiments, the heating assembly 201 comprises a plurality of heating elements 420. Such heating elements in embodiments are spaced from but parallel to each other.

When the heating element 320, 420 of any of the described embodiments utilises utilizes heating via magnetic susceptibility, the inductor coil 252 may be disposed external to the receptacle 212. The inductor coil may encircle the heating zone 215. The helical inductor coil may extend around at least a portion of the heating element 320, 420, acting as a susceptor. The helical inductor coil is configured to generate a varying magnetic field that penetrates the heating element 320, 420. The helical inductor coil is arranged coaxially with the heating chamber 211 and longitudinal axis 102.

Although the illustrated embodiments show devices including either a heating element 320 disposed around the heating zone 215 and at least one heating element 420 disposed within the heating zone 215, any of the described embodiments may utilize both a heating element 320 surrounding the heating zone 215 and one or more heating elements 420 within the heating zone 215.

The heating element 420 protrudes in the heating zone 215 and is received by the article 110. FIG. 2 shows the article 110 received in the device 101. The article 110 is sized to be received by the receptacle 212. The outer dimensions of the article 110 perpendicular to the longitudinal axis of the article 110 substantially correspond with the inner dimensions of the chamber 211 perpendicular to the longitudinal axis 102 of the device 101 to allow insertion of the article 110 into the receptacle 212. In embodiments, a gap 216 is defined between an outer side 111 of the article 110 and an inner side 217 of the receptacle 212. The gap 216 may act as an air passage along at least part of the axial length of the chamber 211. An insertion end 112 of the article 110 is arranged to lie adjacent to the base of the receptacle 212.

FIG. 2 illustrates a basic structure of the device 101. Particular features are omitted in this figure such as the threaded arrangement, as the various envisaged configurations of these will be discussed in terms of the embodiments shown in FIGS. 3 to 5. FIG. 2 does however generally show an article 110 disposed within the heating zone 215 of a device 101. This is an in-use configuration in which the aerosol-generating material in the article may be heated and a user may draw the aerosolized material from the article/device.

FIG. 3 illustrates an arrangement of the device 101. As can be seen, the receptacle 212 comprises a threaded arrangement 350. The threaded arrangement 350, in this embodiment, comprises a thread 351 disposed on the inner surface of the receptacle 212. The thread is helical. Although the pitch of the threaded arrangement 350 is shown in this figure as being rather large, such that the entire threaded arrangement 350 comprises around 2 or 3 turns (turn count) along the length of the receptacle 212, any particular pitch or number of turns for any of the threaded arrangements described herein are envisaged. Generally, a higher pitch, and therefore lower thread count along the length of the threaded arrangement minimizes the number of rotations required upon insertion thereof into the device. In some embodiments, the turn count of the threaded arrangement is between 1 and 5. In FIG. 3, the heating element 320 is positioned surrounding the heating zone 215. This means that the article 110 is heated from the outside.

The threaded arrangement 350 in embodiments forms part of the heating element 320 or may a component placed in proximity to the heating element 320. When the threaded arrangement 350 is part of the heating element 320, or is otherwise thermally conductive, the threads 351 of the threaded arrangement 350 increase the surface area of the article 110 in contact with, or in proximity to, the heating element 320. This helps increase the rate of heating of the article 110 in use, thereby resulting in faster aerosolization of the material in the article 110, a greater aerosolization effect, and greater overall efficiency of the device. In addition, the provision of the threaded arrangement ensures that the article 110 can be simply and securely inserted into the device 101.

FIG. 3a shows an example of an article 110 for use with the device 101 of any of the embodiments described herein. As can be seen, the article 110 is generally cylindrical in shape, although other shapes are envisaged. The article 110 of FIG. 3a is generally malleable to the extent that, when driven into the heating zone 215 into engagement with the threaded arrangement 350, the thread 351 deforms and/or distends the article 110 such that the threads 315 increase their contact surface area with the article 110 and the aerosol-generating material thereof. As mentioned above, this increased contact surface area increases the aerosolization effect of the device 101.

FIG. 3b shows an example of an article 110 for use with the device 101 of FIG. 3, or any other contemplated device 101 also including an internally threaded receptacle 212. As can be seen in the figure, the article 110 is provided with an external thread 353. External thread 353 is configured to match the threading arrangement 350 disposed on the internal surface of the receptacle 212 such that the article 110 may be more easily and precisely screwed into the heating zone 215 of the device 101 in use. Less malleable articles may be used with such external threads. The use of an external thread may also provide for a more secure placement of the article in the device, as well as also providing an increased contact surface area or thermal path between the heating element 320 and the article 110.

FIG. 4 shows a further embodiment of the present invention. In this embodiment, the receptacle 212 is again provided with a threaded arrangement 350 on its internal surface. The threaded arrangement 350 is generally the same as the arrangement 350 described in relation to FIG. 3. In this embodiment, however, the receptacle 212 and the threaded arrangement 350 are free from heating material. Both articles 110 of FIGS. 3a and 3b may be used with the device 101 of FIG. 4. The device 101 of FIG. 4 differs from that of FIG. 3 in that the heating element 420 is instead disposed internally to the heating zone 215. The heating element 420 is in the form of a pin and is configured to pierce the article 110 in use. As can be seen from the figure, the free end 222 of the heating element 420 is provided with a spike in order to facilitate insertion of the element 420 into the article 110. In this embodiment, the heating element is a straight pin. The outer side of the pin is cylindrical. The heating element 420 is free from a threaded arrangement. The downward pressure of the article 110 onto the heating element 420 pierces and is subsequently embedded in the article 110. The heating element 420, by inductive or resistive heating, is configured to produce heat and heat the contents of the article 110 from the inside, thereby aerosolising the aerosol-generating material therewithin. In this embodiment, the threaded arrangement 350 on the internal surface of the receptacle not only provides a more secure positioning of the article 110 in the heating zone 215, but aids in providing the necessary force to pierce the article 110 with the heating element 420. Rotational motion of the article 110 is translated into linear motion by the threaded arrangement 350, which drives the article 110 onto the pin of the heating element 420. This may prevent breakage or damage of the article 110 as compared to known devices, which may be caused by an excessive direct linear downward force exerted on the article 110 by the user to push the article 110 onto the heating element 420.

Although not shown, one embodiment of the invention involves a combination of the embodiments of FIG. 3 and FIG. 4. That is to say, one embodiment of the device 101, with the threaded arrangement 350, includes both a heating element 320 disposed around the heating zone 215 and a heating element 420 protruding in the heating zone 215. Any of the embodiments with an internal heating element 420 may comprise multiply internal heating elements 420. Including both external and internal heating elements increases the heating effect of the article 110, including providing faster heating and a better heat distribution through the article 110.

FIG. 4a shows an example of an article 110 for use with any of the embodiments of the present invention, but particularly those of FIGS. 4 and 5, which comprise an inner pin-shaped heating element 420 protruding in the heating zone 215. The article 110 shown in this figure comprises an internal bore 113 with inner bore surface 114. The bore 113 is pre-formed in the article 110. The bore 113 is formed in embodiments by a tubular portion of the article 110. The bore 113 in embodiments extends partially along the longitudinal axis of the article. The bore 113 has a closed end 115. The heating element 420 is sized to be received in the bore 113. The heating element 420 and bore 113 are complimentary sized. The provision of a bore 113 in general facilitates the insertion of a pin heating element 420 into the article 110. The inner surface 114 of the bore is configured to form a close contact with the heating element to maximize heat transfer between the heating element 420 and the article 110.

In embodiments the outer dimensions of the heating element are greater than those of the bore. In such arrangements, the heating element is configured to deform and/or distend the article 110 to be inserted into the device 101. To facilitate this, the inner heating element 420 is configured to pierce an article 110 that is inserted into the device 101. In such an embodiment, the free end 222 of the heating element 420 comprises a sharp edge or point. The free end 222 of the heating element 420 in embodiments comprises a sharp edge, point or other guide feature to aid location of the heating element 420 in the article 110.

The article 110 shown in FIG. 4a is envisaged to be used with any of the embodiments described herein comprising such an internal heating element 420.

FIG. 5 shows a further embodiment of the invention. In this embodiment, an internal pin heating element 420 is provided. The heating element 420 is provided with a threaded arrangement 450 on its outer surface 223. The threaded arrangement 450 may form part of the heating element 420 or be otherwise thermally conductive. Similar to the threaded arrangement 350 of aforementioned embodiments, the threaded arrangement 450 increases the contact surface area or thermal path between the heating element 420 and the article 110, thereby increasing the heating effect of the heating element 420 on the article 110. The heating element 420 is formed with a shaft and a thread on the shaft. In embodiments the shaft is tapered. The shaft in embodiments is tapered to the free end of the heating element. In embodiments the thread 450 extends to the free end of the heating element.

The heating element 420 may further be provided with a spike on its free end 222 to ease insertion. In use the article 110 is rotated onto the threaded arrangement 450 of the heating element 420 which allows the heating element 420 to pierce the article 110. Although not shown, in any of the described embodiments, a heating element 320 may also be disposed surrounding the heating zone 215 in order to increase heating distribution and power. In addition, although not shown in any of the figures, any embodiment of the invention may include an externally threaded pin heating element 420 as shown in FIG. 5 and also an internally threaded receptacle 212 defining the heating zone as shown in FIG. 3. The combination of these threaded arrangements on the receptacle 212 and the heating element 420 further increase the secure fit, ease of insertion, increased heating effectiveness and overall device efficiency associated with each individual embodiment.

FIG. 5a shows an example of an article 110 for use with any of the embodiments of the present invention. The article 110 of FIG. 5a is generally the same as the article 110 of FIG. 4a, apart from the bore 113 of the article 110 of FIG. 5a is provided with a threaded arrangement 550. Providing the bore 113 with a threaded arrangement 550, which matches a threaded arrangement 450 on the outer surface of an internal heating element 420, further improves the ease of insertion of the heating element 420 into the article 110 and also the contact surface area or thermal path between the heating element 420 and the article 110. As compared with articles 110 with no bore 113, or a straight sided bore 113, the article 110 of FIG. 5a with a threaded arrangement 550 may be employed to enable articles 110 with less malleability to be used in devices 101 as described in the present invention.

Any combination of the aforementioned features relating to each embodiment, such as the external and internal heating elements 320 and 420, the threaded arrangements 350 and 450 on said heating elements, the internal and external threaded arrangements 353 and 550 of the article, and/or the straight-sided internal bore 113 of the article, is contemplated.

Although the heating elements 320 and 420 and the threaded arrangements 350 and 450 thereon have generally been represented as being constant in diameter, in some embodiments, the heating elements may be tapered along their length (along the longitudinal axis 102). A tapered internal pin heating element 420 may further aid in the insertion thereof into an article 110 in use.

In any of the embodiments comprising a heating element 420 internal to the heating chamber 215 comprising an external threaded arrangement 450, the device 101 may further comprise a manual or motorized means of rotating the heating element 420 and/or receptacle 212 with the threaded arrangement 350, 450 with respect to the heating zone 215 and an inserted article. The heating element 420 and/or threaded arrangement 450 may be configured to automatically rotate upon insertion of the article 110, such as by detection of pressure on the device 101 from the article 110. Motorized rotation, via an included actuation mechanism, of the threaded arrangement 450 and/or heating element 420 aids the user in driving the article 110 onto the heating element 450 in the heating zone 215.

FIG. 6 shows an embodiment of the device 101 including an actuation mechanism 600. As described above, the actuation mechanism 600 may be configured to drive rotation of the heating element 420 and/or receptacle 212 with the threaded arrangement 350, 450 with respect to the heating zone 215. The actuation mechanism 600 may be powered by power source 204 and may be activated via a switch or automatically upon detection/insertion of an article 110 in the heating zone 215. Since the actuation mechanism 600 may be configured to rotate one or both of the receptacle 212 and the heating element 420, it may be included in any of the embodiments described herein.

FIGS. 7 to 11 illustrate embodiments of the receptacle 212 of the device 101. The receptacle 212 of the embodiments shown in these figures may be combined with any combination of the specific features described in relation to the aforementioned embodiments. For example, the receptacle 212 of FIGS. 7 to 11 may be provided with a heating element 320 positioned surrounding the heating zone 215, where the heating element 320 forms the receptacle 212 and defines the peripheral wall 214. Alternatively, or in addition, the device 101 may comprise a heating element 420 which protrudes into the heating zone 215.

FIG. 7 illustrates an embodiment of the receptacle 212. In this embodiment, the receptacle is provided with one or more elongate ribs 700. As can be seen from the figure, the one or more ribs 700 may take the form of elongate protrusions, protruding inwardly from the inner surface 214 of the receptacle 212, towards the central axis of the receptacle 212.

The one or more ribs 700 extend at an angle to the longitudinal axis 102 of the receptacle 212. This means that the longest dimension of the one or more elongate ribs 700 extends at least partially circumferentially around the inner surface 214 of the receptacle 212. In other words, the length that the one or more ribs 700 extends around the circumference of the inner surface 214 of the receptacle 212 is greater than the length that the one or more elongate ribs extends along the longitudinal axis 102. To help illustrate, the rib axis 750 has been illustrated in FIG. 7. This is the longitudinal axis of the rib and is the midpoint of the cross-section of the rib along its length. In subsequent discussion of the direction of extension or path of ribs in this disclosure, the direction shall be equivalent to the direction of this axis.

In FIG. 7, the cross-section 701 of the one or more ribs 700 has a trapezoidal shape. However, other shapes are envisaged will be discussed with reference to FIGS. 10A to 11B. With such a trapezoidal cross-sectional shape as shown in FIG. 7, the relatively flat surfaces of the one or more ribs 700 are not configured to significantly deform an article 110 inserted into the receptacle. Instead, the function of the one or more ribs 700 is to separate the article 110, around its outer circumference, from the inner surface 214 of the receptacle 212.

FIGS. 8A and 8B show a receptacle 212 according to the embodiment of FIG. 7 with an article 110 inserted therein. FIG. 8A maintains the view of the one or more ribs 700 on the back wall of the receptacle as viewed from the perspective of the figure. This is for illustrative purposes only. FIG. 8B is closer to a true cross-section of the receptacle 212 with the article 110 inserted therein. However, the one or more ribs 700 on the inner surface 214 closer to the viewer of the figure are still shown with dotted lines, for illustrative purposes only.

As can be seen from the figure, when an article 110 is inserted into the receptacle 212, the separation of the outer surface of the article 110 and the inner peripheral surface 214 of the receptacle 212 creates a gap 800. The gap 800 is configured to allow air to flow therethrough, and can therefore also be denoted as an air channel 800. The thickness of the gap 800, i.e. the separation between the outer surface of the article 110 and the inner surface 214 of the receptacle 212, is dependent on the height 702 of the one or more ribs 700 (shown in FIG. 8C) and in the case of a trapezoidal cross-section rib 700, generally equal to the height of the rib. As can be appreciated, the separation between the article 110 and the inner surface 214 of the receptacle 212 increases the overall maximum airflow therebetween, and across the outer surface of the article. The magnitude of the separation may therefore be chosen to select a particular maximum or working airflow.

The one or more ribs 700 of FIGS. 7 to 8B are shown to be one continuous helical rib 700 extending in a helical fashion around the inner surface 214 of the receptacle. Such a configuration provides a helical air flow path from the open end 104 to the base end 213 between the receptacle and the article 110. In use, air is drawn by a user from the open end 104. This creates a pressure drop in the receptacle which causes an inflow of air from proximate the opening of the receptacle and between the receptacle and the article 110. The article 110 itself is air permeable, such that air passes from the base end and through the article 110 and collects aerosolized material, produced through heating of the article 110. Providing an airflow path with a circumferential element, as in the embodiment of FIGS. 7 to 8B, provides the potential to control the length of the one or more airflow paths between the outer surface of the article and the inner surface 214 of the receptacle.

The airflow path length and overall airflow can be selected accordingly, to provide the desired airflow characteristics, by adjusting the height of the one or more ribs 700 and adjusting the shape and length of the one or more airflow paths provided by said one or more ribs 700. One way this may be done in the embodiment of FIGS. 7 to 8B is by increasing the number of turns of the helical rib 700. It is also anticipated that the width 703 of the article locating face 704 of the one or more ribs 700 (see FIG. 8C) may be adjusted to increase overall air flow or the overall width 705 of the one or more ribs 700 be adjusted to allow more turns to be provided in a helically shaped rib 700. The article locating face 704 is named as such because this is the face of the one or more ribs 700 which contacts the outer surface of the article 110 in use, and therefore aids the location of the article 110 within the receptacle 212.

As discussed above, FIGS. 7 to 8B show the one or more ribs 700 to be a single continuous helical rib 700 extending helically around the inner circumference of the receptacle 212, completely or partially from the base end 213 to the open end 104. However, other embodiments are envisaged. For example, FIG. 9 shows an embodiment of the receptacle 212, wherein the one or more ribs 700 are provided as a series of discontinuous ribs 700 extending in a generally helical fashion along the length of the receptacle. In this way, the embodiment shown in FIG. 9 is similar to that shown in FIG. 7, but with discontinuities in the helical rib 700.

In this embodiment, the ribs 700 of adjacent turns 900 and 901 are shown to be generally in the same circumferential angular position. However, it is anticipated that the ribs of adjacent turns 900 and 901 may be offset from one another circumferentially, such as to avoid any directly axial airflow path through adjacent turns. In other embodiments, the one or more ribs 700 are not in a helical configuration at all, but may extend each in a purely circumferential direction. In this case, is it clear that the one or more ribs 700 must be discontinuous around the circumference of the receptacle. However, the ribs 700 may be near-complete circumferential ribs, with a small discontinuity at one angular position around the circumference of the receptacle, with an adjacent rib 700 having a similar shape but with its discontinuity at another angular position. The airflow path of such a configuration would be maximized by providing a 180 degree circumferential angular displacement between the discontinuities of adjacent ribs 700. In other embodiments, each of the one or more ribs 700 may each extend at different angles to one another, or any combination of equal angles and differing angles.

The one or more ribs 700 may also have different cross-sectional shapes. The ribs 700 shown in FIGS. 7 to 9, as can most clearly be seen from FIG. 8C, have a trapezoidal cross-section. With this shape, the one or more ribs 700 taper axially from the article locating face 704. This tapered edge is useful for ensuring ease of insertion of an article, which is typically inserted axially from the open end 104 of the receptacle 212. Without the tapered edge, a distal end of the article may catch on the rib edge and be damaged as a result thereof. The one or more ribs 700 of the present disclosure may form part of a heating element 320, for example where the receptacle 212 is the heating element 320. That is to say, the one or more ribs 700 themselves may be formed of a material configured to heat in the presence of a varying magnetic field, or by resistive heating. In such embodiments, the width 703 of the article locating face 704 is proportional to the area of contact heating of the article 110 in use, since the width 703 is proportional to the total contact area of the receptacle 212 with the article 110.

In some embodiments, only the one or more ribs 700 are formed from a material configured to heat in the presence of a varying magnetic field or by resistive heating, and the remainder of the receptacle is not. The ratio of total contact area between the one or more ribs 700 and the article to the area of the article 110 not contacted by the one or more ribs 700 is, in effect, a ratio of the intensity of heat applied to the article 110 and the maximum airflow provided around said article 110. Said ratio can be selected by selecting one or more of the number of the one or more ribs 700, the width 703 of the article locating surface 704 of the one or more ribs 700, the overall width 705 of the one or more ribs 700, the number of turns in a helical rib configuration, or the length of one or more ribs 700 in a discontinuous rib configuration, for example. Another advantage of the provision of the one or more ribs 700 is an increase in the grip on the article 110 when inserted into the receptacle 212. Although the ribs 700 have so far been described as being configured not to deform the article 110, it is envisaged that the ribs may slightly deform the article 110 due to the relative diameters of the article 110 and the receptacle 212 between article locating faces 704 of circumferentially opposing ribs 700.

The cross-sections of the one or more ribs 700 may have a shape other than trapezoidal. Some examples of these are shown in FIGS. 10A to 10C. FIG. 10A shows an example of a triangular cross-section rib 710. It is clear that, with this embodiment, in the absence of significant deformation of the article 110, there will be less contact between the rib 710 and article, since the effective article locating surface 704 is a tapered point. This triangular cross-section will be discussed in more detail with reference to FIGS. 11A and 11B. FIG. 10B shows an example of a rectangular cross-section rib 711. An advantage of such a cross-section would be that the article locating surface 704 is maximized with respect to the overall width 705 of the rib 711. This increases the available heating contact area per overall width 705. This means that, in a helical configuration for example, more rib turns, and therefore a longer flow path past an article 110, can be provided without compromising on heating contact area, since less axial space along the receptacle 212 would be taken up by a rectangular cross-section rib 711 as compared with a trapezoidal cross-section rib 700 with an equivalent width 703 article locating face 704. The rectangular cross-section rib 711 is shown in FIG. 10B with right-angled edges. To avoid damage to an article 110 upon insertion thereof into the receptacle 212, and to ease insertion, the ribs 711 may be provided with rounded edges. FIG. 10C shows an example of a rib 712 with an elliptical cross-section. This shape of rib further eases the insertion of the article 110 into the receptacle 212. As noted above, the ribs 700, 712 may form part of a heating element 320. In this case, the dimensions of the rib 712, as with the triangular rib, should ideally be chosen such that the rib at least partially deforms the article 110, so as to increase contact heating surface area.

FIGS. 11A and 11B show a close-up of an article inserted into the receptacle 212, the receptacle 212 comprising a triangular cross-section rib 710 on its inner surface 214. In this configuration, the rib 710 is seen as partially deforming the article 110. In this case, the article locating face 704 is proportional to the amount of deformation of the article 110. As shown, despite the deformation of the article 110, a gap 800 is still provided between the article 110 and the receptacle inner surface 214. When the ribs also form part of a heating element 320, there is also an increase in the heating contact surface area, thereby also increasing the overall heating of the article 110. If the triangular rib 710 is also disposed in a helical configuration, the article 110 may be screwed into position, providing the user with an easier and more secure method of insertion. Such a configuration may also be applied with an elliptical cross-section rib 712 as shown in FIG. 10C. To further increase contact area and ease of insertion, the cross-section of the triangular rib 710 may have a rounded point extending into the heating zone, rather than a sharp point.

In any of the embodiments described, the device 101 may be configured to heat the article 110 by producing a varying magnetic field configured to heat a susceptor heating element positioned within the article 110. That is, the article itself may further comprise a heating element. In embodiments, when located in the heating zone, the susceptor heating element positioned within the article generates heat in the presence of the varying magnetic field and thereby heats the article and produces aerosolized material from the aerosol-generating material. In some of the described embodiments, the heating arrangement is an inductive heating arrangement. In other embodiments, other types of heating arrangement are used, such as resistive heating. The configuration of the device is generally as described above and so a detailed description will be omitted. In such arrangements the heating assembly 201 comprises a resistive heating generator including components to heat the heating element via a resistive heating process. In this case, an electrical current is directly applied to a resistive heating component, and the resulting flow of current in the heating component causes the heating component to be heated by Joule heating. The resistive heating component comprises resistive material configured to generate heat when a suitable electrical current passes through it, and the heating assembly 201 comprises electrical contacts for supplying electrical current to the resistive material.

In embodiments, the heating element forms the resistive heating component itself. In embodiments the resistive heating component transfers heat to the heating element, for example by conduction.

The above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

Number	Date	Country	Kind
2108788.7	Jun 2021	GB	national
2118818.0	Dec 2021	GB	national

AEROSOL GENERATING DEVICE

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