Aerosol Generation Device and Consumable

FIELD OF INVENTION

The present invention relates to aerosol generation devices.

BACKGROUND

Aerosol generation devices, such as electronic cigarettes, are becoming increasingly popular consumer products.

Heating devices for aerosolisation, or vaporisation, are known in the art. Such devices typically include a heater arranged to heat an aerosol generating product. In operation, the aerosol generating product is heated with the heater to aerosolise the constituents of the product for the consumer to inhale. Such devices are typically designed to heat the aerosol generating product without burning it. Aerosol generating products may comprise tobacco in a form similar to a traditional cigarette, or in a capsule; other aerosol generating products may be a liquid, or liquid contents in a capsule.

There is a need to ensure that only suitable aerosol generating products are used with a respective aerosol generation device. An object of the present invention is to address this need.

SUMMARY

In a first aspect, there is provided a consumable for an aerosol generation device, wherein the consumable comprises a housing configured to contain an aerosol generating material, the housing having a first surface configured to engage with the aerosol generation device, the first surface comprising:

a breakable material configured to be broken upon interaction with one or more piercing elements of the aerosol generation device; and
a protective barrier configured to be resistant to the one or more piercing elements;
wherein the breakable material and the protective barrier are arranged such that the protective barrier defines one or more breakable regions in the first surface.

In this way, the consumable can only engage the piercing elements when properly arranged in the chamber. The requirement to properly arrange the consumable in the chamber can improve the child-resistance of the aerosol generation device.

Optionally, the consumable is a capsule or cartridge comprising an aerosol generating material such as an aerosolisable liquid, an aerosolisable solid, or a combination thereof. Alternatively, the consumable is a cigarette-like consumable, also referred to as a tobacco rod, and the aerosol generating material can be tobacco.

Optionally, the one or more breakable regions are arranged to be aligned with cooperating piercing elements of the one or more piercing elements of the aerosol generation device such that the first surface is pierceable by the piercing elements when the arrangement of the breakable regions coincides with an arrangement of the piercing elements.

In this way, the consumable can only be used with an aerosol generation device having the cooperating piercing elements. This can inhibit the use of unauthorised, non-compatible, or counterfeit consumables with the aerosol generation device.

Optionally, the one or more breakable regions provide an airflow path into the housing when pierced by the one or more cooperating piercing elements.

In this way, use of the consumable when not correctly engaged in the device is inhibited, further contributing to stopping the use of unauthorised, or non-compatible, consumables with the aerosol generation device.

Optionally, the one or more breakable regions are defined by one or more openings in the protective barrier.

Optionally, the first surface comprises a layer of barrier material over a layer of breakable material, the barrier material forming the protective barrier and arranged such that the one or more openings in the protective barrier expose the breakable material to form the one or more breakable regions.

In this way, the breakable regions can be fabricated by an efficient two-material process.

Optionally, the consumable comprises a cavity configured to receive a heating element of the aerosol generation device.

In this way, the heating element can be positioned within the consumable so as to efficiently heat the aerosol generating material therein.

In a second aspect, there is provided an aerosol generation device configured to receive a consumable, the aerosol generation device comprising:

one or more piercing elements arranged to pierce one or more cooperating breakable regions in a first surface of the consumable, and to be inhibited from piercing a protective barrier in the first surface of the consumable, such that:
- when the consumable is brought into connection with the aerosol generation device, and each of the one or more piercing elements align with one or more cooperating breakable regions in the first surface of the consumable, the aerosol generation device engages the consumable and the one or more piercing elements pierce the one or more cooperating breakable regions; and
- when the consumable is brought into connection with the aerosol generation device, and at least one piercing element aligns with the protective barrier of the first surface of the consumable, the aerosol generation device is inhibited from engaging the consumable.

In this way, the piercing elements can only engage the consumable when the consumable is properly arranged in the chamber. The requirement to properly arrange the consumable in the chamber can improve the child-resistance of the aerosol generation device. Furthermore, the consumable can only be used with an aerosol generation device having the cooperating piercing elements. This can inhibit the use of unauthorised, non-compatible, or counterfeit consumables with the aerosol generation device.

Optionally, the aerosol generation device is configured to receive the consumable of the first aspect.

Optionally, the one or more piercing elements have airflow channels therethrough arranged to provide an airflow into the consumable when having pierced a cooperating breakable region of the consumable.

In this way, use of the aerosol generation with the consumable is inhibited when not correctly engaged with the consumable. This further contributes to inhibiting the use of unauthorised, or non-compatible, consumables with the aerosol generation device.

Optionally, the aerosol generation device further comprises:

a chamber having an opening for receiving the consumable, and wherein the one or more piercing elements are arranged in the chamber; and
a base portion in the chamber, wherein the one or more piercing elements are arranged on the base portion.

In this way, the piercing elements can be configured to engage the consumable as it is inserted into the chamber for an aerosolisation session. This improves the user experience as a separate step to engage the consumable is not required before or following the insertion of the consumable. As the operator does not need to manually open the consumable separately to inserting it into the device, the risk of the contents of the consumable leaking onto the operator’s hands is reduced.

Optionally, the base portion divides the chamber to define a first chamber portion toward the opening, and a second chamber portion away from the opening.

Optionally, the first chamber portion is configured to heat the consumable to generate an aerosol product, and the second chamber portion is configured to pre-heat an airflow to the consumable.

In this way, the pre-heating of the airflow in the second region of the chamber can improve the user experience by mixing pre-heated air with the aerosol generated in the first region of the chamber. This can create a more consistent temperature for the aerosol product. Furthermore, pre-heating the air before it is drawn into the consumable inhibits the intake of ambient (or cold) air affecting the heating of the aerosol generating material. Such cold air can lower the temperature in the aerosol generating material, thereby requiring more power to be supplied to the heating element for the aerosolisation of the aerosol generating material. By pre-heating the air, less power needs to be supplied to the portion of the heating element used for the aerosolisation as the pre-heated air reduces or inhibits the effect of a temperature drop in the aerosol generating material.

Optionally, the aerosol generation device further comprises a heating element, wherein the heating element passes through an opening in the base portion such that a first heating element portion is arranged in the first chamber portion to heat the consumable, and a second heating element portion is arranged in the second chamber portion to pre-heat the airflow to the consumable.

In this way, a single heating element can have a first portion in the first portion of the chamber to aerosolise the aerosol generating material in the consumable and a second portion in the second potion of the chamber to pre-heat the airflow to the consumable. The portion of the heating element that is in the second portion of the chamber is not engaging the consumable, but can heat the air in the second portion of the chamber which is then drawn into the consumable. This arrangement inhibits the wastage of heat generated in the second portion of the heating element.

Optionally, the base portion is a moveable base configured to move along a length of the chamber.

In this way the moveable base can securely hold consumables of different lengths within the chamber.

In a third aspect, there is provided an aerosol generation system comprising the consumable of the first aspect, and the aerosol generation device of the second aspect.

In a fourth aspect, there is provided an aerosol generation system comprising a consumable for an aerosol generation device and an aerosol generation device configured to receive the consumable;

wherein the consumable comprises a housing configured to contain an aerosol generating material, the housing having a first surface configured to engage with the aerosol generation device, the first surface comprising:
- a breakable material configured to be broken upon interaction with one or more piercing elements of the aerosol generation device; and
- a protective barrier configured to be resistant to the one or more piercing elements;
wherein the breakable material and the protective barrier are arranged such that the protective barrier defines one or more breakable regions in the first surface; and
wherein the aerosol generation device comprises:
- a chamber having an opening for receiving the consumable, and a base portion in the chamber, wherein the base portion divides the chamber to define a first chamber portion toward the opening, and a second chamber portion away from the opening; and
- one or more piercing elements arranged on the base portion in the chamber, to pierce one or more cooperating breakable regions in the first surface of the consumable, and to be inhibited from piercing the protective barrier in the first surface of the consumable, such that:
  - when the consumable is brought into connection with the aerosol generation device, and each of the one or more piercing elements align with one or more cooperating breakable regions in the first surface of the consumable, the aerosol generation device engages the consumable and the one or more piercing elements pierce the one or more cooperating breakable regions; and
  - when the consumable is brought into connection with the aerosol generation device, and at least one piercing element aligns with the protective barrier of the first surface of the consumable, the aerosol generation device is inhibited from engaging the consumable.

Also in this way, the piercing elements can be configured to engage the consumable as it is inserted into the chamber for an aerosolisation session. This improves the user experience as a separate step to engage the consumable is not required before or following the insertion of the consumable. As the operator does not need to manually open the consumable separately to inserting it into the device, the risk of the contents of the consumable leaking onto the operator’s hands is reduced.

Optionally, the one or more breakable regions of the consumable are arranged to be aligned with cooperating piercing elements of the one or more piercing elements of the aerosol generation device such that the first surface is pierceable by the piercing elements when the arrangement of the breakable regions coincides with an arrangement of the piercing elements.

Optionally, the one or more breakable regions of the consumable provide an airflow path into the housing when pierced by the one or more cooperating piercing elements.

Optionally, the one or more breakable regions of the consumable are defined by one or more openings in the protective barrier.

Optionally, the first surface of the consumable comprises a layer of barrier material over a layer of breakable material, the barrier material forming the protective barrier and arranged such that the one or more openings in the protective barrier expose the breakable material to form the one or more breakable regions.

In this way, the breakable regions can be fabricated by an efficient two-material process.

Optionally, the consumable comprises a cavity configured to receive a heating element of the aerosol generation device.

In this way, the heating element can be positioned within the consumable so as to efficiently heat the aerosol generating material therein.

Optionally, the one or more piercing elements of the aerosol generation device have airflow channels therethrough arranged to provide an airflow into the consumable when having pierced a cooperating breakable region of the consumable.

Optionally, the first chamber portion of the aerosol generation device is configured to heat the consumable to generate an aerosol product, and the second chamber portion of the aerosol generation device is configured to pre-heat an airflow to the consumable.

Optionally, the base portion of the aerosol generation device is a moveable base configured to move along a length of the chamber.

In this way the moveable base can securely hold consumables of different lengths within the chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:

FIG. 1A is a cutaway view of an aerosol generation device;

FIG. 1B is a cutaway view of the aerosol generation device with a consumable received therein;

FIG. 2A is a cutaway view of a consumable for an aerosol generation device;

FIG. 2B is a plan view of a consumable for an aerosol generation device;

FIG. 2C is a perspective view of a consumable for an aerosol generation device;

FIG. 3A is a plan view of a base portion of the aerosol generation device;

FIG. 3B is a cutaway view of a base portion of the aerosol generation device;

FIG. 4 is enhanced cutaway view of the chamber region of the aerosol generation device; and

FIG. 5 is a cutaway view of a heating element and base portion.

DETAILED DESCRIPTION

An aerosol generation device 100 is a device arranged to heat an aerosol generation medium or consumable 160 to produce an aerosol for inhalation by a consumer. In a specific example, an aerosol generation medium or consumable 160 can be a capsule or cartridge containing an aerosolisable liquid, an aerosolisable solid, or a combination thereof which when heated generates an aerosol. In an alternative example, an aerosol generation device with corresponding features can be configured for use with an aerosol generation medium or consumable 160 that is a cigarette-like consumable, also referred to as a tobacco rod, in which the aerosol generating material can be tobacco. The tobacco rod can have a tobacco region containing the tobacco, and mouthpiece region for example containing a filter connected by a wrapping paper. The aerosol generation device 100 is configured to heat the tobacco rod to generate an aerosol without burning the tobacco. Such a device can be considered ‘heat-not-burn’ device. An aerosol generation device 100 can also be considered an electronic cigarette, or a vapour generation device. In context of the present disclosure, the terms vapour and aerosol can be used interchangeably.

FIG. 1A shows a cutaway diagram of a cross-section of an aerosol generation device 100 configured to receive a capsule 160 type consumable. It will be readily understood that a similar aerosol generation device 100, with corresponding features to those described subsequently, can be configured to receive a tobacco rod type consumable.

The aerosol generation device 100 is configured to receive an aerosol generation consumable 160 (hereinafter referred to as a capsule) as in FIG. 1B which shows a cutaway diagram of presenting a cross-section of an aerosol generation device 100 with a capsule 160 received therein. The capsule 160 can comprise an aerosol generating material such as an aerosolisable liquid, an aerosolisable solid, or a combination thereof. The capsule is presented in more detail in FIGS. 2A to 2C.

The aerosol generation device 100 has a body 146 in which a chamber 102 is arranged. An opening 104 in the body 146 provides access to the chamber 102. The chamber 102 is configured to receive the capsule 160 through the opening 104. The chamber 102 can have a cross-sectional size and shape defined by internal walls 120 of the chamber 102 corresponding to the size and shape of the capsule such that the capsule 160 securely fits within the chamber 102 and is held in place by the internal walls 120. In an example the chamber 102 is substantially cylindrical in shape. The chamber can be likewise dimensioned to for receiving a tobacco rod, in the example in which the device is configured for use with a tobacco rod type consumable.

A heating element 106 is positioned within the chamber 102 and configured to heat the capsule 160 when received in the chamber 102. In the example of FIGS. 1A and 1B, the heating element 106 is a heating blade that extends inwardly to the chamber 102 from the bottom 114 of the chamber 102. Such a heating blade 106 can be elongate in the axial direction of the chamber 102, and planar in a radial direction of the chamber 102, with an engaging end at an end nearest to the opening 104. In examples, the engaging end can be pointed or spiked in shape. The bottom 114 of the chamber 102 can be considered an end of the chamber 102 opposite to the opening 104. The heating element 106 extends from the bottom 114 of the chamber 102 toward the opening 104 of the chamber 102. The heating element 106 can extend fully along the axial length of the chamber 102, or through a substantial portion of the axial length of the chamber 102. The heating element 106 is positioned substantially centrally within the chamber 102 and is dimensioned so as to fit into a heating element cavity 163 in the capsule 160. When inserted into the chamber 102, the heating element 106 engages a first end portion 162 of the capsule 160; as the capsule 160 is pushed further into the chamber 102, the heating element 106 engages the capsule by sliding through an axial length of the heating element cavity 163.

In the example of a tobacco rod consumable, the heating element 106 can insertable into the tobacco region of the tobacco rod so as the aerosolise the tobacco.

In alternatives to the capsule 160 and aerosol generation device 100 of FIGS. 1A, 1B, 2A, 2B and 2C, the heating element may instead be integrated into or mounted onto the internal walls of the chamber so as to surround the consumable (such as a capsule or tobacco rod). In such an alternative, the heating element can be a coil heater. In further alternatives, the heating element may be a component of the consumable and supplied within the consumable. In such an example, an electrical connection between the aerosol generation device and the consumable can be achieved when the consumable and the aerosol generation device are brought into connection with one another so as to power the heater, or the heating element can be configured to be inductively heated by an induction heater component in the aerosol generation device. In examples such as these, the capsule need not have a heating element cavity configured to receive a heating element component of the aerosol generation device.

Returning to the capsule 160 and aerosol generation device 100 of FIGS. 1A, 1B, 2A, 2B and 2C, the heating element 106 is coupled to a power supply 132, such as a battery, and a controller 134 that operably controls the aerosol generation device 100. The battery 132 and controller 134 can be housed within the body 146 of the aerosol generation device 100. The controller 134 detects when a heater ignition button (not shown) is pressed and controls a power flow from the battery to the heating element 106 so as to heat the heating element 106 for an aerosolisation session. The controller 134 can be a microcontroller unit and can comprise one or more processors and memory storing instructions that are executable by the one or more processors to control the operation of the aerosol generation device 100.

Turning to FIGS. 2A, 2B and 2C, a capsule 160 for use in the aerosol generation 100 of FIGS. 1A and 1B is presented. The capsule 160 has a housing 169 configured to contain the aerosol generating material. The housing defines a internal volume 161 in which the aerosol generating material is arranged. A liquid aerosol generating material may be held within an absorbent or porous material in the internal volume 161; a solid aerosol generating material may be directly stored within the internal volume 161.

The housing 169 of the capsule 160 has a first end portion 162 having a first surface 162a, and a second end portion 164 having a second surface 164a. The first end portion 162 can be an opposite end portion to the second end portion 164, and the first surface 162a can be a surface at an opposite end of the capsule 160 to the second surface 164a. The housing 169 further comprises sidewalls connecting the first surface 162a at the first end portion 162 to the second surface 164a at the second end portion 164.

The first surface 162a can comprise an opening to the heating element cavity 163. The heating element 106 of the aerosol generation device 100 is received in the heating element cavity 163 when the capsule 160 and the aerosol generation device 100 are brought into connection with one another. In this way, the heating element 106 can provide heat energy to the aerosol generating material to generate the aerosol. The heating element 106 can directly aerosolise a solid aerosol generating material, by heating it without burning. The heating element 106 can aerosolise a liquid aerosol generating material by heating and evaporating the liquid held within the absorbent material.

The capsule 160 is insertable into the chamber 102 of the aerosol generation device 100 by first passing the first end portion 162 of the capsule 160 through the opening 104 of the chamber 102 such that the capsule 160 moves into the chamber 102. As the capsule 160 moves into the chamber 102, the heating element 106 moves into the heating element cavity 163 in the capsule 160.

When inserted into the chamber 102 of the aerosol generation device 100, the second end portion 164 of the capsule 160 is proximal to the opening 104 of the cavity 102. The second end portion 164 of the capsule 160 can comprise a integrated mouthpiece (not shown) upon which the user draws to inhale a generated aerosol, when the capsule 160 is inserted into the chamber 102. Alternatively, a separate mouthpiece (not shown) can be engaged with the second end portion 164 to create an airflow path from the capsule 160 into the separate mouthpiece when the capsule 160 has been inserted into the chamber 102; the separate mouthpiece can then be connected to the body 146 of the aerosol generation device 100 to form an arrangement in which the capsule 160 is contained within the mouthpiece and body 146 of the aerosol generation device 100.

In use, as described in more detail subsequently, when the operator inhales upon the mouthpiece, air is drawn into the first end portion 162 of capsule 160 to balance a pressure drop created inside the capsule 160. The air drawn into the capsule 160 mixes with the generated aerosol to create an aerosol product. This generated aerosol, and drawn in air, is drawn through the second end portion 164 of the capsule and into the mouthpiece where it is inhaled by the operator of the aerosol generation device 100.

In the example of a tobacco rod type consumable, the tobacco rod is insertable in a similar configuration to that described for the capsule 160. The first end portion of the tobacco rod can be considered at least part of the tobacco region, and the second end portion of the tobacco rod can be considered at least part of the mouthpiece or filter region. When the tobacco rod is received in the chamber, the mouthpiece region of the tobacco rod extends outwardly from the opening 104 such that the operator can inhale upon the mouthpiece.

Returning to FIGS. 1A and 1B, one or more air inlets 122 are arranged in the body 146 of the aerosol generation device 100, and are connected by air inlet channels 124 to the chamber 102. When the user of the aerosol generation device 100 inhales upon the mouthpiece the pressure within the chamber 102 drops and air is drawn into the chamber 102, from outside the device 100, through the air inlet channels 124. The air inlet channels 124 are arranged to feed the air into the chamber 102 substantially toward the bottom 114 of the chamber 102, or at the bottom 114 of the chamber 102. In some examples, the openings for the air inlets 122 may be arranged adjacent to the opening 104 of the chamber 102 in an end surface of the body 146 of the aerosol generation device 100. In such an example the air inlet channels 124 can run alongside the length of the chamber 102 to feed air into the bottom of the chamber 102; this can be considered an inlet counter-flow as the airflow into the chamber moves substantially in the opposite direction to the airflow moving through the chamber 102 and capsule 160 toward the opening 104. Arranging the openings for the air inlets 122 adjacent to the opening 104 of the chamber 102 inhibits the operator inadvertently blocking the openings of the air inlets 122 with their hand when holding the aerosol generation device 100. Residual heat from the chamber 102 can also warm the airflow as it passes through the channels 124 alongside the chamber 102. In other examples, the openings for the air inlets 122 may be arranged in a sidewall of the body 146 at a location proximal to the bottom of the chamber 102 to provide the shortest airflow path, in the airflow channels 124, into the chamber 102.

A base portion 108 is positioned within the chamber 102. The base portion 108 can be a moveable base 108 that is configured to move along the length of the chamber 102, in the axial direction of the chamber 102 (that is, the direction toward and away from the opening 104 of the chamber 102 along the length of the chamber 102). The moveable base 108 can be attached to a guiding track (not shown) along which guides the movement of the moveable base 108 through the chamber 102. The moveable base 108 is a platform against which the first surface 162a of the capsule 160 presses when the capsule 160 is inserted into the chamber 102. The moveable base 108 has a cross-sectional shape and size dimensioned approximately equal to that of the chamber 102, and a thickness dimension considerably less than the depth of the chamber 102. In an example, the moveable base 108 may have a thickness of 2 to 10 mm and the chamber 102 may have a depth of 10 to 50 mm.

In some examples the moveable base 108 may be resiliently biased, such as by a spring, to a first position, or extended position, within the chamber 102 toward the opening 104 (FIG. 1A). The first position can be substantially central to the length of the chamber 102, or toward the opening 104. When the consumable (such as the capsule 160, or a tobacco rod) is pushed into the chamber 102, it presses against the moveable base 108 and the moveable base 108 moves downward in the chamber 102, away from the opening 104, against the resiliently biasing force. A frictional force between the consumable and the internal walls 120 of the chamber 102 overcomes the resilient biasing force so as to hold the consumable in place with the moveable base 108 in a second position, or retracted position, that is closer to the bottom 114 of the chamber 102 (FIG. 1B). That is, the moveable base 108 is moveable between an extended position at a first distance from the opening 104, and a retracted position at a second distance from the opening 104, the second distance being greater than the first distance. Consumables (including capsules or tobacco rods) of different sizes, or lengths, may be inserted into the chamber 102; if the consumable is of a short length, comparable to or less than the depth of the chamber 102, it would be unfavourable for the consumable to drop into the chamber 102 to an extent that the second end portion 164 is not proximal to the opening 104 of the chamber 102. The resilient biasing force applied to the moveable base 108 inhibits the consumable from slipping further into the chamber 102 than desired. In this way, the moveable base 108 secures the consumable at an operable position within the chamber 102 such that the second end portion 164 is proximal to the opening 104 of the chamber 102. In an example, when a tobacco rod consumable is inserted, the movable base may be in a fully retracted position. In another example, when a capsule 160 type consumable is inserted, the moveable base may be in a semi-retracted position. The moveable base, however, allows for different length capsules and/or different length tobacco rods to be inserted and held securely in place in a fully or semi-retracted position.

Alternatively, or additionally, in other examples the position of the moveable base 108 can be manually controlled by the user of the aerosol generation device 100 between the first position (FIG. 1A) and the second position (FIG. 1B). For example, the moveable base 108 can be connected to an electric motor or solenoid that drives the moveable base 108 in directions toward and away from the opening 104. The electric motor or solenoid can be controlled by the controller 134 of the aerosol generation device 100 to move along the length of the chamber 102 in response to a user of the device 100 selecting an input configured to instruct the controller 134 to move the moveable base 108. In another example, the moveable base 108 can be manually moved by a user of the aerosol generation device 100 in a mechanical manner. A through-pin arranged in a slot or threaded grove can connect the moveable base 108 to a handle on the exterior of the aerosol generation device 100 which when moved by the user in a sliding or rotating manner mechanically causes the moveable base 108 to move along the length of the chamber 102. Advantageously, these means for adjusting the position of the moveable base 108 allow for a user of the aerosol generation device 100 to adjust the depth of the chamber 102 so that capsules of different lengths can be received within the chamber 102, whilst ensuring that the second end portion 164 is proximal to the opening 104 of the chamber 102.

The moveable base 108 can be disc-like in form. The moveable base 108 has a first surface 110 that faces toward to the opening 104 of the chamber 102, and a second surface 112 on an opposite side of the moveable base 108 to the first surface 110 that faces toward the bottom 114 of the chamber 102.

A slot 118 is arranged in the moveable base 108 through which the heating element 106 passes. In this way, the moveable base 108 can move along the length of the heating element 106 when moving in the chamber 102.

In other examples, the base portion 108 is fixed in position rather than being moveable. Such a fixed base 108 can be positioned at an intermediate position between the opening 104 and the chamber 102 and the bottom 114 of the chamber 102. Alternatively, such a fixed base can be substantially at the bottom 114 of the chamber 102. The heating element may pass through the slot in the fixed base, or may extend from the fixed base itself.

When the capsule 160 is inserted into the aerosol generation device 100, the first surface 162a of the capsule 160 interacts with the base portion 108.

The moveable portion 108 is shown in more detail in FIGS. 3A and 3B.

FIG. 3A shows a plan view of the base portion 108, and FIG. 3B shows a cross-sectional view of the base portion 108 along the line A-A.

The base portion 108 comprises one or more piercing elements 116 that are configured to engage and pierce the first surface 162 of the capsule 160 when the base portion 108 and capsule 160 are brought into connection with one another.

The piecing elements project outwardly from the first surface 110 of the base portion toward the opening 104 of the chamber 102. The piercing elements have an engaging end distal from the first surface 110. The engaging end is configured to pierce into the first surface 162a of the capsule 160. In an example, the engaging end can be pointed. The piercing elements can be of spike-type shape in that they taper toward the engaging end. For example, the piercing elements 116 may be conical or pyramid shaped. Alternatively the piercing elements 116 can have a constant diameter through a substantial part of their length, followed by a pointed end at the engaging end. In another alternative, the piercing elements 116 can be of a constant diameter, but with sufficiently narrow cross-section such that they create a high pressure point when engaging the first surface 162a of the capsule 160 so as to pierce through it.

In the example of FIGS. 3A and 3B, six piercing elements 116 are distributed around the slot 118 through which the heating element 106 passes. The slot 118 for the heating element 106 is positioned centrally to the base portion 108 to correspond to the central position of the heating element 106 within the chamber 102. It will be understood that six piercing elements 116 are only presented for exemplary purposes, and the base portion 108 can comprise any suitable number of piercing elements 116. The piercing elements 116 need not be distributed around the slot 118 in the arrangement depicted in FIGS. 3A and 3B, and can instead be distributed in any suitable arrangement in the base portion 108.

The slot 118 can be dimensioned to have a similar cross-sectional shape to the cross-section of the heating element 106, only slightly larger so that the heating element 106 can pass through the slot 118 in an uninhibited manner. Alternatively, the slot 118 can be dimensioned so that the heating element 106 fits therethrough so that there is a snug fit between the heating element 106 and the moveable base 108. As previously described, in some examples the heating element 106 can be arranged in or on the internal wall 120 of the chamber 102. In such examples, when there is no heating element 106 central to the chamber 102, the base portion 108 need not have a slot 118 for the heating element 106.

One or more holes 117 are arranged in the base portion 108. These holes 117 are through-holes forming channels 117 that connect the second surface 112 of the base portion 108 through the base portion 108 and piercing elements 116 so as to allow an airflow to pass through the base portion 108 and piercing elements 116. That is, a through-hole 117 runs from the engaging end of the piercing element 116, through piercing element 116, and base portion 108 and to the second surface 112 of the base portion. This allows for an airflow path from the second surface, through the base portion 108, and through the piercing elements 116. The through-holes 117 extend through the base portion 108 and piercing elements 116 in the direction of the axial length of the chamber 102, that is the direction in which the capsule 160 is inserted into the chamber 102. As such, when the piercing elements engage the capsule, an airflow path from the second portion of the chamber, through the through-holes 117 and into the capsule is brought about. In an example, the through-holes 116 can have diameters in the range of 0.1 to 3.0 mm.

Preferably, the piercing elements 116 and consequently the through-holes 117 are substantially evenly and/or symmetrically distributed in the base portion 108 so as to provide an even airflow into the capsule 160.

It is noted that the through-holes 117 are not shown in FIGS. 1A, 1B, 4 and 5 only for visual clarity.

The base portion 108 can be of a material that is resistant to deformation when heat is applied so as to inhibit the base portion 108 deforming when the heating element 106 heats the capsule 160. Such materials can include, for example, metals, plastics and ceramics. It is also preferable for the base portion 108 to be formed of a thermally conductive material so as to aid the spread of heat across first surface 162a of the capsule 160 that abuts the base portion 108; this can contribute to warming the airflow into the capsule 160. An example of such a material is aluminium.

Returning to FIGS. 2A to 2C, the first surface 162a of the capsule 160 can comprise a breakable, or frangible, material layer 165 configured to be broken upon interaction with the one or more piercing elements 116. A protective barrier layer 166 can be arranged over the breakable material layer 165. In examples, the breakable material layer 165 can comprise aluminium foil, HDPE, silicon or paper, and the protective barrier layer 166 can comprise cardboard, a steel plate, a high temperature plastics such as polyimide, or nylon 66. The protective barrier layer 166 is arranged with the breakable material layer 165 to define one more breakable or frangible regions 167 in the first surface. The protective barrier layer 166 is formed from a resilient material that cannot be readily pierced by the piercing elements 116. That is, the protective barrier layer 166 inhibits the piercing elements from piercing some regions (i.e. non-breakable regions) of the first surface 162a, but allows for the piercing of other regions (i.e. the breakable regions 167) of the first surface 162a. FIG. 2A shows a cross-sectional view of the capsule 160 including the breakable layer 165 and the barrier layer 166.

The one or more breakable regions 167 can defined by one or more openings, or through-holes, in the protective barrier layer 166. That is, the first surface 162a of the capsule 160 comprises a layer of barrier material 166 over a layer of breakable material 165, such that the layer of barrier material 166 is the outermost layer. A series of openings forming the breakable regions 167 can be patterned in the barrier layer 166 to expose the breakable material 165. This can be seen in FIG. 2A, as well as FIG. 2C which presents a perspective view of the capsule 160 showing the layers at the first surface. It is noted that the sidewalls of the capsule 160 may extend over the breakable layer 165 and barrier layer 166, and that the breakable 165 layer and barrier layer 166 are not covered by the sidewalls in FIG. 2C so as to provide context for their arrangement at the first surface 162a.

FIG. 2B presents an exemplary plan view of the first surface 162a of the capsule 160. The barrier material 166 forms the protective barrier and is arranged such that the one or more openings in the protective barrier 166 expose the breakable material 165 to form the one or more breakable regions 167. The one or more breakable regions 167 can be specifically arranged to be alignable with cooperating piercing elements 116 of the one or more piercing elements of the aerosol generation device 100. The first surface 162a is then only pierceable by the piercing elements 116 when the arrangement of the breakable regions 167 coincides with an arrangement of the piercing elements 116. The one or more breakable regions 167 provide an airflow path into the housing 169 when pierced by the one or more cooperating piercing elements 116.

That is, the breakable regions 167 in the first surface 162a of the capsule 160 can be configured to have a corresponding layout to the piercing elements 116 on the first surface 110 base portion 108 of the aerosol generation device 100 (as shown in FIGS. 2B and 3A). In this way, only capsules 160 in which the arrangement of the breakable regions 167 matches the arrangement of the piercing elements 116 of an aerosol generation device 100 can be used with the aerosol generation device 100. When one or more of the piercing elements 116 do not align with a breakable region 167, the piercing element 116 abuts the protective barrier layer 166 which cannot be readily pierced by the piercing element 116. This inhibits the engagement of a capsule 160 with a breakable region 167 layout that does not match the piercing element 116 layout of the aerosol generation device 100. This can prevent the use of unauthorised, or non-compatible, capsules with the aerosol generation device.

In some examples, the second surface 164a of the capsule 160 may also comprise one or more breakable regions in a similar manner to that described with reference to the first surface 162a of the capsule 160. These breakable regions can be engaged by piercing elements in an attachable mouthpiece.

The first surface 162a of the capsule 160 also comprises an opening 168 to the heating element cavity 163 in the capsule 160. In an example, this opening 168 can be dimensioned similarly to, and alignable with, the slot 118 in the base portion 108. The heating element cavity 163 can be dimensioned to closely fit to the heating element 106; this allows for an efficient heat transfer between the heating element 106 and the aerosolisable material in the capsule 160.

When the capsule is inserted into the chamber, the piercing elements 116 align with the breakable regions and pierce the breakable regions. In the case of a resiliently biased moveable base 108, the resilient biasing force is strong enough to allow the piercing elements 116 to pierce the breakable regions 167 without causing the moveable base 108 to retract into the chamber 102; when the piercing elements 116 have pierced and engaged the breakable regions 167, the moveable base 108 is then pushed deeper into the chamber 102 as the operator continues to push the capsule 160 into the chamber 102.

The piercing elements 116 are then received within the capsule 160. The through-holes 117 in the piercing elements 116 provide an airflow path from the air inlets 122 of the aerosol generation device 100 into the capsule 160. In use, when an operator of the aerosol generation device 100 inhales upon the mouthpiece, air is drawn into and through the capsule 160 by the pierced breakable regions 167, from the through-holes 112 in the base portion 108 which creates a pressure drop in the chamber 102. Air is drawn into the chamber 102 from the air inlets 122, through the air inlet channels 124, to balance this pressure drop. As the user continues to inhale, the airflow moves through the through-holes 117 or channels in the base portion 108 and piercing elements 116 and into the first end portion 162 of capsule 160. As the airflow is drawn through the capsule 160, the airflow interacts with the aerosol generated in the capsule 160 by the heating element 106 to form the aerosol product which is drawn through the mouthpiece at the second end portion of the capsule 160 when the user inhales. That is, the through-holes 117 in the piercing elements 116 and base portion 108 contribute to an airflow path from the air inlets 122, through the air inlet channels 124, into the chamber 102, through the through-holes 117 in the base portion 108 and piercing elements 116, into the first end portion 162 of the capsule 160, through the capsule 160 to the second end portion 164 and through the mouthpiece for inhalation.

In some examples, the capsule 160 may comprise a plurality of internal volumes 161 separated from one another and defined by internal walls. Each internal volume may comprise a different aerosol generating material such that, when heated, aerosols are generated from each aerosol generating material and then mix to form the aerosol product. Each internal volume may be accessible by one or more breakable regions 167.

In a similar manner to the capsule 160 type consumable, the tobacco rod type consumable can have a similar first surface that is engageable by the piercing elements. The first surface of the tobacco rod can be the end surface that is first inserted into the chamber and engages the base portion. That is, the first surface of the tobacco rod is an end surface opposite to the end portion comprising the mouthpiece. The first surface of the tobacco rod can have one more breakable or frangible regions configured to align with the piercing elements, as described with reference to the capsule 160 type consumable. The first surface of the tobacco rod can also have an opening to receive the heating element.

FIG. 4 shows an enhanced cutaway diagram of the chamber 102 region of the aerosol generation device 100 in which the base portion 108 is displaced between the opening 104 of the chamber 102 and the bottom 114 of the chamber 102. For clarity a capsule is not shown.

The axial displacement of the base portion 108 from the opening 104 and the bottom 114 of the chamber 102 causes the base portion 108 to bifurcate the chamber 102 into two regions or portions, a first chamber region 136 toward the opening 104 and a second chamber region 138 toward the bottom 114 of the chamber 102. That is, the base portion 108 divides the chamber 102 so as to have a first region 136 toward the opening 104 and a second region 138 away from the opening 104. The first 136 and second 138 regions of the chamber 102 are separated by the base portion 108. The first surface 110 of the base portion 108 faces the first region 136 of the chamber 102, and the second surface 112 of the base portion 108 faces the second region 138 of the chamber 102.

As the heating element 106 extends along axial length of the chamber 102, through the base portion 108, the heating element 106 is also divided into two portions by the base portion 108. A first portion 150 of the heating element 106 is arranged within the first region 136 of the chamber 102, and a second portion 152 of the heating element 106 is arranged the second region 138 of the chamber 102. This division of the heating element 106 into two portions is presented in FIG. 5 which shows a cutaway diagram of the base portion 108 dividing the heating element 106 along the axial direction into a first portion 150 and a second portion 152.

In the example of the base portion 108 being a moveable base, when the moveable base 108 moves, the length of the heating element 106 forming the first portion 150 and the length forming the second portion 152 changes. Likewise, when the moveable base 108 moves, the volume of the chamber 102 forming the first region 136 and the volume forming the second region 138 changes.

As described, the moveable base 108 is either pushed toward the bottom 114 of the chamber 102 by the consumable (such as the capsule 160 or tobacco rod), or moved toward the bottom 114 of the chamber 102 so as to accommodate the consumable. In either case, the moveable base 108 does not move fully to the bottom 114 of the chamber 102 (as shown in FIG. 1B), and as such the second region 138 of the chamber 102 can still be present when the consumable is received in the chamber 102.

When inserted into the chamber 102, the consumable is positioned only in the first region 136 of the chamber 102 and not the second region 138. The first portion 150 of the heating element is inserted into heating element cavity 163 in the capsule 160 type consumable, or into the tobacco region of the tobacco rod type consumable, so as to provide heat energy to the aerosolisable material housed in the capsule 160 or the tobacco material in the tobacco rod. The second portion 152 of the heating element 106 does not engage the consumable. In effect, the second region 138 of the chamber 102 is empty as the consumable is not received in this region, and the second portion 152 of the heating element 106 is not directly heating consumable.

The air inlet channels 124 are arranged toward or at the bottom 114 of the chamber 102 so as to be positioned in the second region 138 of the chamber 102. The air inlet channels 124 feed the air from the air inlets 122 into the second region 138 of the chamber 102. When the heating element 106 is triggered so as to heat the contents of the capsule 160, the first portion 150 of the heating element 106 heats the capsule 160 and the second portion 152 of the heating element 106 heats the air in the second region 138 of the chamber 102. That is, as ambient air 126 (air at a temperature external to the device) is drawn into the second region 138 of the chamber 102, it is heated by the second portion 152 of the heating element 106 to form pre-heated air 128 before being drawn through the through-holes 116 in the base portion 108. This heating of the ambient air 126 in the second region 138 of chamber 102 forms a pre-heated airflow 128 to the capsule 160. As such, the second region 138 of the chamber 102 can be considered a pre-heating region as it pre-heats the airflow, and the first region 136 of the chamber 102 can be considered a heating region as it heats (and aerosolises) the aerosol generating material in the capsule 160. Likewise, for the tobacco rod type consumable, a similar effect is achieved in a similar manner.

In this way, heat generated in the portion of the heating element 106 that does not engage the consumable is not wasted. This is particularly beneficial for consumables of a shorter length; as a greater portion of the heating element 106 does not engage such short consumables, a greater portion of heat would be wasted. The pre-heating region 138 realised by the moveable base 108 and through-holes 117 in the piercing elements 116 allows for this otherwise wasted heat to be utilised for pre-heating the airflow rather than being wasted.

The pre-heating of the air in the second region 138 of the chamber 102 can improve the user experience by mixing pre-heated air with the aerosol generated by aerosolising the aerosol generating material in the consumable. This can create a more consistent temperature for the aerosol product. Furthermore, pre-heating the air before it is drawn into the consumable inhibits the intake of ambient (or cold) air 126 affecting the heating of the aerosol generating material in the consumable by the first portion 150 of the heating element 106. Such cold air 126 can lower the temperature in the consumable, thereby requiring more power to be supplied to the heating element 106. By pre-heating the air 128, less power needs to be supplied to the heating element 106 for the aerosolisation as the pre-heated air reduces or inhibits the effect of a temperature drop in the consumable.

In the aforementioned arrangement, the same power is applied to heat both portions of the heating element 106. In a modified arrangement, the heating element 106 can be divided into a plurality heating zones which can be separately and differently powered and therefore heated to different temperatures. The heating zones may be formed by a plurality of sections of heating track within and along the length of the heating element 106, each section of heating track separately connected to the controller 134 and power supply 132 so as to be separately controlled for heating purposes.

The controller 134 can determine the position of the moveable base 108 along the axial length of the heating element 106. For example the controller 134 determines the position of the moveable base 108 along the guiding track, and from this can determine the corresponding position along the heating element 106. Based upon the determined position of the moveable base 108 along the heating element 106, the controller 134 can determine which heating zones are in the first region 136 of the chamber 102 (i.e. which heating zones form the first portion 150 of the heating element 106) and which heating zones are in the second region 138 of the chamber 102 (i.e. which heating zones for the second portion 152 of the heating element 106) to select a suitable heating profile. Heating profiles correspond to the relative position of the moveable base along the heating element; the heating profiles may be stored in memory accessible by the controller. That is, each heating profile corresponds to a different combination of heating zones in the first portion 150 of the heating element 106 and the second portion 152 of the heating element 106.

For the selected heating profile, the controller 134 controls the power to the heating element 106 such that the heating zones in the first region 136, that is the heating zones forming the first portion 150, are heated to first temperature (or supplied with a first power level) and the heating zones forming the second portion 152 are heated to a second temperature (or supplied with a second power level). The first temperature and the second temperature (or first power level and second power level) can be different. In this way, the first portion 150 of the heating element 106 can be heated to a different temperature to the second portion 152. This allows for the air to be pre-heated in the pre-heating region with the second portion 152 of the heating element 106 at a different temperature to the temperature of the first portion 150 of the heating element 106 used for aerosolisation. For example, it may be preferable to use a higher or lower heating temperature for the pre-heated air, rather than the same temperature as that used for aerosolisation of the aerosol generating material in the consumable.

In some examples, a user input can be used to set the desired temperatures for the first portion 150 of the heating element 106 (i.e. the aerosolisation temperature) and/or the second portion 152 of the heating element 106 (i.e. the pre-heating temperature).

In a further modification, the controller 134 can control the power to the heating element 106 such that heating zones within the second portion 152 of the heating element 106 are not heated (i.e. power is not supplied to them). In this way, the air is not pre-heated in the second region 138 of the chamber 102. In some examples, this can save battery power as power is only supplied to the first portion 150 of the heating element 106 needed for the aerosolisation of the aerosol generating material.

In an exemplary operational procedure, for a capsule 160 type consumable, the operator of the aerosol generation device 100 inserts the capsule 160 into the chamber 102 with the first end portion 162 of the capsule 160 entering first. As the capsule 160 moves into the chamber 102, the heating element 106 is received in the heating element cavity 163. The first surface 162a of the capsule 160 presses against the base portion 108. When the piercing elements 116 align with the breakable regions 167, the breakable regions 167 are pierced and the piercing elements 116 are received within the capsule 160. When at least one piercing element 116 does not align with a breakable region 167, the piercing elements 116 are inhibited from piercing the breakable regions 167 and are not received in the capsule 160.

When the capsule 160 is suitably engaged with the base portion 108, the first portion 150 of the heating element 106 is located in the heating element cavity 163 in the capsule 160.

The operator presses a heater ignition button to heat the heating element 106. The first portion 150 of the heating element 106 heats the aerosol generating material, so as to generate an aerosol within the capsule 160. The second portion 152 of the heating element 106 heats the air in the second region 138 of the chamber 102, below the capsule 160. The operator inhales upon the mouthpiece. This inhalation causes an airflow from the air inlets 122 in the body 146 of the aerosol generation device 100, through the air inlet channels 124 and into the second region 138 of chamber 102. This in-flow of air is pre-heated 128 by the second portion 152 of the heating element 106. The pre-heated airflow 128 passes through the base portion 108, by way of the through-holes 117 in the base portion 108 that extend through the piercing elements 116. This causes the pre-heated airflow 128 to enter the capsule 160 at the first end portion 162. The airflow is drawn through the capsule 160, where it mixes with the generated aerosol, forming the aerosol product, which is inhaled through the mouthpiece at the second end portion 164 of the capsule 160.

A corresponding operational procedure can be used for a tobacco rod type consumable.

It will be readily understood that the features of any of the embodiments described herein can be readily combined with the features of any of the other embodiments described herein without falling outside of the scope of the present disclosure.

Aerosol Generation Device and Consumable

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