AEROSOL PROVISION DEVICE

TECHNICAL FIELD

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

BACKGROUND

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

SUMMARY

In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a body; an airflow path arrangement through the body; the airflow path arrangement comprising a receptacle defining a heating zone arranged to receive at least a portion of an article comprising aerosol generating material; a fluid chamber in the body; and a fluid passage between the airflow path arrangement and the fluid chamber.

The fluid chamber may be a substantially closed chamber.

The fluid chamber may be separated from the airflow path arrangement by a wall.

The fluid passage may comprise a slot in the wall.

The fluid chamber may encircle at least part of the airflow path arrangement.

The fluid chamber may be defined at least in part by a hollow member encircling at least part of the receptacle and spaced from the receptacle to define the fluid chamber.

The hollow member may be a tubular member.

The aerosol provision device may comprise a receptacle support at an end of the receptacle.

The receptacle support may fluidly seal with the receptacle.

The hollow member may extend from the receptacle support.

The receptacle support may be a first receptacle support at a first end of the receptacle and the device may comprise a second receptacle support at a second end of the receptacle.

The hollow member may extend between the first and second receptacle supports.

The hollow member may fluidly seal with the first and second receptacle supports.

The fluid passage may comprise an aperture through the receptacle.

The receptacle may comprise a receptacle wall defining the wall. The fluid passage may comprise a receptacle wall aperture which extends through the receptacle wall.

The receptacle wall aperture may be a slot.

The receptacle may comprise an open end through which at least a portion of an article comprising aerosol generating material is received, and a closed end.

The aperture may be proximal to the closed end.

The airflow path arrangement may comprise a flow path member.

The flow path member may be provided at one end of the receptacle.

The flow path member may define a base of the heating zone.

The flow path member may define a closed end of the receptacle. The airflow path arrangement may define an air path from an open proximal end and between the receptacle and the article to the closed end and then into the article at the closed end to flow back towards the proximal end.

The fluid passage may comprise a flow path member aperture through the flow path member.

The airflow path arrangement may comprise a flow path member at one end of the receptacle. The flow path member may comprise a flow path member wall. The fluid passage may comprise a flow path member wall aperture which extends through the flow path member wall.

The flow path member aperture may be a slot.

The flow path member may comprise a receptacle end and an air inlet end, distal to the receptacle end.

The flow path member aperture may be proximal to the receptacle end.

The fluid chamber may be defined at least in part by a hollow member encircling at least part of the flow path member.

The hollow member may be a tubular member.

The hollow member may be spaced from the flow path member to define the substantially closed chamber.

The aerosol provision device may comprise a receptacle support at a first end of the flow path member.

The aerosol provision device may comprise an air inlet member at a second end of the flow path member. The hollow member may extend between the receptacle support and the air inlet member.

The flow path member may extend from the receptacle at a juncture, and the fluid passage may be located at the juncture.

An end of the flow path member may overlap an end of the receptacle and a gap may be defined between part of the flow path member and part of the receptacle at the overlap.

The flow path member may comprise an expanded portion at the overlap.

The aerosol provision member may comprise a cavity in the receptacle support in fluid communication with the substantially closed chamber.

The receptacle may comprise a heating element.

The heating element may define the heating zone.

The fluid chamber may be a fluidly sealed chamber. It will be understood that in this context, fluidly sealed means fluidly sealed from the rest of the aerosol provision device, but not fluidly sealed from the air flow path since the chamber is in fluid communication with the airflow path arrangement via the fluid passage.

The aerosol provision member may comprise a fluidly sealed enclosure extending around at least part of the heater assembly defining the fluidly sealed chamber.

The fluidly sealed enclosure may comprise an encircling member encircling at least part of at least one of the receptacle and cover member.

The encircling member may be a tubular member.

The receptacle may comprise an outer side, and a sensor on the outer side of the receptacle.

The sensor may be on a diametrically opposite side of the receptacle to the fluid passage.

The aerosol provision device may comprise a fluid impermeable sheath around at least part the receptacle.

The sensor may be located between the sheath and the receptacle.

The sheath may define a layer on the outer side of the receptacle.

The sheath may be formed of a thermally reactive material. In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a receptacle defining a heating zone arranged to receive at least a portion of an article comprising aerosol generating material; a flow path member at one end of the receptacle, the receptacle and flow path member defining at least part of an airflow path through the device; and a condensate collection cavity in the housing in fluid communication with the airflow path.

In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a housing, a receptacle defining a heating zone arranged to receive at least a portion of an article comprising aerosol generating material; and a fluid impermeable sheath around at least part the receptacle.

The receptacle may comprise an outer side, and a sensor on the outer side of the receptacle.

The sensor may be between the sheath and the receptacle.

The sheath may define a layer on the outer side of the receptacle.

The layer may be fluid impermeable.

The sheath may be formed of a thermally reactive material.

The sheath may be configured to at least partially surround the receptacle and shrink onto the receptacle upon heating of the receptacle.

The device as described in any of the above may be a tobacco heating device, also known as a heat-not-burn device.

In accordance with some embodiments described herein, there is provided an aerosol provision system comprising: an aerosol provision device as described in any of the above; and an article comprising aerosol generating material, wherein the article is dimensioned to be at least partially received within the receptacle.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 shows a schematic front view of an aerosol provision device;

FIG. 2 shows a perspective side view of the aerosol provision device of FIG. 1;

FIG. 3 shows a cross-sectional side view of an aerosol generator of the aerosol provision device of FIG. 1;

FIG. 4 shows a cross sectional side view of a portion of the aerosol generator of FIG. 3;

FIG. 5 shows a perspective view of the heating element and air flow path member of the aerosol generator of FIG. 3;

FIG. 6 shows a perspective view of the heating element and air flow path member of FIG. 5, supported by a receptacle support;

FIG. 7 shows a cross sectional side view of the air flow path member and receptacle support of FIG. 6;

FIG. 8 shows a perspective view of the receptacle support;

FIG. 9 shows a cross-sectional side view of another arrangement of the aerosol generator of an aerosol provision device of FIG. 1;

FIG. 10 shows a cross-sectional side view of an aerosol generator of the aerosol provision device of FIG. 1;

FIG. 11 shows a perspective view of a sheath surrounding the heating element of the aerosol generator of FIG. 3; and

FIG. 12 shows a perspective view of another embodiment of an aerosol generator of the aerosol provision device of FIG. 1.

DETAILED DESCRIPTION

As used herein, the term “aerosol-generating material” is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavorants. Aerosol-generating material may include any plant based material, such as 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.

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

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

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

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

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

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

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

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

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

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

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 generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article.

FIG. 1 shows an aerosol provision device 100 for generating aerosol from an aerosol generating material. In broad outline, the device 100 may be used to heat a replaceable article 110 comprising the aerosol generating material, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100.

The device 100 comprises a body 102. A housing arrangement surrounds and houses various components of the body 102. An article aperture 104 in formed at one end of the body 102, through which the article 110 may be inserted for heating by an aerosol generator 200 (refer to FIG. 3). In use, the article 110 may be fully or partially inserted into the aerosol generator 200 where it may be heated by one or more components of the aerosol generator 200. The article 110 and the device 100 together form an aerosol provision system 101.

The device 100 may also include a user-operable control element 150, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 150.

The aerosol generator 200 defines a longitudinal axis.

FIG. 2 shows a perspective view of the device 100. FIG. 3 shows a schematic view of the device 100. The device 100 comprises a first body assembly 130 and a second body assembly 140. The first body assembly 130 comprises the aerosol generator 200. The second body assembly 140 comprises a power source (not shown) and at least one electronics module (not shown).

The first body assembly 130 comprises a first housing 131. The second body assembly 140 comprises a second housing 141. The first and second body assemblies 130, 140 are fixedly mounted. The first and second body assemblies 130, 140 form the body 102.

The body 102 has end surfaces of the device 100. The end of the device 100 closest to the article aperture 104 may be known as the proximal end (or mouth end) 106 of the device 100 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 110 into the aperture 104, operates the aerosol generator 200 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the device 100 along a flow path towards the proximal end of the device 100.

The other end of the device furthest away from the aperture 104 may be known as the distal end 108 of the device 100 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the longitudinal axis.

As used herein, one-piece component refers to a component of the device 100 which is not separable into two or more components following assembly of the device 100. Integrally formed relates to two or more features that are formed into a one-piece component during a manufacturing stage of the component.

As shown in FIG. 3, an air flow passage 180 extends through the body 102. The airflow passage 180 extends to an opening 190. The opening 190 acts as an air inlet. An outer cover 300 covers the opening 190. The outer cover 300 in embodiments is vented to allow the flow of air into the air flow passage 180.

The power source (not shown) may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the aerosol generator 200 to supply electrical power when required and under control of a controller to heat the aerosol generating material.

FIG. 3 shows a cross-sectional view of the aerosol generator 200. In one example, the aerosol generator 200 comprises an induction-type heating system, including a magnetic field generator 210. The magnetic field generator 210 comprises an inductor coil assembly 211. The aerosol generator 200 comprises a heating element 220. The heating element is also known as a susceptor.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

The aerosol generator 200 is an inductive heating assembly and comprises various components to heat the aerosol generating material of the article 110 via an inductive heating process. Induction heating is a process of heating an electrically conducting object (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive heater and the susceptor, allowing for enhanced freedom in construction and application.

The inductor coil assembly 211 includes a first inductor coil 212 and a second inductor coil 213. In embodiments, the number of inductor coils 212, 213 differs. In embodiments, a single inductor coil is used. The inductor coil assembly 211 also comprises a coil support 214. The coil support 214 is tubular. The coil support 214 comprises a guide 215 for the coils 212, 213. The guide 215 comprises a channel on an outer side of the coil support 214.

The heating element 220 is part of a heating assembly 221. The heating element 220 of this example is hollow and therefore defines at least part of a receptacle 222 within which aerosol generating material is received. For example, the article 110 can be inserted into the heating element 220. The heating element 220 is tubular, with a circular cross section. The heating element 220 has a generally constant diameter along its axial length.

The heating element 220 is formed from an electrically conducting material suitable for heating by electromagnetic induction. The susceptor in the present example is 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.

In other embodiments, the feature acting as the heating element 220 may not be limited to being inductively heated. The feature, acting as a heating element, may therefore be heatable by electrical resistance. The aerosol generator 200 may therefore comprise electrical contacts for electrical connection with the apparatus for electrically activating the heating element by passing a flow of electrical energy through the heating element.

The receptacle 222 and article 110 are dimensioned so that the article 110 is received by the heating element 220. This helps ensure that the heating is most efficient. The article 110 of this example comprises aerosol generating material. The aerosol generating material is positioned within the receptacle 222. The article 110 may also comprise other components such as a filter, wrapping materials and/or a cooling structure.

A first end support 230 supports the heating element 220. The first end support 230 supports the heating element 220 at a first, distal, end. A second end support 231 supports the heating element 220. The second end support 231 supports the heating element 220 at a second, proximal, end. The first and second end supports 230, 231 act as receptacle supports.

The air flow passage 180 extends from the heating element 220. The air flow passage 180 is at the first, distal, end. The air flow passage 180 protrudes from the heating element 220. The air flow passage 180 extending from the heating element 220 is defined by a flow path member 182. The heating element 220 and the flow path member 182 forms part of an airflow path arrangement 181.

The flow path member 182 extends between the heating element 220 and the opening 190. The flow path member 182 is tubular. The flow path member 182 defines a bore. The flow path member extends in an axial direction along its length.

The flow path member 182 and the heating element 220 intersect at a juncture 183. The flow path member 182 overlaps the heating element 220. The flow path member 182 comprises a first section 184 having a first diameter and a second section 185 having a second diameter. The diameter of the first section 184 is greater than the diameter of the second section 185. An intermediate section 186 extends between the first and second sections 184, 185. The intermediate section 186 forms a shoulder. The shoulder acts as a stop to limit insertion of the article 110.

The flow path member 182 overlaps the heating element 220 between about 1 mm and about 3 mm. In this particular example, the overlap is 2 mm. In examples, there is no overlap. The juncture 183 assists with forming a thermally conductive path.

Mounting at the juncture 183 is formed in embodiments by a mechanical fabricated joint, for example a weld. The joint at the juncture 183 is formed by a laser weld process, however it will be understood that other methods may be used such as brazing and adhering. The flow path member 182 is formed from a thermally conductive material. In embodiments, the flow path member 182 is formed from a carbon steel. The flow path member 182 in embodiments is formed from the same material as the heating element 220. By such processes the heating element 220 and flow path member 182 are fabricated as a one-piece component.

The abutment of the heating element 220 and the flow path member 182 provides for heat transfer by conduction. As such, it is possible to aid passive heating of the flow path member 182.

The first end support 230 supports the flow path member 182. The first end support 230 forms a collar. In embodiments in which the flow path member 182 is omitted, the first end support 230 engages the heating element 220 directly. The first end support 230 extends away from the first end of the heating element 220 towards the distal end of the device 100.

The second end support 231 defines an insertion chamber 234. The insertion chamber 234 is configured to receive the article 110 therethrough.

The heating element 220 extends between the first and second end supports 230, 231. A barrier member 233 extends between the first end support 231 and the second end support 232.

The barrier member 233 together with the first and second end supports 230, 231 encloses the heating element 220. This acts to assist with thermally isolating the heating element 220 from other components of the device 100. The barrier member 233 is a hollow, tubular member.

The barrier member 233 is fixedly mounted to the first and second end supports 230, 231. The first end support 230 closes the distal end of the barrier member 233. The second end support 231 closes the proximal end of the barrier member 233. The barrier member 233 partially overlaps the first and second end supports 230, 231.

The barrier member 233 forms a fluid seal with the first and second end supports 230, 231. In embodiments a mechanical fabricated joint, for example a weld, is formed between the barrier member 233 and each of the first and second end supports 230, 231. The fluid seal at the junction of the parts is formed by a weld process, however it will be understood that other methods may be used such as brazing and adhering. In embodiments, the barrier member 233, and first and second end supports 230, 231 are formed from the same material.

In embodiments, the barrier member 233 is formed from a non-metallic material to assist with limiting interference with magnetic induction. In this particular example, the barrier member 233 is constructed from polyether ether ketone (PEEK). The first and second end supports 230, 231 are constructed from PEEK. Other suitable materials are possible. Parts formed from such materials help ensure that the barrier member 250 remains rigid/solid when the susceptor is heated.

The heating element 220, the barrier member 233, and the first and second end supports 230, 231 are coaxial around the central longitudinal axis of the heating element 220. The heating element 220, the barrier member 233, and the first and second end supports 230, 231 define a substantially closed chamber 235. The substantially closed chamber 235, acting as a fluid chamber, encircles the heating element 220. The substantially closed chamber 235 is defined by a gap between the heating element 220 and the barrier member 233.

The first end support 230 fluidly seals with the airflow path arrangement 181. The second end support 231 fluidly seals with the airflow path arrangement 181. In embodiments, the first end support 230 fluidly seals with the heating element 220. In embodiments, the first end support fluidly seals with the flow path member 182. The second end support 231 fluidly seals with the heating element 220.

A sensor, such as a thermocouple 240, is disposed in the substantially closed chamber 235. The thermocouple 240 is mounted on the heating element 220. The thermocouple 240 is configured to determine the temperature of the heating element 220. The thermocouple 240 directly detects the temperature of the heating element 220.

The first and second end supports 230, 231 support the coil support 214. An insulation layer 250 is disposed between the barrier member 233 and the coil support 214.

A ferrite shield 255 extends around the inductor coils 212, 213. The ferrite shield acts as an electromagnetic shield. Other suitable materials may be used. The ferrite shield 255 is mounted on the coil support 200. The ferrite shield 255 abuts the coils support 200 and so may be directly mounted to the coil support 200, for example by adhering.

The insulation layer 250 acts as an inner insulation layer 250. An outer insulation layer 251 extends around the inductor coil assembly. The outer insulating layer 251 forms a tubular arrangement.

FIG. 4 shows a cross-sectional plan view of part of the aerosol generator 200. The airflow path arrangement 181 is supported by the first end support 230. As described above, the flow path member 182 comprises first and second sections 184, 185, having first and second diameters respectively. The first section 184 has a circumferential expanded portion 187 in which the diameter of the circumferential expanded portion 187 is increased from the diameter of the rest of the first section 184. As can be best seen in FIG. 5, this expanded portion 187 results in a gap 188 between the heating element 220, and the flow path member 182, and this gap 188 acts as a fluid passage between the airflow path arrangement and the substantially closed chamber 235. In embodiments, the gap 188 is formed by a cutaway portion of the first section 184 forming the overlap.

The expanded portion 187 is located diametrically opposite to the location of the thermocouple 240. This helps restrict condensate coming into contact with the thermocouple 240. Around the remainder of the circumference of the heating element 220, the flow path member 182 is sealably mounted to the heating element 220, for example by welding. This helps provide heat transfer between components.

FIG. 6 shows a perspective view of the heating element 220, flow path member 182, and first end support 230. As can be seen in FIGS. 6, 7, and 8, the first end support comprises a plurality of condensate collection cavities 270 which are provided surrounding the second section 185 of the flow path member 182, and below the first section 184 of the flow path member 182.

The cavities 270 are open at an end which is proximal to the first section 184 of the flow path member 182. In the illustrated embodiment, the cavities are arcuate in cross section so as to efficiently surround the circular cross section of the second section 185 of the flow path member 182.

Since the heating element 220 generates significant heat in use, the contrasting colder temperature of the flow path member 182 results in the formation of condensate on the flow path member 182, especially since the flow path member 182 acts as an inlet for air from outside the device, which is likely to be cold. This condensate can be problematic in the air flow passage 180 and so it is advantageous to reduce the formation of such condensate in the air flow passage 180. The fluid passage formed by the gap 188 between the heating element 220 and the flow path member 182 allows aerosol to escape from the air flow passage 180 into the substantially closed chamber 235. Condensate then forms in the fluid chamber 235, rather than in the air flow passage 180 itself. The expanded portion 187 is formed opposite the thermocouple 240 in order to limit the exposure of the thermocouple to aerosol and the resulting condensate. In the illustrated embodiment, the first end support 230 comprises a plurality of cavities 270. These cavities 270 are positioned such that condensate present in the substantially closed chamber 235 may fall into the cavities 270. In this way, the provision of the cavities 270 may further limit the exposure of the thermocouple 240 to condensate. It is envisaged that the cavities may contain an absorbent material (not shown) to absorb condensate which falls into the cavities 270. In embodiments the cavities are disposed elsewhere. In embodiments, the cavities are omitted.

FIG. 9 shows a cross-sectional plan view of an aerosol generator 400 according to a further embodiment. FIG. 9 shows the heating element 420 with a pair of circumferential slots 423 which act as the fluid passage between the airflow path arrangement and the chamber 435. The slots 423 act as a fluid passage. The circumferential slots 423 perform the same function as the gap 188 formed by the expanded portion 187 in the previously discussed embodiment by allowing aerosol to enter the substantially closed chamber 235, thus reducing the formation of condensate inside the air flow passage 180. Although not shown in FIG. 9, it is envisaged that the heating element 420 may be provided in combination with a first end support 230 comprising a plurality of cavities 270, in the same way as the previously discussed embodiment. The cavities may be omitted. In embodiments, the number and arrangement of the slots 423 may differ. The fluid passage may be a single slot. The or each slot may extend axially. The slot may be an aperture having varying profiles, for example circular. The or each slot may be offset. The or each slot in embodiments is disposed towards the proximal end, the distal end, or both.

In embodiments, the air flow through the flow path through the device differs. As described above, the flow path is defined as a through bore through the device along a flow path member to the receptacle such that air is drawn through the article. In embodiments, the flow path member defines a closed end of the receptacle. The air path is defined from an open proximal end of the receptacle at the aperture 104, between the receptacle and the article to the closed end and then into the article at the closed end to flow back towards the proximal end through the article.

FIG. 10 shoes a cross sectional plan view of an aerosol generator 500 according to a further embodiment. FIG. 10 shows the flow path member 582 with a circumferential slot 523 which acts as the fluid passage between the airflow path arrangement and a substantially closed chamber 525 between the flow path member 582, and a barrier member 533. In the embodiment shown in FIG. 10, the first end support 520 comprises a plurality of cavities 570 in which condensate may collect. The cavities may be omitted. In embodiments, the number and arrangement of the slots 523 may differ. The fluid passage may be a single slot. The or each slot may extend axially. The slot or each may be an aperture having varying profiles, for example circular. The or each slot may be offset. The or each slot in embodiments is disposed towards the proximal end, the distal end, or both.

FIG. 11 shows a perspective view of the heating element 220. Mounted on the heating element 220 is the thermocouple 240, as described in detail above. A sheath 600 is provided which circumferentially surrounds the heating element 220, and overlies the thermocouple 240. As such, the sheath 600 is provided inside the substantially closed chamber 235. The sheath 600 is formed of a fluid impermeable material. The sheath 600 is formed from a thermally reactive material, for example a heat shrink material. In embodiments, when the sheath 600 is mounted over the heating element 220 and thermocouple 240, it may not provide a fluid impermeable layer by virtue of not providing a tight enough fit over the thermocouple 240. However, since the sheath 600 is formed of a thermally reactive material, as the heating element 220 heats up, the sheath 600 will shrink onto the heating element 200 and thermocouple 240, providing a fluid impermeable fit. In this way, the sheath 600 is configured to protect the thermocouple from moisture, such as condensate which is allowed into the substantially closed chamber, for example by fluid passages between the airflow path arrangement and the substantially closed chamber 235. By protecting the electrical contact points 241, 242, 243 of the thermocouple 240 from moisture, the likelihood of short-circuits is reduced. In embodiments, the sheath is a wrap which is bonded to the heating element 220. In embodiments the sheath forms a layer of the heating element 220.

FIG. 12 shows an alternative embodiment in which two sheaths 601 and 602, are provided which circumferentially surround the heating element 220, and overlie thermocouples 240, only at the electrical contact points 241, 242, 243. Such an embodiment may reduce the amount of sheath material required, which may lead to a cost reduction, and further, to a weight saving. Otherwise, the function of the sheaths 601, 602, is substantially identical to that of sheath 600 discussed in relation to FIG. 11.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

AEROSOL PROVISION DEVICE

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