JP7689122B2 - Aerosol generating device having a holder including an engaging element - Patents.com - Google Patents

Description

The present disclosure relates to a holder for an aerosol generating device, the holder having an engagement element for cooperating with an aerosol substrate, and an aerosol generating device incorporating the holder. The present disclosure is particularly applicable to portable aerosol generating devices that may be self-contained and low-temperature. Such devices may heat tobacco or other suitable material by conduction, convection, and/or radiation, rather than combustion, to generate an aerosol for inhalation.

The popularity and use of risk reduction or risk modification devices (also known as vaporizers) has grown rapidly in recent years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling cigarettes. A variety of devices and systems are available that heat or warm an aerosolizable substance, as opposed to burning tobacco in traditional tobacco products.

A commonly available risk reduction or risk modification device is the substrate heated aerosol generating device or heated non-combustion device. This type of device generates an aerosol or vapor by heating an aerosol substrate, which typically contains moist tobacco or other suitable aerosolizable material, to temperatures typically ranging from 100°C to 350°C. By heating, rather than burning or combusting, the aerosol substrate, an aerosol is released that contains the components desired by the user but with reduced or no toxic and carcinogenic by-products of combustion and burning.

In general, it is desirable to rapidly heat the aerosol substrate to a temperature at which an aerosol can be released from the aerosol substrate without burning it, and to maintain the aerosol substrate at that temperature. It will be apparent that the aerosol will be released from the aerosol substrate into a heating chamber and provided to a user when there is air flow past the aerosol substrate.

Because this type of aerosol generating device is a portable device, energy consumption is an important design consideration. The present invention aims to address the problems with existing devices and to provide an improved aerosol generating device and heating chamber therefor.

According to a first aspect, disclosed herein is a holder insertable into an aerosol generation device configured to heat an aerosol substrate supported by a substrate carrier to generate an aerosol, the holder configured to receive the aerosol substrate supported by the substrate carrier, and the holder comprising:
a rim defining an opening, the rim extending about a central axis a first radial distance from the central axis along which a substrate carrier is insertable into the holder through the opening;
a holder including at least two engaging elements, each of the engaging elements having an elongated portion extending generally parallel to the central axis between a first end joined to the rim and a second end distal from the rim, each engaging element not having any electric heating element for supplying heat to the aerosol substrate, and each elongated portion being located at a second radial distance from the central axis, the second radial distance being smaller than the first radial distance;

This configuration allows compression of the aerosol substrate by the engaging element while isolating this compression from heating. This may be useful for providing a removable holder and may also be useful for retrofitting an aerosol generating device with a compression means such as an engaging element on a replacement holder. Compression of the aerosol substrate may eliminate air gaps in the aerosol substrate and improve thermal conduction of the aerosol substrate.

Optionally, each engagement element has a support extending from the second end of the elongate portion toward the central axis to provide a seat for limiting insertion of the substrate carrier along the central axis.

Optionally, the supports of at least two of the engaging elements extend tangentially to one another. Optionally, the supports of all of the engaging elements extend tangentially to one another. In some cases, the supports of the engaging elements extend toward one another but do not touch, and in other cases, they meet, touch, and even join to one another at the central axis.

Optionally, each engagement element is a rod.

Optionally, the engagement elements are evenly spaced around the rim.

Optionally, the engagement elements are spaced apart from one another by an air gap.

Optionally, the engagement element is parallel to the central axis toward the second end of the engagement element.

Optionally, the engagement elements curve inwardly in an arc that approaches the central axis.

Optionally, the air gap is greater than the thickness of the engagement element.

Optionally, the holder further includes a tubular sidewall extending around the at least two engaging elements, the tubular sidewall defining a heating chamber.

Optionally, the elongate element is spaced apart from an inner surface of the tubular sidewall. The inner surface of the tubular sidewall may be spaced apart from the central axis by a third radial distance, the second radial distance being less than the third radial distance.

Optionally, the holder further includes a base located further from the rim than the second end of the elongate portion of the engagement element. For example, the base may have an inner surface located further from the rim than the second end of the elongate portion of the engagement element.

Optionally, the base is joined to the tubular sidewall.

Optionally, the base closes the tubular sidewall to prevent air from flowing into the heating chamber defined by the tubular sidewall, for example in the region of the second end of the elongate portion of the engagement element.

Optionally, the sidewalls and/or base are mesh or have one or more openings.

Optionally, the base is spaced apart from the support.

Optionally, the surface of each engaging element facing the central axis has a convex profile transverse to the central axis, and preferably the convex profile is a circular arc.

Optionally, the first end of the elongate portion of each engaging element has a portion that tapers toward the second end of the elongate portion and toward the central axis. In some examples, only one or some of the engaging elements have this shape.

Optionally, the engagement element comprises a material having a higher heat transfer coefficient than the material of the rim.

Optionally, the engagement element is metallic. Preferably, the engagement element is made of stainless steel or copper.

Optionally, the rim is made of a heat resistant plastic, preferably polyetheretherketone, PEEK.

According to a second aspect, disclosed herein is the above-mentioned holder in combination with a substrate carrier, where the second radial distance is less than half the width of the substrate carrier. In this example, the substrate carrier is elongated along an axis, and the width is a dimension transverse to the axis.

According to a third aspect, there is provided an aerosol generating device comprising a holder as described above, held in a recess of the aerosol generating device.
Power supply,
a heater configured to provide heat to the holder;
and a control circuit configured to control the supply of power from the power supply to the heater.

Optionally, the holder is removable from the aerosol generating device. More specifically, the holder may be removable, e.g., replaceably removable, from the heater.

Optionally, the heater is permanently attached to the aerosol generating device.

Optionally, the heater is attached to the tubular sidewall.

Optionally, the heater is not in conductive thermal contact with the engagement element.

According to a fourth aspect, there is provided an aerosol generating device for generating an aerosol from an aerosol substrate supported by a substrate carrier, comprising:
a holder for receiving a substrate carrier;
a heater configured to provide heat to the aerosol substrate when the substrate carrier is received within the holder;
The holder is positioned between the heater and the aerosol substrate when the substrate carrier is received within the holder, and the holder comprises:
a rim defining an opening, the rim extending about a central axis a first radial distance from the central axis along which a substrate carrier is insertable into the holder through the opening;
An aerosol generating device is provided, comprising at least two engaging elements, each of the engaging elements having an elongated portion extending generally parallel to the central axis between a first end joined to the rim and a second end distal from the rim, each elongated portion being located at a second radial distance from the central axis, the second radial distance being smaller than the first radial distance.

The fourth aspect may include various optional features of the holder of the first aspect, or may include the substrate carrier of the second aspect.

According to a fifth aspect, there is provided an aerosol generating device for generating an aerosol from an aerosol substrate supported by a substrate carrier, comprising:
a heater configured to provide heat to the aerosol substrate when the substrate carrier is contained within the aerosol generating device;
An aerosol generating device is provided comprising: a holder having a rim defining an opening, the rim extending around a central axis along which the substrate carrier is insertable through the opening into the holder to accommodate the substrate carrier within the aerosol generating device, the holder further comprising at least two rod-shaped engaging elements for holding the substrate carrier spaced apart from the heater, the engaging elements extending from the rim in a direction substantially parallel to the central axis.

Various optional features of the first aspect may be applied to the holder of the fifth aspect. Similarly, the fifth aspect may include a substrate carrier.

A preferred embodiment of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings.

FIG. 1 is a schematic perspective view of an aerosol generating device according to a first embodiment of the present disclosure, in which the aerosol generating device is loaded with a substrate carrier comprising an aerosol substrate. 2 is a schematic cross-sectional side view of the aerosol generating device of FIG. 1, in which the aerosol generating device is loaded with a substrate carrier comprising an aerosol substrate. FIG. 2 is a schematic perspective view of the aerosol generating device of FIG. 1, in which the aerosol generating device is loaded with a substrate carrier containing an aerosol substrate. 2 is a schematic cross-sectional side view of the aerosol generating device of FIG. 1, in which the aerosol generating device is loaded with a substrate carrier comprising an aerosol substrate. 1 shows a schematic cross-sectional view of a holder according to a first embodiment inserted into a recess of an aerosol generating device; 1 shows a schematic cross-sectional view of a holder according to a first embodiment inserted into a recess of an aerosol generating device and a substrate carrier including an aerosol substrate inserted into the holder; FIG. 2 shows a schematic perspective view of a holder according to a first embodiment, in which the holder has a support. FIG. 2 is a schematic perspective view of a holder according to a second embodiment, similar to the first embodiment, but without a support; FIG. 13 is a schematic perspective view of a holder according to a third embodiment, similar to the first embodiment, but with supports that do not contact at the central axis. FIG. 13 shows a schematic perspective view of a holder according to a fourth embodiment having an engagement element with a curved profile. FIG. 13 shows a schematic cross-sectional view of a holder according to a fourth embodiment. FIG. 13 shows a schematic perspective view of a holder according to a fifth embodiment having an engagement element with a portion of a first end that slopes toward a second end of the engagement element and toward a central axis of the holder. FIG. 13 shows a schematic cross-sectional view of a holder according to a fifth embodiment. FIG. 13 shows a schematic perspective view of a holder according to a sixth embodiment having a side wall around an engagement element. 13 shows a schematic cross-sectional view of a sixth embodiment of a holder having a support and a base connected to a side wall below the support. FIG. 13 shows a schematic cross-sectional view of a variant of the holder of the sixth embodiment, which does not have a support but has a base connected to the side wall below the lower end of the engagement element. 13 shows a schematic cross-sectional view of a variant of the holder of the sixth embodiment having a support and no base connected to the side wall. FIG. 13 shows a schematic perspective view of a holder according to a seventh embodiment having a side wall around an engagement element and the engagement element passing through a rim of the side wall. 13 shows a schematic cross-sectional view of a seventh embodiment of a holder having a support and a base below the support. FIG. 13 shows a schematic cross-sectional view of a variant of the holder of the seventh embodiment, which does not have a support, has a base connected to the side wall, and the engagement element passes through the base. FIG. 13 shows a schematic cross-sectional view of a variant of the holder of the seventh embodiment, which does not have a support but has a base below the lower end of the engagement element.

1-6, according to a first embodiment of the present disclosure, an aerosol generating device 100 includes an outer casing 102 that houses various components of the aerosol generating device 100. In the first embodiment, the outer casing 102 has a generally pebble shape, however, it will be understood that any shape is possible as long as it is sized to fit the components described in the various embodiments shown herein.

The first end 104 of the aerosol generating device 100 shown at the bottom of each of Figures 1-4 is described for convenience as the bottom, base or lower end of the aerosol generating device 100. The second end 106 of the aerosol generating device 100 shown at the top of each of Figures 1-6 is described as the top or upper end of the aerosol generating device 100. During use, a user typically orients the aerosol generating device 100 with the first end 104 facing downward and/or in a distal position relative to the user's mouth and the second end 106 facing upward and/or in a proximal position relative to the user's mouth.

The aerosol generating device 100 has a recess located toward the second end 106 of the aerosol generating device 100. The recess is defined by a recess base 113 and a recess sidewall 116 extending between the recess base 113 and the open end of the recess. The recess sidewall 116 and the recess base 113 are connected to each other. That is, the recess is cup-shaped. In a first embodiment, the recess sidewall 116 is tubular. More specifically, the recess sidewall 116 is cylindrical. However, in other embodiments, the recess sidewall 116 has other suitable shapes, such as a tube having an elliptical or polygonal cross section. In yet another embodiment, the recess sidewall 116 is tapered. The recess base 113 is closed, e.g., hermetically sealed, against the recess sidewall 116 to prevent the recess from exposing the interior of the outer casing 102 to the outside world. This may help protect the interior of the aerosol generating device 100 from damage due to dust or water getting inside. The recess is open towards the second end 106 of the aerosol generating device 100. Nested inside the recess is a holder 109. As shown in Figures 1-4 and 5B, the holder 109 is arranged to receive an aerosol substrate 128, also known as a "consumable", supported by a substrate carrier 114 through an opening 110 defined by the rim 107. When properly inserted into the aerosol generating device 100, the substrate carrier 114 is received by the holder 109 and sits within the recess.

Typically, the substrate carrier 114 includes a prepackaged aerosol substrate 128, such as tobacco or another suitable aerosolizable material, provided with an aerosol collection region 130. Both the aerosol substrate 128 and the aerosol collection region 130 are encased in an outer layer 132 and abut each other at an interface midway along the substrate carrier 114. The aerosol substrate 128, which can be heated to generate an aerosol for inhalation, is located toward a first end 134 (or "tip") of the substrate carrier 114. The aerosol substrate 128 extends across the entire width of the substrate carrier 114 within the outer layer 132. In other embodiments, the recess is configured to receive other forms of aerosol substrate 128, such as loose cut material or otherwise packaged solid material.

In FIG. 6, the holder 109 is shown separately from the aerosol generating device 100. It can be seen that the rim 107 extends about the central axis C a first radial distance R ₁ from the central axis C. As will be described in detail below, the central axis C also defines a direction in which the substrate carrier 114 can be inserted into the holder 109 through the opening 110. The rim 107 has a plurality of engaging elements 140 in the form of rods, which are joined to the rim 107 at their first ends 142a to hold the engaging elements 140 in place relative to one another and to help reduce breakage (e.g. bending) of the engaging elements 140. In some cases, the engaging elements 140 can be flat bars or other cross-sections rather than rod-shaped. In some examples, the engaging elements 140 may not even have a constant cross-section along their length, and the cross-section can vary along their length, for example to provide a rough surface for gripping or to provide a particular compression profile. Each engaging element 140 has an elongate portion 144 that extends generally parallel to the central axis C and extends from the rim 107 to a second end 142b that is distal to the rim. The engaging elements 140 are equally spaced around the rim 107 in the sense that the gap between adjacent engaging elements 140 is always the same, although in some instances this spacing may vary.

When the substrate carrier 114 is inserted into the holder 109, the elongated portion 144 is configured to contact and compress the aerosol substrate 128. The holder 109 is configured such that when the substrate carrier 114 is properly inserted into the holder 107, the engagement element 140 is aligned with the aerosol substrate 128 to enable this compression.

To allow the aerosol substrate to be compressed, each elongate portion 144 is located a second radial distance _R2 from the central axis C, the second radial distance _R2 being less than the first radial distance _R1 . More specifically, each elongate portion 144 has at least a portion of its length that is intended to contact the substrate support 114 that is located the second radial distance R2 _{or less} from the central axis C.

The substrate carrier 114 also has a radial extent R ₄ from its own central axis (not shown, but coinciding with the central axis C of the holder 109 in FIGS. 5A, 5B and 6). Since in this embodiment the substrate carrier 114 is cylindrical, the width of the substrate carrier is equal to twice this radial extent R ₄ , for example 2R _4. This radial extent R ₄ is smaller than the first radial distance R ₁ in order to be able to fit the substrate carrier 114 through the opening, but is larger than the second radial distance R ₂ in order to create the above-mentioned compression. In the illustrated embodiment, the second radial distance R ₂ is smaller than half the width of the substrate carrier 114. However, if the substrate carrier 114 is not cylindrical, the radial extent R ₄ of the substrate carrier 114 will vary depending on the circumferential position (i.e. the angle around the central axis of the substrate carrier 114) considered. This means that the first radial distance R ₁ and the second radial distance R ₂ may also need to be varied in a complementary manner to accommodate both the insertion of the substrate carrier 114 through the opening 110 and the provision of the desired compression. This may further mean that the desired effect may only be achieved when the substrate carrier 114 is inserted into the holder in one or more specific orientations, although it will be understood that suitable non-cylindrical designs are feasible (e.g. based on an elliptical or square cross section). Note that FIG. 5B illustrates the relationship between the first and second radial distances R ₁ , R ₂ and the radial range R ₄ , where the radial range R ₄ is shown in the uncompressed portion of the substrate carrier 114, and the portion of the substrate carrier 114 aligned with the engagement element 140 (and therefore compressed) is shown with a smaller width to illustrate this compression. Note that FIG. 5B is not necessarily drawn to scale, but is shown to emphasize the compression effect.

The engaging element 140 does not have an electric heating element for supplying heat to the holder 109 located on or within the engaging element 140. Any heat source for heating the holder 109 is located in the aerosol generating device 100, particularly in the recess sidewall 116 in this embodiment. In other words, the engaging element 140 does not have a heating element on or within the engaging element 140. That is, heat is not supplied from the engaging element 140, but from somewhere else. This means that heat is not generated by elements on, within, or in direct contact with the engaging element 140. Such a configuration allows the holder 109 to be easily removable from the aerosol generating device 100, since there is no need to provide a connection between a heat source located in the removable holder 109 and a power source. This simplifies the design of the holder 109 and the method of connecting the holder 109 to the aerosol generating device 100, and also makes it possible to retrofit a compression means, such as the engagement element 140 provided on the replacement holder 109, to the aerosol generating device 100.

The holder 109 provided as a separate element may allow for a repeatedly removable holder 109, for example, to ensure that the substrate carrier 114 is properly seated in the holder. The holder 109 may be mounted on the substrate carrier 114 (and the correct alignment may be visually verified) before both the holder 109 and the substrate carrier 114 are inserted into the recess. This configuration also allows for easy cleaning of the holder 109 once it is removed from the recess. In another example, the holder 109 may be supplied as a separate element for retrofitting an aerosol generating device 100 manufactured without the engaging element 140, providing the device 100 with the engaging element 140. The removable holder 109 may be configured to be clipped into place in the aerosol generating device 100 to hold the removable holder 109 in place, either permanently in a retrofitted state or removably (by a clip, latch, etc., not shown) to allow repeated removal and insertion. This configuration may also aid in removing the substrate carrier 114 after use without damaging the substrate carrier 114, since the substrate carrier 114 may be removed simultaneously with the holder 109 while still being held within the holder 109. This further reduces the likelihood of the substrate carrier collapsing and leaving debris in the recess, thereby reducing the need to clean the recess.

The configuration described herein separates the compression function from the heating function while still allowing compression of the aerosol substrate 128 by the engagement element 140. In other words, the advantage of separating the heating and compression functions is that it allows for more flexible adaptation to different substrate carriers 114 and/or aerosol generating devices 100.

The engaging element 140 is aligned with the aerosol substrate 128 when the substrate carrier 114 is properly inserted into the holder 109. Additionally, the second end 142b of each engaging element 140 is bent to extend toward the central axis C, forming a support 148. In the first embodiment, the support 148 of each engaging element 140 meets at the central axis C. Accurate alignment between the engaging element 140 and the substrate carrier 114 can be ensured because the support 148 prevents overinsertion of the substrate carrier 114 along the central axis C by providing a seat for contacting the tip 134 of the substrate carrier 114, thereby aligning the aerosol substrate 128 and the engaging element 140. This further ensures that the aerosol substrate 128 is compressed but not other portions of the substrate carrier 114. In another example, the recessed base 113 can also help prevent overinsertion of the substrate carrier 114. In either case, if an element such as the support 148 or recessed base 113 functions to prevent over-insertion of the substrate carrier 114, the user can ensure correct insertion by pushing the substrate carrier 114 into the holder 109 and feeling an increase in resistance as the tip 134 contacts the support 148.

In a first embodiment, the supports 148 of the engagement element 140 abut, touch, or join at the central axis C. In other examples, including some of the embodiments described below, this is not the case, e.g., the supports 148 may not extend all the way to the central axis C, e.g., extend toward the central axis C (and each other) but leave a gap at the central axis C. In some cases, the supports 148 do not even touch each other.

In the first embodiment, the substrate carrier 114 is generally cylindrical and the rim 107 has a generally circular opening 110. Similarly, the engaging elements are configured such that their innermost surfaces (the parts that contact the substrate carrier 114) are arranged in a generally circular configuration. That is, the shapes of the openings 110, the contact surfaces of the engaging elements 140 and the substrate carrier 114 all correspond to each other. It will be understood that in all embodiments, there is a general principle that the shapes and sizes of the openings 110 and the engaging elements 140 are selected to allow the substrate carrier 114 to pass through the openings 110 and to allow contact and compression between the engaging elements 140 and the substrate carrier 114. In other words, the invention is not limited to any particular shape of the substrate carrier 114 and the holder 109, and any desired shape of these elements can be selected, subject to the above.

The dimensions R ₁ , R ₂ and R ₄ are simply interpreted in the case where the opening 110, the substrate carrier 114 and the engaging element 140 have a circular/cylindrical geometric shape. Specifically, R ₁ is the radius of the circular opening 110, R ₄ is the radial dimension of the cylinder representing the substrate carrier 114 and R ₂ is the radial dimension of the portion of the engaging element 140 that contacts the substrate carrier. When generalized to a situation where the engaging element 140 is arranged in a shape other than cylindrical to accommodate the holder 109 to the shape of the substrate carrier 114 (e.g., a cube-like shape to provide pressure to a cube-like substrate carrier 114), R ₁ , R ₂ and R ₄ instead refer to characteristic dimensions of the opening 110, the engaging element 140 and the substrate carrier 114, respectively. As an example, the characteristic dimensions can be the straight edges of a polygon, e.g., the largest or smallest such edge, the major or minor axis of an oval, etc.

As described above, the interaction between _R1 and _R4 is such that the opening 110 is sized and shaped to allow the substrate carrier 114 to pass through the opening 110. If the opening 110 is not circular (e.g., square, rectangular, elliptical, etc.), the opening 110 may be used to encourage the user to correctly align (by sight or feel) the substrate carrier 114 for insertion, for example, by aligning a flat surface of the substrate carrier 114 with a straight edge of the opening 110 or by aligning the major axis of the elliptical cross section of the substrate carrier 114 with the major axis of the opening 110. This may help the user to correctly insert the substrate carrier 114 into the holder 109 and achieve the desired degree of compression, since the engaging element 140 is held in a predetermined position relative to the opening 110. In general, the contact surface of the engaging element 140 is positioned to form a shape corresponding to (but smaller than) the shape of the substrate carrier 114.

The heater 124 is attached to the outer surface of the recess sidewall 116. That is, the heater 124 is attached on the surface of the recess sidewall 116 that faces away from the interior volume of the recess. In other words, the heater 124 is permanently attached to the aerosol generating device 100. This may help protect the heater 124 from damage when the substrate carrier 114 and holder 109 are inserted into the recess, while still being configured to provide heat from the heater 124 to the holder 109. The heater 124 is typically electrically powered.

The first embodiment may be considered to disclose an aerosol generating device 100 for generating an aerosol from an aerosol substrate 128 supported by a substrate carrier 114. In this example, the aerosol generating device 100 has a holder 109 for accommodating the substrate carrier 114 and a heater 124 configured to provide heat to the aerosol substrate 128 when the substrate carrier 114 is accommodated in the holder 109. When the substrate carrier 114 is accommodated in the holder 109, the holder 109 is located between the heater 124 and the aerosol substrate 128. The holder 109 further includes a rim 107 defining an opening 110. The rim 107 extends about and from the central axis C a first radial distance R _1. The substrate carrier 114 is insertable into the holder 109 along the central axis C through the opening 110. The holder has at least two engaging elements 140 (in this case there are eight engaging elements 140), each of which has an elongate portion 144 extending generally parallel to the central axis C between a first end 142a joined to the rim 107 and a second end 142b distal from the rim 107. Each elongate portion 144 is located a second radial distance _R2 from the central axis C. The second radial distance _R2 is less than the first radial distance _R1 .

Another aspect of the disclosure of the first embodiment is that an aerosol generating device 100 is provided for generating an aerosol from an aerosol substrate 128 supported by a substrate carrier 114. The aerosol generating device 100 includes a heater 124 configured to provide heat to the aerosol substrate 128 when the substrate carrier 114 is housed within the aerosol generating device 100. There is a holder 109 having a rim 107 that defines an opening 110, the rim 107 extending around a central axis C. To house the substrate carrier 114 within the aerosol generating device 100, the substrate carrier 114 is insertable into the holder 109 through the opening 110 (e.g., along the central axis C). The holder 109 has at least two bar-shaped engaging elements 140 (in this case, there are eight engaging elements 140) for holding the substrate carrier 114 spaced apart from the heater 124. The engagement element 140 extends from the rim 107 in a direction substantially parallel to the central axis C.

As described elsewhere herein, each of the engagement elements 140 has a portion for contacting and compressing the substrate carrier 114. The portion for contacting and compressing the substrate carrier 114 provides a reduced or limited cross-sectional area for receiving the substrate carrier 114 (i.e., smaller than the opening 110 that would allow the substrate carrier 114 to pass through unstressed and undamaged), thereby ensuring that compression occurs when the substrate carrier 114 is inserted.

In a first embodiment, the aerosol generating device 100 is electrically powered. That is, the aerosol generating device 100 is configured to heat the aerosol substrate 128 using electrical power. For example, the heater 124 is a film heater comprising a conductive (e.g. metal) track laminated on a flexible electrically insulating backing material (e.g. polyimide). To this end, the aerosol generating device 100 has a power source 120, e.g. a battery. The power source 120 is coupled to a control circuit 122. The control circuit 122 is in turn coupled to the heater 124. The aerosol generating device 100 is operated by a user using control means (not shown) configured to couple the power source 120 to the heater 124 and to decouple the power source 120 from the heater 124 via the control circuit 122.

The recess sidewalls 116 are spaced apart from the inner surface of the outer casing 102 to prevent heat from flowing into the outer casing 102. To improve the insulation of the recess, the recess may further be surrounded by an insulator, for example a fibrous or foam material such as cotton wool, aerogel or gas, or in other examples may be provided with a vacuum insulator.

As mentioned above, the holder 109 has eight engaging elements 140 provided around and connected to the rim 107 to hold the substrate carrier 114 in a central position within the holder 109. Other numbers, for example, two or more engaging elements 140, may be used, but fewer than four engaging elements 140 may result in poor centering of the substrate carrier 114 within the holder 109. The engaging elements 140 provide and maintain a controlled gap for an air flow path (arrow B) between the inner surface of the recess sidewall 116 (between adjacent engaging elements 140) and the substrate carrier 114. The aerosol generating device 100 works by convection heating, where air in the air gap between the inner surface of the recess sidewall 116 and the outer surface of the substrate carrier 114 is heated and drawn through the substrate carrier 114. Arrow B (see FIG. 4) shows the air flow path to the recess. The air is heated by the heater 124 as it passes through the portion of the recess sidewall 116 that corresponds to the location of the heater 124. Air flows down the sides of the substrate carrier 114 (before and after the engaging elements 140). The recessed base 113 blocks further downward airflow. This means that the air enters the tip 134. Arrow A shows the air flow path through the aerosol substrate 114 and out the second end 136 (top) of the substrate carrier 114. Comparison with FIG. 6 shows that the wedge-shaped gap between the supports 148 of adjacent engaging elements 140 allows air to enter the tip 134 of the substrate carrier 114.

The space bounded by adjacent engaging elements 140, the sidewall 116, and the outer layer 132 of the substrate carrier 114 defines the area available for airflow. The smaller this space, the harder the user must inhale to draw air into the aerosol generating device 100 (known as increased resistance to inhalation). The size, number, and spacing of the engaging elements 140 can be adjusted to provide a satisfactory resistance to inhalation that is neither too low nor too high. To increase the airflow channel between the sidewall 116 and the substrate carrier 114, the engaging elements 140 can be made thicker (i.e., extending further radially from the recessed sidewall 116 toward the central axis C), but there is a practical limit to this before the gap between the recessed sidewall 116 and the substrate carrier 114 becomes too large to cause the heater 124 to become ineffective. Typically, a gap of 0.2 mm to 0.3 mm around the outer surface of the substrate carrier 114 is a good compromise, allowing the resistance to inhalation to be fine-tuned within tolerances by varying the dimensions of the engagement element 140. Compression of the aerosol substrate by the engagement element 140 has also been found to increase the resistance to inhalation, which, in combination with the airflow channel suppression effect described above, provides a comfortable level of resistance to inhalation.

When a user wishes to use the aerosol generating device 100, the user first loads the substrate carrier 114 into the aerosol generating device 100 by inserting the substrate carrier 114 into the holder 109. The substrate carrier 114 is inserted into the holder 109 with the first end or tip 134 of the substrate carrier 114 oriented to enter the holder 109 first such that the aerosol substrate 128 is located adjacent to the support 148 with the tip 134 in contact with the support 148. In this embodiment, there is an additional effect due to the interaction between the upper end 142a of the engagement element 140 and the boundary between the aerosol substrate 128 and the adjacent aerosol collection region 130 of the low compressibility substrate carrier 114, which may also serve to inform the user that the substrate carrier 114 has been inserted sufficiently deep into the aerosol generating device 100. Before or after this, the holder 109 is inserted into the recess until the lower edge of the support 148 rests on the inner surface of the recess base 113.

In use, when a user switches on the aerosol generating device 100, power from the power source 120 is provided to the heater 124 via (and under the control of) the control circuit 122. The heater 124 heats the recess sidewall 116, which in turn heats the air inside the recess. This causes some heating of the portion of the substrate support 114 inside the recess by conduction. When a user pulls air (arrow A) through the substrate support 114, the heated air passes over and heats the aerosol substrate 128, causing it to emit an aerosol and/or vapor.

3 and 4, it can be seen that when the substrate carrier 114 is inserted as deeply as possible into the holder 109, only a portion of the length of the substrate carrier 114 is inside the holder 109. The remainder of the length of the substrate carrier 114 protrudes from the holder 109. When the holder 109 is in the recess, at least a portion of the remaining length of the substrate carrier 114 also protrudes from the second end 106 of the aerosol generating device 100 and can be used as a mouthpiece from which a user draws aerosol from the aerosol substrate 128 by inhalation. In other embodiments, all or substantially all of the substrate carrier 114 can be contained within the aerosol generating device 100 such that no portion or substantially no portion of the substrate carrier 114 protrudes from the aerosol generating device 100.

It will be appreciated that as the user inhales the aerosol in the direction of arrow A in FIG. 4, ambient air is drawn into the recess from the environment surrounding the aerosol generating device 100 (through the flow path indicated by arrow B in FIG. 4). This ambient air flows through the space provided between the recess sidewall 116 and the outer layer 132 of the substrate support 114, where it is further heated by the heater 124, thereby starting the cycle again.

The user can continue to inhale the aerosol as long as the aerosol substrate 128 continues to generate aerosol, e.g., as long as there are vaporizable components remaining in the aerosol substrate 128 for vaporization into a suitable aerosol. The control circuit 122 adjusts the power supplied to the heater 124 to prevent the temperature within the recess from exceeding a threshold level, e.g., the temperature at which the aerosol substrate 128 begins to burn.

5A and 5B show a close-up of the holder 109 being inserted into the recess. As can be seen, the holder 109 fits into the recess and is aligned with the recess sidewall 116. Although FIGS. 5 and 5B show the substrate carrier 114 being inserted into the holder 109 only after the holder 109 has been inserted into the recess, as described above, in some instances the substrate carrier 114 may be fitted into the holder 109 and both parts may be inserted into the recess together. The rim 107 may also be used to limit how far the holder 109 can be inserted into the recess, for example by allowing interaction between the rim 107 and the upper edge of the recess sidewall 116. This may create a gap between the support 148 and the inner surface of the recess base 113, which may be further used to increase the volume of heated air in the recess for heating the aerosol substrate. This may increase the time it takes to heat the air in the recess to a desired temperature (because there is more air), but once heated, the greater amount of warm air in the recess provides a larger reservoir from which the user can inhale, which may allow the user to inhale a larger amount of aerosol and/or vapor, or multiple inhalations in a short interval. Optionally, all or part of the rim 107 may protrude from the recess, for example to assist the user in gripping the holder 109 to remove it from the recess.

In FIG. 5A, the heater is not shown to emphasize the insertion procedure of the holder 109 into the recess. In FIG. 5B, the heater 124 is shown adjacent only a portion of the aerosol substrate 128 and located toward the lower end of the recess. In other cases, the heater 124 may be located in a different position, for example closer to the upper end of the recess, or the heater 124 may be larger, covering all or substantially all of the exterior surface of the recess sidewall 116 (or corresponding to the entire or substantially entire aerosol substrate 114). Since the recess and holder 109 are configured to provide convective heating, localization of heating is not a major issue in terms of uniformly heating the aerosol substrate 128, since the heated air passes over the entire aerosol substrate 128 in any case in a convectively heated system. In either case, if more of the recess sidewall 116 is to be heated, the heater 124 may include a heat transfer layer (e.g., a layer of copper or gold or other high thermal conductivity material) to spread the heat over an area of the recess sidewall 116 that is larger than the heater's footprint.

The rim 107 may comprise any material capable of withstanding repeated heating by the heater 124 to a temperature of approximately 200° C. Suitable materials include ceramics, such as machinable glass ceramics, and other suitable materials, such as high temperature plastics. In some cases, polymers, such as polyetheretherketone (PEEK), with an upper operating temperature of up to 250° C., may be used. The engaging element 140 may be made of any suitable durable material for compressing the aerosol substrate, such as 300 series stainless steel, which is also approved for medical use. In general, metals are preferred materials because they are strong, malleable, and easy to mold and form. In addition, the thermal properties of different metals vary widely and can be tailored by careful alloying as necessary to allow or prevent conductive heat flow through the engaging element 140 to the aerosol substrate 128. In this disclosure, "metal" refers to elemental (i.e., pure) metals as well as alloys with two or more metals or other elements, such as carbon.

In some cases, the fit between the holder 109 and the recess sidewall 116 is close enough that a significant amount of heat is also conducted from the heater 124 to the engaging element 140. In these cases, the heating of the aerosol substrate 128 is a balance between conductive and convective heating. This balance can be shifted toward conductive heat transfer by increasing the contact area between the engaging element 140 and the recess sidewall 116 (which further reduces the air gap and reduces convective heating). In other cases, conductive heat flow can be promoted by including a thermally conductive layer (e.g., made of a high thermal conductivity layer of copper, gold, etc.) to improve heat transfer from the recess sidewall 116 to the engaging element 140. In other examples, the thermally conductive layer can be softer than the recess sidewall 116 and/or the engaging element 140 such that the thermally conductive layer deforms slightly to improve contact between the recess sidewall 116 and the engaging element 140. The thermal engaging element 140 can be made of a material that has a higher heat transfer coefficient than the material of the rim 107. This allows the engagement element 140 to assist in conducting heat to the substrate carrier 114 while preventing heat from escaping the recess through the rim 107.

In another example, the heater 124 is not in conductive thermal contact with the engagement element 140. For example, the engagement element 140 may be spaced apart from the inner surface of the recess sidewall 116, such that the transfer of heat from the heater 124 to the aerosol substrate 128 is primarily convective.

Although the holder above has been described in relation to a holder for use within an aerosol generating device 100, the example shown in FIG. 6 illustrates that the present disclosure extends to the holder 109 alone, for example as described above with respect to retrofitting an existing device.

Now, alternative embodiments will be described by showing the holder 109 alone. By analogy with FIG. 6 of the first embodiment, any of the holders 109 in the following embodiments can replace the holder 109 shown in the aerosol generating device 100 of FIGS. 1-4, with the operation of the aerosol generating device being substantially the same as described above. However, each of the following embodiments of the holder 109 is shown without a substrate carrier 114 inserted therein to highlight the differences between the embodiments. Nevertheless, the present disclosure extends to the holder 109 including the substrate carrier 114 inserted therein.

Second Embodiment Referring to Figure 7, the aerosol generating device 100 according to the second embodiment is identical to the aerosol generating device 100 of the first embodiment described with reference to Figures 1 to 6, except as described below, and the same reference numbers are used to refer to similar features.

In the second embodiment, the lower end 142b of the engaging element 140 does not bend around and extend toward the central axis C. Instead, there is no support 148. This means that no part of the engaging element 140 blocks airflow to the tip 134 of the substrate carrier 114, thereby improving airflow to the substrate carrier 114 and through the aerosol substrate 128. The engaging element 140 is sufficiently rigid to withstand deformation in response to the substrate carrier 114 being inserted into the holder, thereby providing the compression described above.

Because there is no support 148, once the substrate carrier 114 is inserted into the holder 109 the correct distance (i.e., to align the aerosol substrate 128 with the engagement element 140), there is nothing to prevent further insertion of the substrate carrier 114. In some instances, the recess base 113 prevents overinsertion of the substrate carrier 114 in the sense that when the holder 109 is mounted in the recess, the substrate carrier 114 is prevented from further movement by the recess base 113, and therefore the substrate carrier 114 cannot be inserted further than desired.

In another example, over-insertion is prevented by interaction of the upper end 142a of the engaging element 140 with the interface between the aerosol substrate 128 and the aerosol collection region 130. More specifically, because the aerosol collection region 130 is harder, stiffer, or less compressible than the aerosol substrate 128, the user can feel a difference in resistance as the force required to continue inserting the substrate carrier increases when the upper end 142a of the engaging element 140 is aligned with this interface.

In yet another example, the rim 107 is configured to rest on the upper edge of the recess sidewall 116 (the end of the recess sidewall 116 closest to the outer casing 102) with the engagement element 140 not extending all the way around the recess base 113. This means that a user can mount the holder 109 on the substrate carrier 114 outside of the aerosol generating device and visually check that the tip 134 of the substrate carrier 114 is aligned with the second end 142b of the engagement element 140. In this example, since the engagement element 140 does not extend all the way around the recess base 113, the tip 134 is also spaced apart from the recess base 113 when the holder 109 and substrate carrier 114 are inserted together into the recess. Each of these options ensures that the entire area of the tip 134 is exposed, improving airflow to the substrate carrier 114.

Third Embodiment Referring to FIG. 8, the holder 109 according to the third embodiment is identical to the holder 109 of the first embodiment described with reference to FIGS. 1 to 6, except as described below, and the same reference numbers are used to refer to similar features.

The configuration of the third embodiment is very similar to that shown in FIG. 6, but in FIG. 8, the supports 148 of the engagement elements 140 are not in contact and are not bonded to each other. The engagement elements 140 are sufficiently rigid to withstand deformation in response to the substrate carrier 114 being inserted into the holder, thereby providing the compression described above.

The third embodiment balances some of the benefits of the first and second embodiments. The substrate carrier 114 is prevented from being over-inserted into the holder 109 by the support preventing further movement, and similar to the first embodiment, the thickness of the support 148 holds the tip 134 of the substrate carrier 114 spaced apart from the recess base 113. Similarly, the support 148 of the engagement element 140 does not contact at the central axis, exposing more area of the tip 134 of the substrate carrier 114 compared to the first embodiment. Thus, the third embodiment features improved airflow to the substrate carrier 114 compared to the first embodiment.

In some variations of the third embodiment, some but not all of the supports 148 of the engagement element 140 may contact (and possibly even be coupled to) other supports 148 near the central axis C.

Fourth Embodiment Referring to Figures 9A and 9B, the holder 109 according to the fourth embodiment is identical to the holder 109 of the second embodiment described with reference to Figure 7, except as described below, and the same reference numbers are used to refer to similar features.

The configuration of the fourth embodiment is very similar to that shown in FIG. 7, but in FIGS. 9A and 9B, the elongated portion 144 of the engagement element 140 is curved inward toward the central axis C, rather than being straight.

More specifically, the upper end 142a of each engaging element 140 is connected to the rim 107 as described above. The rim 107 has an opening 110 with a radius R _1. As previously described, the engaging element 140 extends inwardly from the inner surface of the rim 107 to a second radial distance R _2. However, instead of extending parallel to the central axis toward its second end 142b, the engaging element 140 now curves inwardly in an arc closest to the central axis C, as shown here as R′ _2. This shape of the engaging element 140 can provide increased compression toward a central portion of the aerosol substrate 128. In other examples, the closest radius R′ ₂ can be located away from the middle of the elongated portion 144, for example toward the upper end 142a or the lower end 142b of the engaging element 140. In other words, the surface of each engaging element 140 facing the central axis C has a convex profile transverse to the central axis C. The convex profile shown is a circular arc, but other curves are possible. In fact, the closest _R'2 can be obtained linearly, in the sense that the elongated portions 144 can be straight, but do not extend parallel to the central axis C. In this embodiment, the engaging elements 140 are not connected to each other at their lower ends 142b, so that the lower ends 142b are more susceptible than the other parts to being pushed outward by the substrate carrier 114 when the substrate carrier 114 is inserted, because the lower ends 142b are farther away from their fixed point on the rim 107 and can deviate further from their default position. Configuring the engaging elements 140 to extend in a direction non-parallel to the central axis C can be useful to ensure that the lower ends 142b of the engaging elements 140 are closest to the central axis C and compensate for their distance from the rim 107.

Additionally, in some cases, it may be advantageous to apply additional compression to tip 134 to help hold spilled material in place so that it does not fall and contaminate the recess. On the other hand, over-compression of tip 134 may cause more material to spill, making the situation worse. Similarly, the portion of aerosol substrate 128 closest to the interface between aerosol substrate 128 and aerosol collection region 130 may be protected from compression by aerosol collection region 130. Thus, a smaller space (smaller R' ₂ ) may be required to achieve the desired level of compression. For these reasons, it may be desirable to provide different amounts of compression along the length of aerosol substrate 128.

In other examples, the engaging elements 140 may be smoothly curved in the sense that the entire length of each engaging element 140 is a smoothly curved line and there is no initial portion that extends inwardly to radius _R2 before the curved portion begins.

In further examples, the engagement element 140 may not have a curved profile, but may be more angular and/or result in a pointed profile.

In yet another example, only some of the engaging elements 140 may be curved, as shown, or each of the engaging elements 140 (or one or more subsets) may have different _R'2 values representing different curvatures.

Some examples of the fourth embodiment may feature engaging element 140 having a more complex curvature, for example, to provide multiple portions of elongate portion 144 that approach central axis C. In some cases, each locally nearest portion of engaging element 140 may be the same distance _R'2 from central axis C. In other examples, each locally nearest portion of engaging element 140 may be located at a different distance ( _R'2 , _R''2 , R''' ₂ , etc.) from central axis C. This may provide additional compression of particularly advantageous portions, such as tip 134 and midpoints of aerosol substrate 128, as desired, while providing reduced compression (or indeed no compression at all) elsewhere.

Indeed, some or each of the engagement elements 140 may correspond to a different one of the variations described above (or indeed the engagement elements 140 shown in FIG. 7).

Fifth Embodiment Referring to Figures 10A and 10B, the holder 109 according to the fifth embodiment is identical to the holder 109 of the second embodiment described with reference to Figure 7, except as described below, and the same reference numbers are used to refer to similar features.

The configuration of the fourth embodiment is very similar to that shown in FIG. 7, but in FIGS. 10A and 10B, the upper end 142a of the engagement element 140 is angled in a direction from the rim 107 toward the central axis C and toward the second end 142b of the engagement element 140.

The upper end 142a shown in the figures is linearly tapered, but in other examples may have a curved profile. Because the upper end 142a acts somewhat like a funnel, the upper end 142a of the engagement element 140 having this shape helps guide the substrate carrier 114 toward alignment with the central axis C as it is inserted into the holder 109. This may be particularly useful when the holder 109 is mounted in a recess such that the user may not be able to clearly see the insertion process.

Furthermore, the configuration of the holder 109 may help to adapt (e.g., modify) a recess designed for a larger (e.g., wider) substrate carrier 114 to receive and heat a smaller (specifically, thinner) substrate carrier 114. It will be appreciated that, although the shape of the engagement element 140 in Figures 10A and 10B results in a significant narrowing, the somewhat shorter, sloping upper end 142a may make the second radial distance _R2 narrower and thus tailored to a thinner substrate carrier. This also applies to some extent to the other embodiments in that _R2 (and/or _R'2 ) may be made as narrow as desired to adapt an existing recess to a smaller sized substrate carrier 114.

Sixth Embodiment Referring to Figures 11A-11D, the holder 109 according to the sixth embodiment is identical to the holder 109 of the first embodiment described with reference to Figure 6, except as described below, and the same reference numbers are used to refer to similar features.

The configuration of the sixth embodiment is very similar to that shown in FIG. 6, but in FIG. 11A, the holder includes a tubular sidewall 126 located around the engaging element 140 (at a radial distance farther from the central axis C than the engaging element 140). In addition, a base 112 is provided at the lower end of the tubular sidewall 126 below the lower end 142b (and support 148) of the engaging element 140 (farther from the rim 107 than the lower end 142b (and support 148) of the engaging element 140). The tubular sidewall 126 contains the engaging element 140 and defines the heating chamber 108. It can also be seen that the base 112 helps define the heating chamber 108 by closing the lower end of the tubular sidewall 126. FIG. 11A shows the holder 109 in a perspective view, and FIGS. 11B-11D show cross-sectional views of variations of the internal structure.

Providing the sidewalls 126 and base 112 that encase the engaging element 140 may help protect the engaging element 140 (and the substrate carrier 114 when inserted into the holder 109) from damage. This protective effect may also prevent the engaging element 140 from bending outward when the substrate carrier 114 is inserted into the holder, since there is a limit to how far the engaging element 140 can bend outward before the sidewalls 126 prevent further movement. This may be particularly advantageous in cases such as shown in FIG. 11C, where there is no support 148 that can help hold the lower end 142b of the engaging element 140 a distance _R2 from the central axis.

The provision of the sidewall 126 and base 112 may be considered to provide a self-contained heating chamber 108 having many of the same characteristics as the holder 109 and recess combination described above. The advantage of providing the holder 109 as a self-contained unit is that the requirements for the recess in the aerosol generating device 100 are less stringent. For example, the recess may be of any size or shape, and the sidewall 126 may be sized to closely connect with the recess sidewall 116 to transfer heat from the heater 124 to the interior of the heating chamber 108. Similarly, the engaging element 140 may be spaced any distance from the inner surface of the sidewall 126 to grip and press against a substrate carrier 114 of any size. Similarly, the length of the sidewall 126 may be selected to fit securely into the recess and press against the recess base 113, for example to hold the rim 107 at a desired distance from the recess base 113 to align the engaging element 140 with the heater 124.

The base 112 functions to catch any spilled material that falls from the substrate carrier so that the holder 109 can be removed and cleaned (if the holder 109 is removable). Even if the holder 109 is not removable (e.g., a permanently fixed, retrofit situation), the presence of the base 112 reduces the requirements for the recess in which the holder 109 is mounted in that the recess base 113 does not need to completely seal the recess, since the base 112 and sidewall 126 together prevent ingress of spilled material, moisture, etc. into the interior of the aerosol generating device 100.

The base 112 is joined to the lower end of the sidewall 126. In some examples, the base 112 closes the tubular sidewall 126 in the sense that the airflow exiting the lower end of the sidewall 126 is blocked by the base 112. This can help guide the air flowing down the inner surface of the sidewall 126 to the tip 134 of the substrate carrier 114, promoting the advantage of providing a self-contained heating chamber 108. Furthermore, the base 112 can prevent air from flowing into the heating chamber 108 defined by the tubular sidewall 126 in the region of the second end 142a of the elongated portion 144 of the engagement element 140. This provides greater control over the heating of the aerosol substrate 128, since it ensures that the air flowing into the tip 134 is heated by the heater. This of course also applies to the recesses shown in Figures 2, 4, 5A and 5B and described with reference to the first embodiment. By providing the sidewall 126 and base 112 connected to each other in this sealed state, it is possible for the recess to have a different shape than that described in the first embodiment.

Optionally, the sidewall 126 and/or base 112 are formed from a mesh or have one or more openings. These may allow air heated by the heater 124 to flow into the heating chamber 108, improving convective heating of the overall aerosol generating device 100 without relying on conduction through the sidewall 126. Additionally, the use of mesh material and/or openings reduces the amount of material forming the sidewall 126 and base 112. This means less energy is required to heat the holder 109, thereby improving the efficiency of the aerosol generating device 100.

Consider FIGS. 11B and 11C, which show a holder 109 corresponding to the holder 109 of FIGS. 6 and 7, respectively, but with a sidewall 126 and base 112 containing the engagement element 140. In each of FIGS. 11A and 11B, the base 112 is spaced from the lower end 142b of the engagement element 140 (and from the support 148 in FIG. 11B). This provides space for collecting spilled material that falls from the tip 134 of the substrate carrier 114 without blocking the air flow path to the tip 134. This also provides a reservoir of heated air below the tip 134 to allow a larger amount of air to be drawn through the substrate carrier 114. In other examples, the lower end 142b and/or the support 148 may contact the base 112 or may even be located in a recess in the base 112 or may be bonded to the base 112.

The sidewall 126 has an inner surface located at a third radial distance _R3 from the central axis. _R3 is greater than _R2 , but can be greater than _R1 , less than _R1 , or equal to _R1 . Although the engaging element 140 is shown spaced apart from the sidewall 126, in some instances the engaging element 140 can contact (and even be joined to) the sidewall 126. In such cases, the contact between the sidewall 126 and the engaging element 140 is close enough that a significant amount of heat is also conducted from the heater 124 through the sidewall 126 to the engaging element 140. In these cases, the heating of the aerosol substrate 128 is a balance between conductive and convective heating. This balance can be shifted toward conductive heat transfer by increasing the contact area between the engaging element 140 and the sidewall 126 (which further reduces the air gap and reduces convective heating). In other cases, conductive heat transfer can be improved by including a thermally conductive layer (e.g., a high thermal conductivity material such as copper, gold, etc.) to improve heat transfer from the sidewall 126 to the engaging element 140. In a further example, the thermally conductive layer can be softer than the sidewall 126 and/or the engaging element 140 such that the thermally conductive layer deforms slightly to improve contact between the sidewall 126 and the engaging element 140.

11D shows a further variation of the sixth embodiment with sidewalls 126 but no base 112. As mentioned above, sidewalls 126 can provide protection for the engagement element 140. Furthermore, the absence of base 112 can help lighten the heating chamber 108 when the user is attaching the holder 109 to the substrate carrier 114 outside the device. This further helps the user visually confirm that the substrate carrier 114 is correctly attached in the holder 109. In yet another example, sidewalls 126 are not present, while base 112 can be provided bonded to the lower end 142b of engagement element 140.

Seventh Embodiment Referring to Figures 12A-12D, the holder 109 according to the seventh embodiment is identical to the holder 109 of the first embodiment described with reference to Figure 6, except as described below, and is also similar to Figures 11A-11D, with the same reference numbers being used to refer to like features.

The seventh embodiment is very similar in construction to that shown in FIG. 6, but in FIG. 12A, the holder includes a tubular sidewall 126 located around the engaging element 140 (at a radial distance farther from the central axis C than the engaging element 140). In addition, a base 112 is provided at the lower end of the tubular sidewall 126 below the lower end 142b (and support 148) of the engaging element 140 (farther from the rim 107 than the lower end 142b (and support 148) of the engaging element 140). The tubular sidewall 126 contains the engaging element 140 and defines the heating chamber 108. It can also be seen that the base 112 helps define the heating chamber 108 by closing the lower end of the tubular sidewall 126. FIG. 12A shows the holder 109 in a perspective view, and FIGS. 12B-12D show cross-sectional views of variations of the internal structure.

11A-11D, a separate rim 107 is not provided, but instead the upper end of the sidewall 126 serves as the rim 107, because the upper end 142a of each engagement element 140 is attached to the upper end of the sidewall 126. For this reason, the upper end of the sidewall 126 is called the rim 107 in the seventh embodiment. In the illustrated example, the upper end 142a of the engagement element 140 is attached to the rim by passing it through an opening in the rim 107. In other cases, the engagement element 140 may simply be joined to the rim 107 by welding or soldering, or may be attached to a recess in the sidewall 126 that does not penetrate the entire sidewall. This configuration provides the functionality described above with respect to the sixth embodiment in a simpler manner, since a second rim 107 is not required. It will be apparent that if the rim 107 had previously interacted with another element, such as the top of the recess sidewall 116, to prevent overinsertion of the holder 109 into the recess, the protruding portion of the upper end 142a of the engagement element 140 could perform this same function.

12B operates essentially the same as FIG. 11B, except for the differences highlighted above. It will not be described in further detail. FIG. 12C shows a variation in which the lower end 142b of the engaging element 140 penetrates the base 112 and projects outward from the exterior surface of the base. This can provide stability to the engaging element 140 by providing an anchor point on the base 112, which gives the engaging element 140 additional stiffness and allows it to be made thinner without sacrificing the desired compression effect. This can help compensate for situations in which the engaging element 140 does not have a support 148 to connect to another support 148, thereby allowing the engaging element to be forced away from the central axis C when the substrate carrier 114 is inserted into the holder 109. In such a case, the base 112 provides the role of the support 148 in preventing the substrate carrier 114 from being inserted further than intended. A similar effect is seen in other embodiments in which the lower end 142b of the engaging element is connected (e.g., soldered, welded, etc.) to the inner surface of the base 112 or is maintained in a predetermined position within a recess that does not penetrate the entire thickness of the base 112.

12D shows a holder 109 similar to that shown in FIG. 12C, except that the lower end 142b of the engagement element 140 does not extend to the base 112. This functions substantially identically to the holder shown in FIG. 11C and need not be detailed again.

DEFINITIONS AND ALTERNATIVE EMBODIMENTS From the above description, it will be understood that many features of the various embodiments are interchangeable, and the disclosure extends to further embodiments including those in which features of the various embodiments are combined together in a manner not specifically mentioned.

For example, any of the configurations described in the first through fifth embodiments may include either a sidewall 126 or a base 112, or both, as described with respect to the sixth and seventh embodiments. Similarly, each embodiment may be a permanently mountable (retrofit) within the recess of the aerosol generating device 100 or may be a repeatedly removable example.

The various variations in the shape of the engaging elements 140 for compressing the aerosol substrate 114 described in the fourth embodiment, along with their associated advantages, may be provided in any of the other embodiments. Similarly, although each embodiment shows eight engaging elements 140, a holder 109 according to the above teachings having any number of engaging elements 140 greater than two may be provided and dimensioned to accommodate any suitable recess.

Each holder 109 may include a rim 107 in the form shown in the first to sixth embodiments or an engagement element 140 directly coupled to the sidewall 126 as in the seventh embodiment.

6-12D show the holder 109 separated from the aerosol generating device 100 and the corresponding recess. This emphasizes that the advantageous features described for each embodiment configuration of the holder 109 are independent of other features of the aerosol generating device 100. In particular, the holder 109 has many applications, not all of which are relevant to the aerosol generating device 100 described herein.

Furthermore, the thickness of the engaging elements 140 (including the thickness of the support portions 148 (which may differ from the thickness of the engaging elements 140)) can be selected to achieve a desired effect and need not follow the relative dimensions shown in the figures. Indeed, different engaging elements 140 (and support portions 148) can have different thicknesses, as desired.

It will be appreciated that the closest distance (R ₂ ) that each engaging element extends toward the central axis C may be different for each engaging element 140. Similarly, the distance that each support 148 extends toward the central axis C may be different for each support 148. Although each embodiment shows the upper end 142a of each engaging element 140 joining the rim 107 at the same height (i.e., distance from the opening 110), in some embodiments this height may not be the same for each engaging element 140.

The term "heater" should be understood to mean any device for outputting sufficient thermal energy from the aerosol substrate 128 to form an aerosol. The transfer of thermal energy from the heater 124 to the aerosol substrate 128 can be by conduction, convection, radiation, or any combination of these means. As a non-limiting example, a conductive heater can be in direct contact with and press against the aerosol substrate 128, or it can be in contact with a separate component that itself causes heating of the aerosol substrate 128 by conduction, convection, and/or radiation. Convection heating may include heating a liquid or gas, which results in the transfer of thermal energy (directly or indirectly) to the aerosol substrate.

Radiative heating includes, but is not limited to, transferring energy to the aerosol substrate 128 by emitting electromagnetic radiation in the ultraviolet, visible, infrared, microwave or radio frequency portions of the electromagnetic spectrum. The radiation thus emitted may be absorbed directly by the aerosol substrate 128 causing heating, or the radiation may be absorbed by another material, such as a susceptor or fluorescent material, such that the radiation is re-emitted at a different wavelength or spectral weighting. In some cases, the radiation may be absorbed by a material, which then transfers heat to the aerosol substrate 128 by any combination of conduction, convection and/or radiation.

The heater may be electrically powered, combustion powered, or powered by any other suitable means. Electrically powered heaters may include resistive track elements (optionally including insulating packaging), inductive heating systems (including, for example, electromagnets and radio frequency oscillators), and the like. The heater 128 may be positioned around the outside of the aerosol substrate 128, may penetrate partway or completely within the aerosol substrate 128, or any combination thereof.

The term "temperature sensor" is used to describe an element capable of determining the absolute or relative temperature of a portion of the aerosol generating device 100. This may include a thermocouple, a thermopile, a thermistor, etc. The temperature sensor may be provided as part of another component or may be a separate component. In some examples, multiple temperature sensors may be provided, for example to monitor the heating of various portions of the aerosol generating device 100, for example to determine a thermal profile.

With reference to the above-described embodiments, the aerosol substrate 128 includes tobacco, e.g., in a dried or cured form, optionally with additional ingredients for flavor or to provide a smoother or more satisfying effect. In some examples, the aerosol substrate 128, such as tobacco, may be treated with a vaporizer. The vaporizer may enhance the generation of aerosol from the aerosol substrate. The vaporizer may include, for example, a polyol, such as glycerol, or a glycol, such as propylene glycol. In some cases, the aerosol substrate may not include tobacco or even nicotine, but may instead include natural or synthetic ingredients for flavoring, volatility, improved smoothness, and/or other satisfying effects. The aerosol substrate 128 may be provided as a solid or paste-type material in shredded, pelleted, powdered, granular, strip or sheet form, optionally a combination thereof. Similarly, the aerosol substrate 128 may be a liquid or a gel. Indeed, in some examples, both solid and liquid/gel portions may be included.

The aerosol generating device 100 may therefore be equally referred to as a "heated tobacco device," a "heated non-combustion tobacco device," a "device for vaporizing tobacco products," etc., and is to be construed as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol substrate.

Embodiments of the aerosol generating device 100 are described as being configured to house the aerosol substrate 128 within a pre-packaged substrate carrier 114. The substrate carrier 114 may generally resemble a cigarette with a tubular region having the aerosol substrate arranged in an appropriate manner. Some designs may also include filters, aerosol collection regions, cooling regions, and other structures. For example, an outer layer of paper or other foil or other flexible flat material to hold the aerosol substrate in place may also be provided to further enhance the resemblance to a cigarette or the like.

As used herein, the term "fluid" shall be construed as generically describing a type of non-solid material that is capable of flowing, including, but not limited to, liquids, pastes, gels, powders, and the like. Correspondingly, a "fluidized material" shall be construed as a material that is inherently fluid or that has been modified to behave as a fluid. Fluidization may include, but is not limited to, powderization, dissolving in a solvent, gelling, thickening, thinning, and the like.

As used herein, the term "volatile" refers to a material that can be readily changed from a solid or liquid state to a gaseous state. As a non-limiting example, a volatile material may have a boiling or sublimation temperature near room temperature at ambient pressure. Thus, "volatilize" or "volatilize" shall be interpreted to mean to cause (a material) to volatilize and/or to evaporate or disperse into a vapor.

As used herein, the term "vapour" (or "vapor") means: (i) the form into which a liquid is spontaneously transformed by the action of a sufficient degree of heat; or (ii) liquid/moisture particles suspended in the atmosphere and visible as a cloud of steam/smoke; or (iii) a fluid that fills space like a gas, but can be liquefied by pressure alone when below a critical temperature.

Consistent with this definition, the term "vaporize" (or "vaporize") means: (i) to change or cause to change into a vapor, and (ii) when a particle changes physical state (i.e., from a liquid or solid to a gaseous state).

As used herein, the term "atomize" (or "atomize") shall mean: (i) the conversion (of a substance, especially a liquid) into very small particles or droplets; and (ii) where the particles remain in the same physical state (liquid or solid) as they were before atomization.

As used herein, the term "aerosol" shall mean a system of particles dispersed in air or gas, such as a mist, fog, or smoke. Accordingly, the term "aerosolize" (or "aerosolize") means to make into an aerosol and/or to disperse as an aerosol. Note that the meaning of aerosol/aerosolize is consistent with each of volatilization, atomization, and vaporization defined above. For the avoidance of doubt, aerosol is used consistently to describe a mist or droplets containing atomized, volatilized, or vaporized particles. Aerosol also includes a mist or droplets containing any combination of atomized, volatilized, or vaporized particles.

Claims (19)

A holder (109) insertable into an aerosol generating device (100), the aerosol generating device (100) configured to heat an aerosol substrate (128) supported by a substrate carrier (114) to generate an aerosol, the holder (109) configured to receive the aerosol substrate (128) supported by the substrate carrier (114) when inserted into the aerosol generating device (100), and the holder (109) comprises:
a rim (107) defining an opening (110), the rim extending about a central axis (C) such that a surface of the rim facing said central axis (C) is at a first radial distance (R ₁ ) from said central axis (C), along which said substrate support (114) is insertable into said holder (109) through said opening (110);
at least two engaging elements (140), each of the engaging elements (140) having an elongated portion (144) extending generally parallel to the central axis (C) between a first end (142a) joined to the rim (107) and a second end (142b) distal from the rim (107), each engaging element (140) not having any electric heating element for supplying heat to the aerosol substrate (128), and each elongated portion (144) being located such that a radially innermost position of the elongated portion (144) with respect to the central axis (C) is a second radial distance (R ₂ ) from the central axis (C), the second radial distance (R ₂ ) being less than the first radial distance (R ₁ );
Each of said engaging elements (140) is a holder (109) which is a rod. The holder (109) of claim 1, wherein each engagement element (140) has a support portion (148) extending from the second end of the elongated portion (144) toward the central axis (C) to provide a seat for limiting insertion of the substrate carrier (114) along the central axis (C). The holder (109) of claim 2, wherein the support portions (148) of the at least two engaging elements (140), preferably a plurality of engaging elements, extend in contact with each other. A holder (109) according to any one of claims 1 to 3, wherein the engagement elements (140) are equally spaced around the rim (107). The holder (109) of any one of claims 1 to 4, wherein the engagement elements (140) are spaced apart from one another by an air gap. The holder (109) of any one of claims 1 to 5, further comprising a tubular sidewall (126) extending around the at least two engaging elements (140), the tubular sidewall (126) defining a heating chamber (108). The holder (109) of claim 6, wherein the elongated element (144) is spaced apart from the inner surface (142) of the tubular side wall (126). The holder (109) of claim 6 or 7, further comprising a base (112) located farther from the rim (107) than the second end of the engagement element (140). The holder (109) of claim 8, wherein the sidewall (126) and/or the base (112) is a mesh or has one or more openings. A holder (109) according to any one of claims 1 to 9, wherein the first end of the elongated portion (144) of each engaging element (140) has a portion that slopes toward the second end of the elongated portion (144) and toward the central axis (C). A holder (109) according to any one of claims 1 to 10, wherein the engagement element (144) comprises a material having a higher heat transfer coefficient than the material of the rim (107). A holder (109) according to any one of claims 1 to 11, wherein the engagement element (140) is metal. A holder (109) according to any one of claims 1 to 12, wherein the rim (107) is made of a heat-resistant plastic, preferably polyetheretherketone, PEEK. A holder (109) according to any one of claims 1 to 13, wherein the engaging element (140) is parallel to the central axis (C) toward the second end (142b) of the engaging element (140). A holder (109) insertable into an aerosol generating device (100), the aerosol generating device (100) configured to heat an aerosol substrate (128) supported by a substrate carrier (114) to generate an aerosol, the holder (109) configured to receive the aerosol substrate (128) supported by the substrate carrier (114) when inserted into the aerosol generating device (100), and the holder (109) comprises:
a rim (107) defining an opening (110), the rim extending about a central axis (C) such that a surface of the rim facing said central axis (C) is at a first radial distance (R ₁ ) from said central axis (C), along which said substrate support (114) is insertable into said holder (109) through said opening (110);
At least two engaging elements (140), each of the engaging elements (140) extending from a first end (142a) joined to the rim (107) along the central axis (C) to a second end (142b) distal from the rim (107), and having an elongated portion (144) having an arc shape that approaches the central axis (C) between the first end (142a) and the second end (142b), each engaging element (140) does not have any electric heating element for supplying heat to the aerosol substrate (128), and each elongated portion (144) is located such that a radially innermost position with respect to the central axis (C) is a second radial distance (R ₂ ) from the central axis (C), the second radial distance (R ₂ ) being smaller than the first radial distance (R ₁ and at least two engaging elements (140) each smaller than the engagement element (140). A system comprising a holder (109) according to any one of claims 1 to 15 and a substrate carrier (114), wherein the second radial distance (R ₂ ) is less than half the width or diameter of the substrate carrier (114). An aerosol generating device (100) comprising a holder (109) according to any one of claims 1 to 15, held in a recess of the aerosol generating device (100). The aerosol generating device (100) of claim 17, wherein the holder (109) is removable from the aerosol generating device (100). An aerosol generating device (100) including the system according to claim 16, wherein the holder (109) is held in a recess of the aerosol generating device (100).

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