JP7764593B2 - Non-combustion aerosol delivery device - Google Patents

Description

The present invention relates to a non-combustion aerosol delivery device.

background

There are efforts to increase the recyclability and sustainability of consumer products in order to reduce harm to the environment. Manufacturers and suppliers can also benefit from recycling, as they can reduce production costs by reusing recycled components.

Getting consumers involved in recycling is often difficult, especially when recycling activities impose additional burdens on consumers, such as sorting waste into different recyclable types.

overview

According to some embodiments described herein, in a first aspect, there is provided a non-combustion aerosol delivery device configured to generate an aerosol by heating a consumable product, the device comprising means for engaging a component of the consumable product when the consumable product is inserted into the device, such that the component is retained by the means when a portion of the consumable product is removed from the device, causing the component to separate from the portion of the consumable product.

FIG. 1 is a schematic diagram of a non-combustion aerosol delivery device. 2 is a schematic diagram of a system including the non-combustion aerosol delivery device of FIG. 1 and a consumable item. 2 is a schematic diagram of an article including a heating element for use with the non-combustion aerosol delivery device of FIG. 1. FIG. 2 is a detailed view of the functional parts of the device of FIG. 1; FIG. 2 is a detailed view of the functional parts of the device of FIG. 1; 2 is a schematic diagram of an article including a heating element for use with the non-combustion aerosol delivery device of FIG. 1. FIG. 1 is a schematic diagram of a non-combustion aerosol delivery device. FIG. 8 is a perspective view of an article including a heating element for use with the non-combustion aerosol delivery device of FIG. 7. FIG. 9 is a schematic diagram of the article of FIG. 8. FIG. 1 is a perspective view of an article including a heating element for use with a non-combustion aerosol delivery device.

Detailed Description

In accordance with this disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not burned or incinerated to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of multiple aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and consumables for use with the non-combustion aerosol delivery device.

In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use in non-combustion aerosol delivery devices. These consumables may also be referred to as articles throughout this disclosure.

In some embodiments, a non-combustion aerosol delivery system (e.g., a non-combustion aerosol delivery device) can include a power source and a controller. The power source can be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source comprises a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat conducting material proximate to the heat generating power source.

In some embodiments, the non-combustion aerosol delivery device may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage areas, aerosol-generating material delivery components, aerosol generators, aerosol-generating areas, housings, wrappers, filters, mouthpieces, and/or aerosol modifiers.

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

As used herein, an active substance may be a bioactive material, which is a material intended to obtain or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive agents. The active substance may be naturally occurring or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plants.

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

As used herein, an active agent may include or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material obtained from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruit, pollen, husks, and the like. Alternatively, the material may include active compounds naturally occurring in the plant or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed grains, granules, pellets, chips, strips, sheets, and the like. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. The mint may be any of the following mint varieties: cool mint, Mentha c.v., Mentha spp ... You can choose from Egyptian mint (Mentha niliaca), common mint (Mentha piperita), lime mint (Mentha piperita citrata c.v.), black peppermint (Mentha piperita c.v.), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), long-leaved mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), bordeaux mint (Mentha pulegium), Moroccan mint (Mentha spicata c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the plant is tobacco.

In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, where the botanicals are selected from eucalyptus, star anise, cocoa, and hemp.

In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the plants are selected from rooibos and fennel.

In some embodiments, the substance to be delivered includes a fragrance.

As used herein, the terms "flavoring" and "flavoring agent" refer to materials that may be used in products for adult consumers to produce a desired flavor, aroma, or other bodily sensation, where permitted by local regulations. These include naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha green tea, menthol, Japanese peppermint, aniseed (aniseed), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc.). Fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jalapenos Sumin, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, Pedunculaceae, curcuma, cilantro, myrtle, black currant, valerian, pimento, may The flavor enhancers may include other additives such as spices, spice blends, flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. These may be imitation, synthetic, or natural ingredients, or mixtures thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

In some embodiments, the flavoring includes menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and/or red berry flavoring ingredients. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring ingredients extracted from tobacco. In some embodiments, the flavoring includes flavoring ingredients extracted from cannabis.

In some embodiments, the fragrance may include a sensation elicitor intended to produce a bodily sensation, typically chemically induced and perceived, by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that produce a warming, cooling, tingling, or numbing effect. Suitable warming agents may include, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may include, but are not limited to, eucalyptol and WS-3.

An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. Aerosol-forming materials may be in the form of, for example, a solid, liquid, or semi-solid (e.g., a gel), which may or may not contain active substances and/or flavorings.

The aerosol-forming material may include a binder and an aerosol-forming agent. Optionally, an active substance and/or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-forming material may or may not be soluble. In some embodiments, the aerosol-forming material is substantially free of plant material. In particular, in some embodiments, the aerosol-forming material is substantially free of tobacco.

The aerosol-generating material may be or include an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within its interior. In some embodiments, the aerosol-generating material may include, for example, about 50%, about 60%, or about 70% to about 90%, about 95%, or about 100% amorphous solid by weight.

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

The aerosol-generating material may include one or more active substances and/or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

The aerosol-forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and/or an antioxidant.

These materials may be present on or in a support to form a substrate. The support may be, or may include, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

A consumable is an item containing or composed of an aerosol-forming material, some or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol-forming material storage area, an aerosol-forming material supply component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that, upon use, releases heat to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

An aerosol modifier is a substance configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another characteristic of the aerosol, typically located downstream of the aerosol-generation region. The aerosol modifier can be provided to an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, strings, or granules. The aerosol modifier may not include a filtration material.

An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to apply one or more of vibration, increased pressure, or electrostatic energy to the aerosol-generating material.

In the figures described herein, the same reference numerals are used to indicate equivalent features, items, or components.

A non-combustion aerosol delivery device 20 (referred to herein simply as "device 20") is shown schematically in FIG. 1. Device 20 comprises a wall 21 defining a rod-shaped consumable-receiving space 22 (referred to herein simply as "receiving space 22") and a heater 23 configured to heat consumable-receiving space 22.

The device further comprises a power supply 24 and a control unit 25, which are configured to power and control the heater 23, respectively. The power supply 24 may be, for example, a battery 24, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), alkaline batteries, etc.

The various components of the device, including the heater 23, receiving space 22, battery 24 and control unit 25, are held within the housing 26.

The device 20 is approximately sized and shaped to allow a user to hold the device 20 in one hand. In use, a consumable 1 containing an aerosol-forming material 5 is inserted into the receiving space 22 and heated by a heater 23. This heat causes one or more volatiles from the aerosol-forming material 5 to form an aerosol. The consumable's mouthpiece 12 protrudes from the device, as shown in FIG. 2. To inhale the aerosol generated by the heated consumable 1, the user draws on the mouthpiece 12 of the consumable 1 in the same manner as a conventional cigarette.

The device further includes an inlet 27, shown in Figure 1. When a user inhales on the consumable 1, air is drawn through the inlet 27 and through the consumable.

Device 20 further includes a first activation button 28 that allows a user to turn device 20 on or off, and a second activation button 29 that activates heater 23. To use device 20, a user draws on mouthpiece 12 of consumable 1 and simultaneously presses second activation button 29, causing heater 23 to heat consumable 1 and generate aerosol.

The inlet 27 may include a pressure sensor (not shown) that functions as a "puff sensor." The puff sensor is configured to detect a decrease in pressure at the air inlet 27 that indicates a user is inhaling on the consumable product 1 placed in the receiving space 22. The device 20 is thereby configured to activate the heater 23 in response to a decrease in pressure detected at the air inlet 27.

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

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

The heater 23 may be an induction heating assembly 23 and may include various components for heating the consumable receiving space via an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) via electromagnetic induction. The induction heating assembly may include an induction element, such as one or more induction coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. This varying magnetic field penetrates a susceptor appropriately positioned relative to the induction element, generating eddy currents within the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore, the flow of eddy currents against this resistance heats the susceptor via Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis loss in the susceptor, i.e., by the magnetic dipoles of the magnetic material varying as a result of aligning with the varying magnetic field. Induction heating allows for rapid heating because heat is generated inside the susceptor, compared to heating by conduction, for example. Furthermore, there is no need for any physical contact between the induction heater and the susceptor, allowing for greater flexibility in design and application.

In the example shown in FIG. 1, the induction heating assembly includes an inductor coil 201. The inductor coil 201 is made from a conductive material. For example, the inductor coil 201 can be made from a litz wire/cable that is spirally wound around the wall 21. The litz wire is composed of multiple individual wires that are individually insulated and twisted together to form a single wire. The litz wire is designed to reduce skin effect losses in the conductor. The inductor coil 201 is made from copper litz wire with a rectangular cross section. In other examples, the litz wire can have a cross section of other shapes, such as circular. The inductor coil 201 is configured to generate a varying magnetic field to heat the susceptor.

Figure 3 shows article 1, which in some embodiments forms part of a non-combustion aerosol delivery system comprising article 1 and non-combustion aerosol delivery device 20. Article 1 is rod-shaped and includes a mouthpiece 12 and a distal end 12' opposite mouthpiece 12.

The article 1 comprises an aerosol-generating portion 2 surrounded by a wrapper 3. In the illustrated embodiment, a heating element 4 extends axially within the aerosol-generating portion 2. The heating element 4 is a susceptor including a material configured to be heated by induction. Thus, when the article 1 is inserted into a non-combustion aerosol-delivery device 20, the heating element 4 is inductively heated by a heater 23 of the device 20 to heat the aerosol-generating portion 2. Heat from the heating element 4 is transferred from the heating element 4 to the aerosol-generating material 5 in the aerosol-generating portion 2 to generate an aerosol for inhalation by a user.

The article of FIG. 1 further comprises a filter plug 6 coaxially disposed within the aerosol-generating section 2 and attached by a paper wrapper 8 surrounding the entire length of the article 1. The filter plug 6 may be further enclosed in a plug wrap 7 disposed between the filter plug 6 and the paper wrapper 8. Such articles 1 are typically discarded after use. Encouraging consumer participation in recycling would be beneficial from an environmental perspective.

The heating element 4 can be made from any material suitable for induction heating. In this embodiment, the heating element is made from a ferrous material, such as steel. Such materials must be separated from the aerosol generation unit 2 for recycling.

Referring again to FIG. 1 , the device 20 comprises means 202 for engaging a component of the consumable 1 when the consumable 1 is inserted into the device 20, such that when a portion of the consumable 1 is removed from the device 20, the component is held by said means 202 and separated from the portion of the consumable 1. In particular, the device 20 comprises means 202 for engaging the heating element 4 of the consumable 1 when the consumable 1 is inserted into the receiving space 22. said means 202 is configured to hold the heating element 4 with the device 20 when the portion of the consumable 1 is removed from the device 20. Thus, the heating element 4 is separated from the portion of the consumable 1 for recycling. It should be understood that a "portion of the consumable 1" in this specification refers to a portion of the consumable that is not held by said means.

The means 202 is configured to engage a portion of the heating element 4 at the distal end 12' of the consumable 1. Figures 4 and 5 show detailed views of a portion of the receiving space 23, the means 202 for engaging the heating element 4, and the waste chamber 203. In the illustrated embodiment, the means 202 includes an engagement portion 204 that rises from a base 205 of the receiving space 22.

The engagement portion 204 illustrated in FIG. 4 is configured for an embodiment in which the heating element 4 comprises a magnetic material. The engagement portion 204 includes a protrusion 206 that penetrates the axial end of the consumable 1 when the consumable is inserted into the receiving space 22. The protrusion 206 is positioned adjacent to the heating element 4. The engagement portion 204 includes an electromagnet 207 that, when activated, magnetizes the protrusion 206 and attracts the heating element 4. The electromagnet 207 includes a coil 208 connected to the power source 24. The coil 208 is provided at the lower end of the protrusion 206, i.e., the end of the protrusion 206 that is not configured to be inserted into the consumable 1. When a current is supplied to the coil 208, the protrusion 206 is magnetized and attracts the heating element near the protrusion 206 toward the protrusion 206.

5 includes a pair of protrusions 209 that penetrate the axial ends of the consumable 1 when the consumable 1 is inserted into the receiving space 22. The pair of protrusions 209 are positioned within the receiving space 22 so that the protrusions 209 are located on either side of a portion of the heating element 4. The engaging portion 204 includes an actuator 210 that moves the protrusions 209 toward each other. When an electric current is supplied to the actuator 210, the protrusions 209 move toward each other, capturing the heating element 4 between the protrusions 209. In the illustrated embodiment, the protrusions 209 further include a barb 211 on one of the protrusions 209 that engages with the heating element 4. The barb extends in the direction of movement of the protrusion 209. The barb 211 can be configured to penetrate the heating element 4 or to engage an opening in the heating element 4.

A consumable sensor 212 is provided that relays the presence of the consumable to the control unit 25 when the consumable is inserted into the receiving space 22. The control unit 25 can power the engagement portion 204 after receiving a signal from the consumable sensor 212 indicating the presence of the consumable. Thus, the engagement portion 204 is activated when the consumable is inserted. When the user removes the consumable, the consumable sensor 212 no longer relays the presence of the consumable to the control unit 25. The control unit 25 is configured to deactivate the engagement portion 204 only a predetermined period after the end of the signal indicating the presence of the consumable. This allows the user to completely remove a portion of the consumable while the engagement portion 204 is still activated. Thus, the heating element 4 remains attached to the engagement portion 204 even when a portion of the consumable is removed.

In the particular embodiment of FIG. 4 , the consumable sensor 212 relays the presence of the consumable 1 to the control unit 25, which then powers the electromagnet 207. Thus, the electromagnet 207 is activated when the consumable 1 is inserted. When the user removes a portion of the consumable 1, the consumable sensor 212 ceases to relay the presence of the portion of the consumable 1 to the control unit 25. The control unit 25 is configured to deactivate the electromagnet 207 only a predetermined period of time after the end of the signal indicating the presence of a portion of the consumable 1. This allows the user to completely remove the portion of the consumable 1 while the electromagnet 207 is still activated. Thus, the heating element 4 remains attached to the protrusion 206 even when the portion of the consumable 1 is removed due to the electromagnetic force induced by the electromagnet 207.

In the particular embodiment of FIG. 5, the consumable sensor 212 relays the presence of the consumable 1 to the control unit 25, which then distributes power to the actuator 210. Thus, the protrusions 209 move toward each other and grip the heating element 4 when the consumable 1 is inserted. When the user removes a portion of the consumable 1, the consumable sensor 212 no longer relays the presence of a portion of the consumable 1 to the control unit 25. The control unit 25 is configured to activate the actuator 210 to pull the protrusions apart and release their grip on the heating element 4 only a predetermined period after the end of the signal indicating the presence of a portion of the consumable 1. This allows the user to fully remove the portion of the consumable 1 while the heating element 4 is still held by the protrusions 209.

The waste chamber 203 is provided for used heating elements 4. A "used heating element 4" refers to a heating element 4 that has been removed from a portion of the consumable 1 by the means 202 and is retained within the device 20. The waste chamber 203 is disposed below the receiving space 22. That is, the waste chamber 203 is disposed below the receiving space 22 when the device 20 is oriented as shown in FIG. 2, with the consumable 1 protruding from the top surface of the device 20. Therefore, when the engagement portion 204 is inactive, the heating element 4 can fall into the waste chamber 203 by gravity. The waste chamber 203 collects the heating element 4 as the consumable 1 passes through the device 20. Although not shown, the waste chamber 203 may include a removable tray to allow the waste chamber 203 to be emptied. For example, a portion of the waste chamber 203 may be removable from the device 20, the portion including a tray and configured to retain used heating elements 4.

The trapdoor 213 is provided for selectively opening and closing the waste chamber 203. When the trapdoor 213 is open, the receiving space 22 is in communication with the waste chamber 203. When the trapdoor 213 is closed, the receiving space 22 is isolated from the waste chamber 203. The trapdoor 213 is electronically operated. In one embodiment, the control unit 25 distributes power to the trapdoor 213 to selectively open and close it. The control unit 25 can send a signal to the trapdoor 213 to open it a predetermined period of time after the consumable sensor 212 no longer relays to the control unit 25 that the consumable 1 is present. Thus, the trapdoor 213 is opened only after the consumable 1 is removed. The trapdoor 213 is preferably opened simultaneously with the release of the engagement portion 204 so that the heating element 4 is released from the engagement portion 204 and falls into the waste chamber 203. The control unit 25 may be configured to close the trapdoor 213 upon receiving a signal from the consumable sensor 212 indicating that the consumable 1 is present.

In another embodiment shown in FIG. 6 , in which similar features retain the same reference numerals, the heating element 4 extends beyond the axial end of the consumable 1 to protrude from the consumable 1. In such an embodiment, it is not required that the engagement portion 204 penetrate the axial end of the consumable 1. Instead, the receiving space 22 can be configured so that the axial end of the consumable is supported at a distance from the base 205 of the receiving space 22. This can be achieved, for example, by narrowing the receiving space 22 near the base 205 or by a protrusion (not shown) extending into the receiving space 22 and supporting the axial end of the consumable 1. In such an example, the extension 9 of the heating element 4 contacts the engagement portion 204 even if the consumable 1 is not fully inserted into the base of the receiving space 22. This is useful, for example, when the axial end of the consumable 1 is not well suited for penetration by the engagement portion 204. In the example of FIG. 6 , the axial end of the consumable 1 includes a distal end plug 14. The distal end plug 14 is less susceptible to penetration than the distal end of the aerosol-generating material 5. The distal end plug 14 is provided to prevent condensed water from seeping from the distal end 12' of the article 1 into the receiving space 22 of the aerosol-delivery device 20 during use. The distal end plug 14 has its own plug wrap 15 and is adjacent to the distal end 12' of the aerosol-generating portion 2 by a paper wrapper 3. The heating element 4 extends from the distal end 12' of the article 1 through the distal end plug 14 and terminates in an extension 9. The paper wrapper 3 is adhered to the plug wrap 15 to ensure that the distal end plug 14 remains in place throughout use of the article 1, including during removal of the heating element 4.

The consumable 1 may include any additional segments required. The example in Figure 6 shows a cooling segment 10 and an extension segment 11 coaxially positioned about the aerosol-generation unit 2 and filter plug 7 and attached by a series of overlapping wrapping material. The cooling segment 10 and extension segment 11 are positioned between the aerosol-generation unit 2 and the filter plug 7. The cooling segment 10 is directly adjacent to the aerosol-generation unit 2. The extension segment 11 is positioned between and directly adjacent to the cooling segment 10 and the filter plug 7. A wrapping material 13 extends over both segments 10, 11 and is positioned between the segments 10, 11 and the paper wrapper 8.

The aerosol-forming material 5 of the aerosol-generating unit 2 may include a solid aerosol-forming substrate, which may include one or more of powders, granules, pellets, shreds, spaghetti strands, strips, or sheets, including one or more of herb leaves, tobacco leaves, tobacco rib fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco. The solid aerosol-forming substrate may be in loose form. The aerosol-forming substrate may include a plug of solid aerosol-forming substrate.

In the embodiment shown in Figures 3 and 6, the aerosol-generating material 5 comprises one or more sheets of homogenized tobacco material gathered into a rod, surrounded by a wrapper 3, and cut to provide the aerosol-generating portion 2. The homogenized tobacco material preferably comprises a sheet of homogenized tobacco material that has been compressed and gathered. The folds formed in the compressed and gathered sheet preferably extend axially through the aerosol-generating portion 2. Thus, the compressed and gathered sheet of homogenized tobacco material does not impede axial movement of the heating element 4 when it is removed. The homogenized tobacco material may comprise at least one of fiber, a binder, and an aerosol-forming agent. The sheet of homogenized tobacco material is preferably a cast leaf. A cast leaf is a form of reconstituted tobacco formed from a slurry containing tobacco particles, fiber particles, an aerosol-forming agent, and a binder. The cast leaf may further comprise one or more flavorings.

In the embodiments shown in Figures 3 and 6, therefore, the heating element 4 preferably has a smooth outer surface so that it can slide out of the aerosol-generating unit 2 without getting caught on the aerosol-generating material 5 of the aerosol-generating unit 2. The heating element 4 can be a cube, a rod, or any other suitable shape. In some embodiments, the heating element 4 can have a flat profile. By "flat profile" we mean that the heating element 4 is a cube whose thickness is significantly less than its width or length. The heating element 4 therefore resembles a thin, flat strip.

Figures 7-9 show an alternative embodiment of an aerosol delivery system including a non-combustion aerosol delivery device 30 and a consumable item 50 for use with the device.

Figure 7 is a cross-sectional view of a schematic diagram of the aerosol delivery device 30. Figures 8 and 9 show a consumable item 40 for use with the device 30. The aerosol delivery device 30 comprises an outer housing 31, a power source 32, a control circuit 33, a plurality of aerosol generating components 34, a receptacle or aerosol forming chamber 35, a mouth end 36, an air inlet 37, an air outlet 38, an activation button 39, and an inhalation sensor 40. The outer housing 31 is configured so that the power source 32, the control circuit 33, the aerosol generating components 34, the receptacle 35, and the inhalation sensor 40 are disposed within the outer housing 31. The outer housing 31 also defines the air inlet 37 and the air outlet 38, which are described in more detail below. The activation button 29 is disposed on the exterior of the outer housing 31.

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

8 and 9 show a consumable product 50. The consumable product 50 (also referred to herein as article 50) includes a carrier material 51, a heating element 52, and an aerosol-generating material 53 disposed on the heating element 52. In this example, the carrier material 51 is made of card and is the primary structural component of the article 50, providing the article 50 with sufficient rigidity to maintain its shape during normal handling, such as inserting and removing the article 50 from the aerosol delivery device 30. The carrier material 51 is wide and cubic in shape and has a substantially flat profile. By "flat profile," we mean that the thickness of the carrier material 51 is less than its width and length. As a specific example, the length of the carrier material 51 can be 30-80 mm, the width can be 7-25 mm, and the thickness can be between 0.2 and 1 mm. However, it should be understood that these are exemplary dimensions of the carrier material 51, and that in other embodiments, the carrier material 51 can have different dimensions, as appropriate.

The heating element 52 is adhered to the carrier material 51. The heating element 52 comprises a narrow strip of material suitable for induction heating. In the illustrated embodiment, the heating element 52 has substantially the same length and width as the carrier material 51 so that the heating element 52 can be superimposed and adhered onto the carrier material 51.

FIG. 9 shows a cross-section of article 50. An adhesive layer 54 is provided between heating element 52 and carrier material 51 to bond the heating element 52 and carrier material 51 to one another. A portion of the heating element 52 is not bonded to the carrier material 51, thereby forming a tab 55 on the heating element 52 that is free for a user to pull from the carrier material 51. A user can therefore peel the heating element 52 from the carrier material 51 to separate the heating element 52 from the carrier material 51 for recycling. In the illustrated embodiment, one area between the carrier material 51 and the heating element 52 is free of adhesive to form tab 55. However, it should be understood that in other embodiments, the carrier material 51 and the heating element 52 may be bonded to one another across the entire overlap region between the carrier material 51 and the heating element 52. In such an embodiment, tab 55 may instead be formed by the heating element 52 extending beyond the carrier material 51. The adhesive used in adhesive layer 54 is selected to prevent separation of heating element 52 from carrier material 51 during insertion and removal of article 50 from device 30, yet have a bond strength weak enough to allow a user of ordinary dexterity to peel heating element 52 from carrier material 51 when necessary.

A plurality of individual portions 53 of aerosol-generating material are provided directly on the heating element 52. While three circular portions 53 of aerosol-generating material are provided, it should be understood that any number may be provided as desired. For example, in another embodiment, a 2 x 3 array of individual portions 53 of aerosol-generating material is provided. Importantly, the number and spacing of the aerosol-generating portions 53 match the number and spacing of the aerosol-generating components 34 in the device 30, such that the aerosol-generating portions 53 are positioned directly above the aerosol-generating components 34 when the article 50 is properly installed in the receptacle 35.

Although not shown in FIG. 7, the device 30 may include a lid portion and a base portion configured to engage with each other to secure the item 50 within the receptacle 35. Various configurations for the lid portion and base portion are contemplated; for example, although not shown in FIG. 7, the device 30 may include a hinged door or removable portion of the outer housing 31 to provide access to the receptacle 35 so that a user can insert and/or remove the item 50 from the receptacle 35. The hinged door or removable portion of the outer housing 31 may also function to retain the item 50 within the receptacle 35 when closed.

In the illustrated embodiment, the aerosol-forming material 53 includes a gelling agent (sometimes referred to as a binder) and an aerosol-forming material (which may include, for example, glycerol). Optionally, the aerosol-forming material may include one or more of the following: an active agent (which may include tobacco extract), a flavoring agent, an acid, and a filler. Other ingredients may also be present as desired.

In the illustrated embodiment, the aerosol-generating component 34 is an induction heater configured to generate a varying magnetic field to induce eddy currents in the heating element 52 immediately beneath the individual portions 53 of the aerosol-generating material.

The device 30 further comprises means 202 for engaging a component of the consumable 50 when the consumable 50 is inserted into the device 30, such that the component is retained by the means 202 and separated from the portion of the consumable 50 when the portion of the consumable 50 is removed from the device 30. In particular, the device 30 comprises means 202 for engaging the carrier material 51 of the consumable 50 when the consumable 50 is inserted into the receptacle 35 of the device 30. The means 202 is configured to retain the carrier material 51 within the device 30 when the portion of the consumable 50 is removed from the device 30. The carrier material 51 is thus separated from the portion of the consumable 50 for separate disposal.

In the illustrated embodiment, the means 202 comprises a suction cup 41. The suction cup 41 is a disk-shaped elastic diaphragm that, upon actuation, is configured to create a partial vacuum between the flat lower surface of the carrier material 51 and the diaphragm, as further described below.

To use the device 30, an article 50 is inserted into the receptacle 35, and the device 30 is turned on by a sensor (not shown) that determines the presence of the article 50 in the receptacle 35. Alternatively, the device 30 may be turned on by user interaction with the activation button 39. In either case, a signal indicating the presence of the article 50 is sent to the control circuit 33. The control circuit then distributes power to the actuators 42 of the suction caps 41. The actuators transition the diaphragm of each suction cap 41 from a flat state to a conical state, thereby creating a partial vacuum between the diaphragm and the underside of the carrier material 51 to securely hold the article 50 within the receptacle 35.

With the article 50 attached to the receptacle 35, a user can draw on the mouthpiece 36 of the device 30. As the user draws on the mouthpiece 36 of the device 30, airflow is directed through the inlet 37 into the receptacle 35 and exits through the outlet 38 for inhalation. An inhalation sensor 40 determines the pressure drop at the inlet 37 and generates a signal that is sent to the control circuit 33. The control circuit 33 distributes power from the power source 32 to the aerosol-generating component 34, which heats the heating element 52 as described. The heat from the heating element 52 vaporizes volatile components in the individual portions 53 of the aerosol-generating material, which are carried into the airflow passing through the device 30 for inhalation. The control circuit 33 can be configured to distribute power to all of the aerosol-generating components 34 at once, or more preferably, sequentially. Thus, each portion of the aerosol-generating material 53 is heated at a different time. Each portion of the aerosol-generating material 53 is preferably heated for a predetermined time or a predetermined number of puffs before the adjacent portion of the aerosol-generating material 53 is heated. After each portion of the aerosol-generating material 53 has been heated for a predetermined time or a predetermined number of puffs, the device indicates to the user that the article 50 should be replaced. This can be determined, for example, by the control circuit 33. The control circuit 33 sends a signal to the end-of-use indicator 43, indicating to the user that the article 50 should be removed. The end-of-use indicator 43 may be a light source or any other suitable display device. The suction cap 41 remains conical to retain the carrier material within the receptacle 35 when the user removes a portion of the article 50. In particular, the user pulls and grasps the tab 55 to peel the heating element 52 from the carrier material 51. The heating element 52 is thus separated from the carrier material 51 for separate recycling. After a further predetermined period, the control circuit 33 energizes the actuators 42 of the suction caps 41. The actuators cause the diaphragm of each suction cap 41 to transition from a conical state to a flat state, thereby releasing the partial vacuum between the diaphragm and the underside of the carrier material 51 and allowing the carrier material 51 to be removed from the receptacle 35. The device further includes a second indicator 44 for indicating to a user that the carrier material 51 is no longer being held by the suction cap 41. In other words, after a further predetermined period, the control circuit 33 sends a signal to the second indicator 44 to indicate to a user that the carrier material 51 can be removed from the receptacle 35 for separate disposal.

While the illustrated embodiment of the means 202 includes a suction cap 41, it should be understood that the device 30 may be configured to engage the carrier material 51 in any other suitable manner. For example, in another embodiment, the carrier material 51 extends beyond the heating element 52 to form a portion 56 of the carrier material 51 for clamping. An article 50 according to this embodiment is shown in FIG. 10 , with like features retaining the same reference numerals. In such an embodiment, the means 202 includes a clamp for clamping the extended portion of the carrier material 51. The clamp is electronically operated. As described above, when the article 50 is inserted into the device 30, a signal is sent to the control circuit 33 to indicate the presence of the article 50. Upon receiving the signal, the control circuit 33 is configured to distribute power to the clamp to clamp the extended portion of the carrier material 51. If the article 50 is to be replaced, the carrier material 51 remains clamped to hold the carrier material 51 in the receptacle 35 as the user removes the portion of the article 50. In particular, the user pulls and grasps tab 55 to peel heating element 52 from carrier material 51. Thus, heating element 52 is separated from carrier material 51 for separate recycling. After a period of time, control circuit 33 energizes the clamp to unclamp carrier material 51, allowing carrier material 51 to be removed from receptacle 35. Control circuit 33 then sends a signal to second indicator 44 to indicate to the user that carrier material 51 can be removed from receptacle 35 for separate disposal.

The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as representative examples of embodiments and are not intended to be exhaustive and/or limiting. It is understood that the advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein should not be considered as limiting the scope of the invention as defined by the claims or as limitations on the equivalents of the claims, and that other embodiments may be used and changes may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, configurations, features, components, steps, means, etc., other than those specifically described herein. The present disclosure may also include other inventions not currently recited in the claims but which may be described in the future.

Claims (15)

1. A non-combustion aerosol delivery system comprising:
a non-combustion aerosol delivery device;
a consumable rod for use in the non-combustion aerosol delivery device;
Equipped with
the consumable includes an aerosol generating unit and a heating element extending axially within the aerosol generating unit;
A non-combustion aerosol delivery system, wherein the device is configured to generate an aerosol by heating the aerosol generating portion of the consumable using the heating element , and includes means for engaging the heating element of the consumable when the consumable is inserted into the device, such that when a portion of the consumable is removed from the device, the heating element is held by the means and the heating element separates from the portion of the consumable. The non-combustion aerosol delivery system of claim 1 , further comprising a receiving space for receiving a rod-shaped consumable product. 3. The non-combustion aerosol delivery system of claim 2, wherein the means comprises a protrusion configured to penetrate an axial end of a rod-shaped consumable inserted into the receiving space. 4. The non-combustion aerosol delivery system of claim 3, wherein the protrusion rises from a base of the receiving space. 5. The non-combustion aerosol delivery system of claim 2 or 4, wherein the means comprises a pair of protrusions configured to grip the heating element when the consumable is inserted into the device. The non-combustion aerosol delivery system of any one of claims 2 to 4, further comprising a waste chamber in communication with the receiving space. 7. The non-combustion aerosol delivery system of claim 6, further comprising a trap door for selectively opening and closing the waste chamber. The non-combustion aerosol delivery system of any one of claims 2 to 4, further comprising a power source for heating the rod-shaped consumable product and the heating element received in the receiving space. 9. The non-combustion aerosol delivery system of claim 8, wherein the heating element comprises an induction heater. The non-combustion aerosol delivery system of any one of claims 1 to 4, wherein the means comprises an electromagnet. 3. The non-combustion aerosol delivery system of claim 2 , further comprising a consumable sensor and a control unit, the consumable sensor configured to send a signal to the control unit indicating the presence of a consumable within the receiving space. 12. The non-combustion aerosol delivery system of claim 11, wherein the control unit is configured to engage the means with the heating element upon receiving the signal from the consumable sensor indicating the presence of a consumable within the receiving space. 13. The non-combustion aerosol delivery system of claim 12, wherein the control unit is configured to cause the means to disengage from the heating element a predetermined period of time after termination of the signal indicating the presence of a consumable product in the receiving space. 10. The non-combustion aerosol delivery system of claim 1 , wherein the aerosol- generating portion comprises one or more sheets of homogenized tobacco material. 15. The non-combustion aerosol delivery system of claim 14, wherein the sheet of homogenized tobacco material is compressed into a rod of homogenized tobacco material, the homogenized tobacco material including fold lines extending axially of the rod of homogenized tobacco material.