CA3019228A1

CA3019228A1 - Apparatus and method for heating smokable material and cartridge for use therewith

Info

Publication number: CA3019228A1
Application number: CA3019228A
Authority: CA
Inventors: Joseph Sutton; Dominic Woodcock; Hitesh VALLABH; Neil LITTEN; Harpal Singh; David Russell; Darren Seymour; Ahmad BITAR
Original assignee: British American Tobacco Investments Ltd IFI
Current assignee: Nicoventures Trading Ltd
Priority date: 2015-03-31
Filing date: 2016-03-31
Publication date: 2016-10-06
Anticipated expiration: 2036-03-31
Also published as: WO2016156509A1; GB201505592D0; CA3019228C

Abstract

A cartridge (40) is provided for use with an apparatus (1) for heating smokable material (43). The cartridge (40) has a housing (41) defining a chamber (42), wherein the housing (41) has a carrier (41d) having a first side and a second side. Smokable material (43) is located within the chamber (42) and in contact with the first side of the carrier (41d). An exterior surface of the cartridge (40) has a cavity (44) for receiving a heater (21) for heating the smokable material (43). The second side of the carrier (41d) defines at least part of the cavity (44). There is also provided apparatus (1) for heating smokable material (43) having a heating device which has a wedge-shaped or dome- shaped heater. A method of manufacturing apparatus (1) for heating smokable material (43) is also disclosed in which a heater is folded.

Description

APPARATUS AND METHOD FOR HEATING SMOKABLE MATERIAL
AND CARTRIDGE FOR USE THEREWITH
Technical Field The present invention relates to apparatus for heating smokable material to volatilise at least one component of the smokable material, to a cartridge for use with apparatus for heating smokable material, to a kit comprising a cartridge and apparatus for heating smokable material, to a method of manufacturing apparatus for heating smokable material, to an article for use with apparatus for heating smokable material, and to a method of manufacturing a cartridge.
Background Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combusting.
Examples of such products are so-called "heat not burn" products or tobacco heating devices or products, which release compounds by heating, but not burning, material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.
Summary A first aspect of the present invention provides a cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material, the cartridge comprising:
a housing defining a chamber, wherein the housing comprises a carrier having a first side and a second side; and smokable material located within the chamber and in contact with the first side of the carrier;
wherein an exterior surface of the cartridge has a cavity for receiving a heater for heating the smokable material, and wherein the second side of the carrier defines at least part of the cavity.

2 In an exemplary embodiment, the carrier and the cavity are arranged so as to abut a heater of the apparatus for heating smokable material when the heater is received in use in the cavity.
In an exemplary embodiment, the cavity is a blind hole.
In an exemplary embodiment, the cavity is a wedge-shaped cavity.
In an exemplary embodiment, the cavity is a dome-shaped cavity.
In an exemplary embodiment, the carrier has a thickness of no more than 300 micrometres.
In an exemplary embodiment, the carrier comprises one or more materials selected from the group consisting of: foil, paper, a polymer, a plastics material, and a combination of foil and paper.
In an exemplary embodiment, the carrier comprises a first layer of material and a second layer of material attached to the first layer of material, the smokable material is in contact with the first layer of material, and the second layer of material defines at least part of the cavity.
In an exemplary embodiment, the smokable material is more readily bondable or aiherable to the material of the first layer of material than to the material of the second layer of material.
In an exemplary embodiment, the material of the second layer of material is more rigid or robust than the material of the first layer of material.
In an exemplary embodiment, the smokable material encircles the carrier.
In an exemplary embodiment, the smokable material is adhered to the carrier.

3 In an exemplary embodiment, the housing has an air flow inlet extending therethrough for admitting air into the chamber from an exterior of the housing.
In an exemplary embodiment, the carrier has the air flow inlet extending therethrough for admitting air into the chamber from the cavity.
In an exemplary embodiment, the carrier is made of porous material for admitting air into the chamber from the cavity.
In an exemplary embodiment, the housing comprises a first housing part attached to a second housing part that is non-unitary with the first housing part, and the first and second housing parts define the air flow inlet between the first and second housing parts.
In an exemplary embodiment, the first and second housing parts cooperate so as to define the chamber.
In an exemplary embodiment, the second housing part is the carrier.
In an exemplary embodiment, the first and second housing parts and the carrier cooperate so as to define the chamber.
In an exemplary embodiment, the housing comprises a first housing portion, a second housing portion, and a hinge connecting the first housing portion to the second housing portion; the first housing portion contains the smokable material; and the first housing portion is rotatable about the hinge towards the second housing portion to a closed position at which the exterior surface defines the cavity between the first housing portion and the second housing portion.
In an exemplary embodiment, the first housing portion abuts the second housing portion when the first housing portion is at the closed position.

4 In an exemplary embodiment, the hinge is a living hinge.
In an exemplary embodiment, the carrier defines the hinge.
In an exemplary embodiment, the housing has a volatilised material outlet extending therethrough for permitting volatilised material to pass from the chamber out of the housing.
In an exemplary embodiment, the cartridge comprises a mass of aerosol containment material located between the smokable material and the housing.
In an exemplary embodiment, the mass of aerosol containment material encircles the smokable material.
In an exemplary embodiment, the mass of aerosol containment material is in contact with the smokable material.
In an exemplary embodiment, the mass of aerosol containment material is in contact with the housing.
In an exemplary embodiment, the mass of aerosol containment material fills a space between the smokable material and the housing.
In an exemplary embodiment, the aerosol containment material comprises one or more materials selected from the group consisting of: wadding, fleece, non-woven material, non-woven fleece, woven material, knitted material, nylon, foam, polystyrene, polyester, polyester filament, polypropylene, and a blend of polyester and polypropylene.
In an exemplary embodiment, the smokable material comprises tobacco.

A second aspect of the present invention provides apparatus for heating smokable material to volatilise at least one component of the smokable material, the apparatus comprising a heating device having a wedge-shaped or dome-shaped heater for insertion into a cavity of a cartridge or article.

5 In an exemplary embodiment, the heater is dome-shaped.
In an exemplary embodiment, the heater has a surface that is curved or polygonal or a combination of curved and polygonal.
In an exemplary embodiment, the heater is wedge-shaped.
In an exemplary embodiment, the heater is a folded heater.
In an exemplary embodiment, the apparatus comprises a controller for controlling the supply of electrical power from an electrical power source to the heater.
In an exemplary embodiment, the interface comprises a recess, and the heater projects into the recess.
In an exemplary embodiment, the apparatus defines an opening into the recess at a first end of the recess, and the heater projects into the recess from a second end of the recess.
In an exemplary embodiment, the heating device has a hole extending therethrough, and the hole is in fluid communication with an inlet of the apparatus.
In an exemplary embodiment, the heater comprises electrically-conductive material, and the heater is heatable by passing an electric current through the electrically-conductive material.

6 In an exemplary embodiment, the electrically-conductive material is patterned electrically-conductive material.
In an exemplary embodiment, the electrically-conductive material is etched or printed electrically-conductive material.
In an exemplary embodiment, the heater comprises a support for supporting the electrically-conductive material.
In an exemplary embodiment, the support is resistant to heat at least over a temperature range of 150 degrees Celsius to 300 degrees Celsius, or 170 degrees Celsius to 220 degrees Celsius.
In an exemplary embodiment, the support comprises one of polyimide and a ceramic material.
There is also provided a kit comprising a cartridge according to the first aspect of the present invention and apparatus for heating the smokable material to volatilise at least one component of the smokable material, wherein the apparatus has a heating .. device comprising a heater for insertion into the cavity.
In an exemplary embodiment, the apparatus is arranged to heat the smokable material to volatilise the at least one component of the smokable material without combusting the smokable material when the heater is in the cavity.
In an exemplary embodiment, the apparatus comprises a controller for controlling the supply of electrical power from an electrical power source to the heating device.
In an exemplary embodiment, the apparatus comprises a controller arranged to control heating of the heating device so as to cause heating of the smokable material to

7 volatilise the at least one component of the smokable material without combusting the smokable material when the heater is in the cavity.
In an exemplary embodiment, the apparatus is according to the second aspect of the present invention.
A third aspect of the present invention provides a method of manufacturing apparatus for heating smokable material to volatilise at least one component of the smokable material, the method comprising:
providing a heater; and folding the heater to form a folded heater.
In an exemplary embodiment, the folding comprises folding the heater to form a wedge-shaped heater.
In an exemplary embodiment, the heater comprises electrically-conductive material.
In an exemplary embodiment, the providing comprises patterning the electrically-conductive material.
In an exemplary embodiment, the heater comprises a support for supporting the electrically-conductive material.
In an exemplary embodiment, the support comprises polyimide.
In an exemplary embodiment, the folding comprises folding the support.
There is also provided an article for use with apparatus for heating smokable material to volatilise at least one component of the smokable material, the article comprising smokable material; wherein an exterior surface of the article comprises a cavity for receiving a heater for heating the smokable material, wherein the cavity has

8 a mouth, and wherein a cross-sectional size of the cavity decreases with distance from the mouth over at least a majority of a length of the cavity.
In an exemplary embodiment, the cross-sectional size of the cavity decreases with distance from the mouth over the full length of the cavity.
In an exemplary embodiment, the cavity is a wedge-shaped cavity.
In an exemplary embodiment, the cavity is a dome-shaped cavity.
In an exemplary embodiment, the article comprises a carrier, the smokable material is arranged on a first side of the carrier, and a second side of the carrier defines at least part of the cavity.
There is also provided a cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material, the cartridge comprising:
a housing defining a chamber; and smokable material located within the chamber;
wherein the housing comprises a carrier defining part of an exterior surface of the cartridge, wherein the smokable material is arranged on the carrier, and wherein the carrier has a thickness of no more than 300 micrometres In an exemplary embodiment, the exterior surface of the cartridge comprises a cavity for receiving a heater for heating the smokable material, and the carrier defines at least part of the cavity.
In respective exemplary embodiments, the cartridge according to the sixth aspect of the present invention comprises the feature(s) of the above-discussed respective exemplary embodiments of the cartridge according to the first aspect of the present invention.

9 PCT/EP2016/057094 There is also provided a cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material, the cartridge comprising:
a housing comprising a first housing portion, a second housing portion, and a hinge connecting the first housing portion to the second housing portion;
wherein the first housing portion and/or the second housing portion contains smokable material; and wherein the first housing portion is rotatable about the hinge towards the second housing portion to a closed position at which an exterior surface of the cartridge defines a cavity between the first housing portion and the second housing portion for receiving a heater for heating the smokable material.
In an exemplary embodiment, the first housing portion abuts the second housing portion when the first housing portion is at the closed position.
In an exemplary embodiment, the housing comprises a carrier having a first side and a second side, the smokable material is in contact with the first side of the carrier, and the second side of the carrier defines at least part of the cavity when the first housing portion is at the closed position.
In an exemplary embodiment, the first housing portion comprises a first housing part, and the smokable material is located within a chamber defined by and between the first housing part and the carrier.
In an exemplary embodiment, the carrier defines the hinge.
In respective exemplary embodiments, the cartridge according to the seventh aspect of the present invention comprises the feature(s) of the above-discussed respective exemplary embodiments of the cartridge according to the first aspect of the present invention.

There is also provided a method of manufacturing a cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material, the method comprising:
providing a first housing portion and a second housing portion;
5 locating smokable material in the first housing portion and/or in the second housing portion; and providing a hinge connecting the first housing portion to the second housing portion;
wherein the first housing portion is rotatable about the hinge towards the second

10 housing portion to a closed position at which an exterior surface of the cartridge defines a cavity between the first housing portion and the second housing portion for receiving a heater for heating the smokable material.
In an exemplary embodiment, the step of providing the hinge occurs after the step of providing the first housing portion and the second housing portion.
In an exemplary embodiment, the step of providing the hinge comprises providing a carrier, and attaching the carrier to the first housing portion and the second housing portion.
In an exemplary embodiment, the first housing portion abuts the second housing portion when the first housing portion is at the closed position.
Brief Description of the Drawings Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Figure 1 shows a schematic top view of an example of a cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material;
Figure 2 shows a schematic cross-sectional view of the cartridge of Figure 1;

11 Figure 3 shows a schematic top view of an example of another cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material;
Figure 4 shows a schematic cross-sectional view of the cartridge of Figure 3;
Figure 5 shows a schematic perspective view of an example of another cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material;
Figure 6 shows a schematic cross-sectional view of the cartridge of Figure 5;
Figure 7 shows a schematic cross-sectional view of an example of another cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material, the cartridge being in a closed position;
Figure 8 shows a schematic cross-sectional view of the cartridge of Figure 7 in an open position;
Figure 9 shows a schematic cross-sectional view of the cartridge of Figure 7 in an intermediate position between the open position of Figure 8 and the closed position of Figure 7;
Figure 10 shows a partially cut-away perspective view of an example of an apparatus for heating smokable material to volatilise at least one component of the smokable material;
Figure 11 shows a partially cut-away perspective view of an example of another apparatus for heating smokable material to volatilise at least one component of the smokable material;

12 Figure 12 shows a schematic cross-sectional view of a partially-formed heater of the apparatus of Figure 11, in which an electrically-conductive body is provided on a support body;
Figure 13 shows a schematic cross-sectional view of the heater of Figure 12, in which the electrically-conductive body has been patterned on the support body;
Figure 14 shows a schematic cross-sectional view of the heater of Figure 13, in which the heater has been folded; and Figure 15 shows a partially cut-away perspective view of an example of another apparatus for heating smokable material to volatilise at least one component of the smokable material.
Detailed Description As used herein, the term "smokable material" includes materials that provide volatilised components upon heating, typically in the form of an aerosol.
"Smokable material" may be a non-tobacco-containing material or a tobacco-containing material.
"Smokable material" may, for example, include one or more of tobacco per se, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenised tobacco or tobacco substitutes. The smokable material can be in the form of ground tobacco, cut rag tobacco, extruded tobacco, gel or agglomerates. "Smokable material"
also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine.
As used herein, "polyimide" refers to any polymer comprising or substantially formed of imide monomers and may be saturated or unsaturated. The polyimide may be hydrophobic.
Referring to Figures 1 and 2, there are shown a schematic top view and a schematic cross-sectional view of an example of a cartridge 40 according to an

13 embodiment of the invention. The cartridge 40 of this embodiment is usable with the apparatus 1 shown in Figure 10, described below.
The cartridge 40 of this embodiment comprises a housing 41 defining a chamber 42, and smokable material 43 located within the chamber 42. The housing 41 comprises a first housing part 41a and a second housing part 41b that is non-unitary with the first housing part 41a. The first and second housing parts 41a, 41b may be made of any suitable material, such as a plastics material. The first housing part 41a is attached to the second housing part 41b, such as by a snap-fit connection, adhesive, or the like. The first and second housing parts 41a, 41b define an air flow inlet 41c between the first and second housing parts 41a, 41b. The air flow inlet 41c extends through the housing 41 for admitting air into the chamber 42 from an exterior of the housing 41.
In other embodiments, the housing 41 may take a different form. For example, in some embodiments the first and second housing parts 41a, 41d may be unitary, such as following welding, e.g. sonic welding.
The housing 41 further comprises a carrier 41d, and the smokable material 43 is in contact with, and is adhered to, a first side of the carrier 41d. In this embodiment, the carrier 41d is located inside the first and second housing parts 41a, 41b.
In this embodiment, an end 41j of the carrier 41d is attached to an inner surface of the second housing part 41b, such as by an adhesive or pinning, but in other embodiments the carrier 41d may be attached to the first or second housing part 41a, 41b in a different manner. In some embodiments, the end 41j of the carrier 41d may be more rigid or robust than the rest of the carrier 41d. In this embodiment, the first and second housing parts 41a, 41b and the carrier 41d cooperate so as to define the chamber 42.
The carrier 41d is thermally-conductive and is for conducting heat from a second side of the carrier 41d to the smokable material 43 on the first side of the carrier 41d. In this embodiment, the carrier 41d comprises a metal foil, such as aluminium foil, but in other embodiments the carrier 41d may comprise one or more materials selected from the group consisting of: foil, paper, a polymer, a plastics material, and a combination of foil and paper, such as paper overlaid with foil, or the like.

14 An exterior surface of the cartridge 40 comprises a cavity 44 for receiving a heater 21 (see Figure 10) for heating the smokable material 43 in use. The "exterior surface" may be a surface that envelops the rest of the cartridge 40, or that delineates the cartridge 40. The exterior surface of the cartridge 40 comprises a portion that is recessed to provide the cavity 44. In this embodiment, the cavity 44 is a blind hole having a mouth 44a, first and second trunk sections 44b, 44c, and a closed end 44d. In other embodiments the cavity 44 could instead be a through hole. The first trunk section 44b connects the mouth 44a to the second trunk section 44c, and the second trunk section 44c connects the first trunk section 44b to the closed end 44d. The cavity 44 has a length that is measured from the mouth 44a to the closed end 44d, and that extends along an axis of the cavity 44. The cavity 44 also has a width that is perpendicular to the length, and a height that is perpendicular to both the width and the length. In this embodiment, the cavity 44 is defined by a combination of the second housing part 41b and the second side of the carrier 41d. More specifically, the second housing part 41b defines the mouth 44a and a first trunk section 44b, and the carrier 41d defines the second trunk section 44c and the closed end 44d. In this embodiment, the second trunk section 44c is of constant, or substantially constant, cross-sectional shape and size (for example, a width, a height, a diameter, a dimension, or an area) throughout its length between the first trunk section 44b and the closed end 44d. On the other hand, a cross-sectional size (for example, a width, a height, a diameter, a dimension, or an area) of the first trunk section 44b decreases with distance from the mouth 44a so as to have a tapered profile. The tapered profile helps a user to guide the heater 21 into the cavity 44 in use.
In this embodiment, apertures 41e extend through the first housing part 41a at an end opposite to the end adjoining the second housing part 41b. Each of the apertures 41e is a volatilised material outlet 41e for permitting volatilised material created by the heating of the smokable material 43 to pass from the chamber 42 out of the housing 41.
In other embodiments, there may be only one aperture 41e in place of the plurality of apertures 41e, or the volatilised material outlet(s) 41e may take some other form and/or may extend through a different part of the housing 41.

In this embodiment, the smokable material 43 encircles the carrier 41d and surrounds the cavity 44. However, in other embodiments this may not be the case. For example, in some embodiments, the smokable material 43 may be arranged on only a portion, or only some portions, of the carrier 41d. As will be described in more detail 5 below, in use the smokable material 43 in the cartridge 40 is heated to volatilise at least one component of the smokable material 43 without combusting, or burning, the smokable material 43.
In this embodiment, the cartridge 40 comprises a mass of aerosol containment 10 material 45. The mass of aerosol containment material 45 is a porous material for the containment of aerosol generated in the cartridge 40 in use, so as to help avoid the aerosol condensing on an inner surface of the housing 41 of the cartridge 40.
The mass of aerosol containment material 45 is located between the smokable material 43 and the housing 41. More specifically, in this embodiment, the mass of aerosol containment

15 material 45 is wrapped around the smokable material 43 and the carrier 41d, so that the mass of aerosol containment material 45 encircles the smokable material 43 and the carrier 41d and surrounds the cavity 44. However, in other embodiments this may not be the case. For example, in some embodiments, the mass of aerosol containment material 45 may overlie only a portion, or only some portions, of the smokable material 43. In this embodiment, the mass of aerosol containment material 45 comprises wadding or fleece, with a density of about 100 gsm or about 120 gsm. In this embodiment, the mass of aerosol containment material 45 is inside the first and second housing parts 41a, 41b, and contacts the smokable material 43 and the housing 41, and fills a space between the smokable material 43 and the housing 41. In other embodiments, the mass of aerosol containment material 45 may be spaced from the smokable material 43 and/or the housing 41. In some embodiments, there may be a further layer of material between the smokable material 43 and the mass of aerosol containment material 45. Such a further layer of material may help hold different regions of the smokable material 43 together. In some embodiments, the mass of aerosol containment material 45 may be omitted.

16 The arrows in Figure 2 indicate the flow path(s) which fluid takes during use of the cartridge 40. Air is drawn into the chamber 42 via the air flow inlet 41c.
The air passes through the mass of aerosol containment material 45, so as to pick up the volatilised material generated within the cartridge 40 by heating the smokable material 43. The volatilised material, typically in the form of an aerosol, is then drawn from the mass of aerosol containment material 45 and from the chamber 42 to the exterior of the housing 41 via the volatilised material outlets 41e by a user for inhalation.
Referring to Figures 3 and 4, there are shown a schematic top view and a schematic cross-sectional view of an example of another cartridge 50 according to an embodiment of the invention. Like elements in Figures 1 to 4 are indicated with like reference numerals. The cartridge 50 of this embodiment is usable with the apparatus 2 shown in Figure 11. The cartridge 50 of this embodiment is the same as the cartridge 40 shown in Figures 1 and 2 and discussed above, except for the features described in the following paragraphs.
In the cartridge 50 of Figures 3 and 4, the carrier 41d and the second housing part 41b are shaped and relatively positioned so that the cavity 44 of the exterior surface of the cartridge 50 is a wedge-shaped cavity 44. In this embodiment, the wedge-shaped .. cavity 44 is symmetrical or rotationally-symmetrical. In other embodiments, it may instead be asymmetrical. In contrast to the cavity 44 of the cartridge 40 of Figures 1 and 2, a cross-sectional size (for example, a width, a height, a diameter, a dimension, or an area) of the cavity 44 of the cartridge 50 decreases with distance from the mouth 44a of the cavity 44 over the full length of the cavity 44 from the mouth 44a to the .. closed end 44d. In this embodiment, the cross-sectional size of the cavity 44 decreases at a linear rate with distance from the mouth 44a. In other embodiments, the rate may be non-linear. For example, in some embodiments, the cross-sectional size of the first trunk section 44b may decrease at a first rate with distance from the mouth 44a, whereas the cross-sectional size of the second trunk section 44c may decrease at a second, .. different rate with distance from the first trunk section 44b. The second rate may be more than the first rate. The term "wedge" has been used herein to describe an object having one relatively thick end which, over the length of the object, tapers to a relatively

17 thin end and which has a polygonal cross-sectional shape, such as for example a rectangular cross-sectional shape or other multi-sided cross-sectional shape.
By providing that the cross-sectional size (for example, the width, the height, the diameter, the dimension, or the area) of the cavity 44 decreases with distance from the mouth 44a over the full length of the cavity 44, the wedge-shaped heater 21 of the apparatus 2 shown in Figure 11 is introducible into the cavity 44 in a direction non-parallel to the second side of the carrier 41d. Therefore, rubbing of the heater 21 against the second side of the carrier 41d during insertion of the heater 21 is minimised or avoided. This can help reduce or avoid the carrier 41d being torn or otherwise damaged by insertion of the heater 21, and reduces wear of the heater 21. Once inserted, the heater 21 may be a close fit with the second side of the carrier 41d in use.
This provides good conduction of heat from the heater 21 to the carrier 41d and the smokable material 43.
In this embodiment, although the cavity 44 and the carrier 41d are of a different form to the corresponding elements of the cartridge 40 of Figures 1 and 2, the smokable material 43 still encircles the carrier 41d and surrounds the cavity 44. In this embodiment, a first portion 43a of the smokable material 43 is located on a first portion of the carrier 41d at a first side of the cavity 44, and a second portion 43b of the smokable material 43 is located on a second portion of the carrier 41d at a second side of the cavity 44. Moreover, the mass of aerosol containment material 45 still is wrapped around the smokable material 43 and the carrier 41d, so that the mass of aerosol containment material 45 encircles the smokable material 43 and the carrier 41d and surrounds the cavity 44. However, the features of any of the above-discussed variations to the cartridge 40 of Figures 1 and 2 may also be provided in variations to the cartridge 50 of Figures 3 and 4. For example, in some embodiments, the smokable material may be arranged on only a portion, or only some portions, of the carrier 41d.
In this embodiment, the mass of aerosol containment material 45 is in contact with the smokable material 43 and the housing 41, but does not fully fill a space between the smokable material 43 and the housing 41. However, in other embodiments, the mass of aerosol containment material 45 may do so, or may be omitted.

18 In a variation to the cartridge 50 shown in Figures 3 and 4, the carrier 41d and the second housing part 41b may be shaped and relatively positioned so that the cavity 44 is a dome-shaped cavity rather than a wedge-shaped cavity. Such a dome-shaped cavity may be symmetrical or rotationally-symmetrical, or asymmetrical.
Referring to Figures 5 and 6, there are shown a perspective view and a schematic cross-sectional view of an example of another cartridge 60 according to an embodiment of the invention. The cartridge 60 of this embodiment is usable with the apparatus 3 shown in Figure 15, described below.
The cartridge 60 of this embodiment comprises a housing 41 defining a chamber 42, and smokable material 43 located within the chamber 42. The housing 41 comprises a first housing part 41a and a second housing part 41d that is non-unitary with the first housing part 41a. The second housing part 41d is attached to the first housing part 41a, such as by a snap-fit connection, adhesive, or the like. In this embodiment, the first and second housing parts 41a, 41d cooperate so as to define the chamber 42. In other embodiments, the housing 41 may take a different form. For example, in some embodiments the first and second housing parts 41a, 41d may be unitary, such as following welding, e.g. sonic welding.
In the embodiment, the first housing part 41a is cup-shaped and the second housing part 41d is attached as a cap to the first housing part 41a. The second housing part 41d is a carrier 41d, and the smokable material 43 is in contact with, and is adhered to, a first side of the carrier 41d. The carrier 41d is thermally-conductive and is for conducting heat from a second side of the carrier 41d to the smokable material 43 on the first side of the carrier 41d. In this embodiment, the carrier 41d comprises a metal foil, such as aluminium foil, but in other embodiments the carrier 41d may comprise a different material, such as one or more materials selected from the group consisting of:
foil, paper, a polymer, a plastics material, and a combination of foil and paper.

19 An exterior surface of the cartridge 60 comprises a cavity 44 for receiving a heater 21 for heating the smokable material 43 in use. In this embodiment, the cavity 44 is a dome-shaped cavity 44 defined by the second side of the carrier 41d.
In this embodiment, the dome-shaped cavity 44 is symmetrical or rotationally-symmetrical.
In other embodiments, it may instead be asymmetrical. In this embodiment, the second side of the carrier 41d comprises a surface that is a combination of curved and polygonal portions. However, in other embodiments, the dome-shaped cavity 44 may be defined by a surface of the carrier 41d that is only polygonal or only curved. As the cavity 44 is dome-shaped, a cross-sectional size (for example, a width, a height, a diameter, a dimension, or an area) of the cavity 44 decreases with distance from the mouth over the full length of the cavity 44. The term "dome" has been used to describe an object which in general terms is formed by taking the surface of revolution of an arc. The arc may be for example a quarter of a circle, that is it subtends an angle of 900, or at least approximately a quarter of a circle or some other similarly curved shape, so that the dome is hemispherical or at least approximately hemispherical.
As will be described in more detail below, in use the smokable material 43 in the cartridge 60 is heated to volatilise at least one component of the smokable material 43 without combusting, or burning, the smokable material 43. In this embodiment, the .. cartridge 60 comprises a mass of aerosol containment material 45. The mass of aerosol containment material 45 is a porous material for the containment of aerosol generated in the cartridge 60 in use, so as to help avoid the aerosol condensing on an inner surface of the housing 41 of the cartridge 60. In this embodiment, the mass of aerosol containment material 45 comprises wadding or fleece, with a density of about 100 gsm or about 120 gsm. In this embodiment, the mass of aerosol containment material 45 is located between the smokable material 43 and the first housing part 41a. More specifically, the mass of aerosol containment material 45 is inside the first housing part 41a, contacts the smokable material 43 and the first housing part 41a, and fills a space between the smokable material 43 and the first housing part 41a. However, in other embodiments, there may be a further layer of material between the smokable material 43 and the mass of aerosol containment material 45. Such a further layer of material may help hold different regions of the smokable material 43 together. In other embodiments, the mass of aerosol containment material 45 may be omitted.
In this embodiment, the carrier 41d has an air flow inlet 41c extending 5 therethrough for admitting air into the chamber 42 from the cavity 44. In this embodiment, the carrier 41d is made of non-porous material, but in other embodiments the carrier 41d may be made of porous material for admitting air into the chamber 42 from the cavity 44. In some embodiments, such a porous carrier 41d also has the air flow inlet 41c extending therethrough.
In this embodiment, the first housing part 41a has an aperture 41e extending therethrough. The aperture 41e is a volatilised material outlet 41e for permitting volatilised material created by the heating of the smokable material 43 to pass from the chamber 42 out of the housing 41. In other embodiments, there may be more than one aperture 41e in place of the single aperture 41e, or the volatilised material outlet(s) 41e may take some other form and/or may extend through a different part of the housing 41. In this embodiment, a passage 46 extends through the cartridge 60 and connects the air flow inlet 41c to the volatilised material outlet 41e. In this embodiment, the passage 46 is defined by the smokable material 43 and the mass of aerosol containment material 45. During use of the cartridge 60, air is drawn into the chamber 42 via the air flow inlet 41c. The air passes through the passage 46, so as to pick-up the volatilised material generated within the cartridge 60. The volatilised material, typically in the form of an aerosol, is then drawn from the mass of aerosol containment material 45 and from the chamber 42 to the exterior of the housing 41 via the volatilised material outlet 41e by a user for inhalation.
In a variation to the cartridge 60 shown in Figures 5 and 6, the second side of the carrier 41d may define a cavity 44 that is wedge-shaped rather than dome-shaped.
Such a wedge-shaped cavity may be symmetrical or rotationally-symmetrical, or asymmetrical.

Although in the cartridges 40, 50,60 of Figures 1 to 6 the carrier 41d defines at least part of the cavity 44 for receiving the heater 21 for heating the smokable material 43, in other embodiments this may not be the case. That is, in some embodiments, the carrier may defme a portion of an exterior surface of a cartridge, and the portion of the exterior surface does not comprise any part of a cavity.
Referring to Figure 7, there is shown a schematic cross-sectional view of an example of another cartridge 70 according to an embodiment of the invention.
Like elements in Figures 2 and 7 are indicated with like reference numerals. The cartridge 70 of this embodiment is usable with the apparatus 1 shown in Figure 10.
The housing 41 of the cartridge 70 of Figure 7 comprises a first housing portion 71a, a second housing portion 71b, and a hinge 41f connecting the first housing portion 71a to the second housing portion 7 lb. In this embodiment, each of the first housing portion 71a and the second housing portion 71b contains smokable material 43a, 43b.
However, in other embodiments the smokable material 43b may be omitted from the second housing portion 71b, so that only the first housing portion 71a contains smokable material 43a. The first housing portion 71a is rotatable about the hinge 41f relative to the second housing portion 7 lb between an open position, as shown in Figure __ 8, and a closed position, as shown in Figure 7, via an intermediate position, as shown in Figure 9. In Figure 7, the first housing portion 71a has been rotated about the hinge 79 towards the second housing portion 71b to the closed position. In this embodiment, at the closed position, the first housing portion 71a abuts the second housing portion 7 lb. In other embodiments, that may not be true. Moreover, in this embodiment, at the closed position, an exterior surface of the cartridge 70 defines a cavity 44 between the first housing portion 71a and the second housing portion 71b for receiving a heater for heating the smokable material 43. The cartridge 70 may be used with the apparatus 1 when the first housing portion 71a is at the closed position. In this embodiment, the cavity 44 has the same shape as the cavity 44 of the cartridge 40 shown in Figure 2. In other embodiments, the cavity 44 of the cartridge 70 may have a different shape, such as a wedge shape or a dome shape.

In this embodiment, the housing 41 comprises a carrier 41d having a first side and a second side. In this embodiment, the smokable material 43a, 43b is in contact with the first side of the carrier 41d. Moreover, in this embodiment the second side of the carrier 41d defines at least part of the cavity 44 when the first housing portion 71a is at the closed position relative to the second housing portion 71b.
Therefore, when a heater is introduced into the cavity 44 in use, the carrier 41d is able to conduct heat efficiently from the heater directly to the smokable material 43a, 43b.
In this embodiment, the first housing portion 71a comprises a first housing part 41a, and a first portion of the smokable material 43a and a first mass of aerosol containment material 45a are located within a chamber defined by and between the first housing part 41a and the carrier 41d. Similarly, the second housing portion 71b comprises a second housing part 41b, and a second portion of the smokable material 43b and a second mass of aerosol containment material 45b are located within a chamber defined by and between the second housing part 41b and the carrier 41d. Each of the first and second housing parts 41a, 41b defines an air flow inlet 41c and a volatilised material outlet 41e therethrough, which act similarly to the equivalent elements of the cartridge 40 of Figures 1 and 2.
In this embodiment, the hinge 41f is a living hinge defined by the carrier 41d.
First and second portions 41g, 41h of the carrier 41d are attached to the first and second housing parts 41a, 41b, respectively, and the carrier 41d is folded between the portions 41g, 41h of the carrier 41d to form the hinge 41f. In this embodiment the first and second portions 41g, 41h of the carrier 41d are unitary. In other embodiments, the first and second portions 41g, 41h of the carrier 41d may be separate parts.
Moreover, in some embodiments, the hinge 41f may be a non-living hinge.
In some embodiments, the first and second housing portions 71a, 71b may have co-operable respective engagement parts for retaining the first housing portion 71a at the closed position relative to the second housing portion 71b, so as to maintain the form of the cavity 44 between the first and second housing portions 71a, 71b.

The cartridge 70 of Figure 7 may be manufactured according to a method comprising: providing the first and second housing portions 71a, 71b, locating the smokable material 43a, 43b in the first and/or second housing portion 71a, 71b; and providing the hinge 41f connecting the first housing portion 71a to the second housing portion 71b. In some embodiments, the step of providing the hinge 41f may occur after the step of providing the first and second housing portions 71a, 71b. For example, the step of providing the hinge 41f may comprise providing the carrier 41d, and attaching the carrier 41d to the first and second housing portions 71a, 7 lb. In other embodiments, the step of providing the hinge may occur simultaneously with the step of providing the first and second housing portions 71a, 71b. For example, in some embodiments, the first and second housing portions 71a, 71b and the hinge may be respective sections of a unitary component.
During manufacture of the cartridge 70 of Figure 7, the first and second housing parts 41a, 41b may be thermoformed, injection moulded or compression moulded, for example. In some embodiments, the smokable material 43a and/or 43b may be attached to the carrier 41d, and then the carrier 41d may be attached to the first and second housing parts 41a, 41b. In other embodiments, the smokable material 43a and/or 43b may be inserted into the chamber of the first and/or second housing parts 41a, 41b, and then the carrier 41d may be attached to the first and/or second housing parts 41a, 41b.
In some embodiments, the first and/or second masses of aerosol containment material 45a, 45b may be attached to the smokable material 43a and/or 43b and then inserted into the into the chamber of the first and/or second housing parts 41a, 41b with the smokable material 43a and/or 43b. In other embodiments, the first and/or second masses of aerosol containment material 45a, 45b may be inserted into the chamber of the first and/or second housing parts 41a, 41b, and then the smokable material 43a and/or 43b may be inserted into the chamber(s).
In each of the above-described embodiments of the cartridge 40, 50,60, 70, the carrier 41d is a foil, such as a metal foil, with a thickness of about 300 micrometres. In other embodiments, the carrier 41d may comprise one or more materials selected from the group consisting of: foil, paper, a polymer, a plastics material, and a combination of foil and paper. In some embodiments, the carrier 41d may have a different thickness, such as a thickness of less than 300 micrometres.
In respective variations to the above-described embodiments, the carrier 41d may comprise a first layer of material and a second layer of material, which may be the same or different. The smokable material 43 may be in contact with the first layer of material, and the second layer of material may define at least part of the cavity 44. That is, the first layer of material may define the first side of the carrier 41d, and the second layer of material may define the second side of the carrier 41d. In some embodiments, the smokable material 43 may be more readily bondable or atherable to the material of the first layer of material than to the material of the second layer of material. In some embodiments, the material of the second layer of material may be more rigid or robust than the material of the first layer of material. Thus, in some embodiments, the first layer of material may facilitate adhering the smokable material 43 to the carrier 41d, and the second layer of material may increase the rigidity or robustness of the carrier 41d. In another embodiment of the present invention, the smokable material 43 is mounted on an intermediary material and the intermediary material is mounted on the carrier 41d to provide an intermediary layer between the smokable material 43 and the carrier 41d. The intermediary material may be made of thermally-conductive material to conduct heat to the smokable material 43 mounted on it. Suitable materials include metals, which may for example be in the form of a mesh or a sheet.
In some embodiments, the carrier 41d may be omitted. For example, in a variation to the cartridge 50 shown in Figures 3 and 4, the carrier 41d is omitted and the smokable material 43 itself defines part of the wedge-shaped cavity 44. In a variation to the cartridge 60 shown in Figures 5 and 6, the carrier 41d is omitted and the smokable material 43 defines all of the dome-shaped cavity 44. In some such embodiments, the smokable material may include a binder to give rigidity to the smokable material.
Each of the cartridges 40, 50, 60, 70 of Figures 1 to 9 may be considered an embodiment of a cartridge 40, 50, 60, 70 for use with apparatus 1, 2, 3 for heating smokable material to volatilise at least one component of the smokable material, wherein the cartridge 40, 50, 60, 70 comprises a housing defining a chamber;
and smokable material 43 located within the chamber; wherein the housing 41 comprises a carrier 41d defining part of an exterior surface of the cartridge 40, 50, 60, 70, wherein 5 the smokable material 43 is arranged on the carrier 41d, and wherein the carrier 41d has a thickness of no more than 300 micrometres.
In each of the above-described embodiments, the carrier 41d should be able to withstand contact with a heater 21 in use. In an embodiment of the present invention 10 the carrier 41d is arranged to be in direct contact with the heater 21 in use. The carrier 41d should also be resistant to heat at least over the expected range of temperatures of the heating device 20 of the apparatus 1, 2, 3 that will arise in operation, such as for example 150 to 300 degrees Celsius or 170 to 220 degrees Celsius as discussed below, and should not degrade when subjected to such operation temperatures. The carrier 41d 15 should further be suitable for conducting heat from a second side of the carrier 41d to the smokable material 43 on the first side of the carrier 41d in use. In some embodiments, by providing that the carrier 41d has a thickness of no more than micrometres, the thermal-resistivity of the carrier 41d is decreased as compared to a carrier 41d of greater thickness, and the quantity of material required to make the carrier

20 41d, and thus the cartridge as a whole, is less than is required to make a carrier 41d of greater thickness.
The cartridges 40, 50, 60, 70 of Figures 1 to 9 may be considered respective articles 40, 50, 60, 70 for use with apparatus 1, 2, 3 for heating smokable material to 25 volatilise at least one component of the smokable material. Each of the articles 50, 60 of Figures 3 to 6 comprises smokable material 43, and in each of the articles 50, 60 an exterior surface of the article 50, 60 comprises a cavity 44 for receiving a heater 21 for heating the smokable material 43. In each of the articles 50, 60, the cavity 44 has a mouth 44a and a cross-sectional size (for example, a width, a height, a diameter, a dimension, or an area) of the cavity 44 decreases with distance from the mouth 44a over a full length of the cavity 44, but in other embodiments the cross-sectional size of the cavity 44 may decrease with distance from the mouth 44a over only a majority of the length of the cavity 44.
In some embodiments, an article for use with apparatus for heating smokable material to volatilise at least one component of the smokable material may be other than a cartridge. For example, in some embodiments, the article may comprise smokable material arranged on a first side of a carrier, wherein a second side of the carrier defines a cavity for receiving a heater for heating the smokable material, wherein the cavity has a mouth, and wherein a cross-sectional size (for example, a width, a height, a diameter, a dimension, or an area) of the cavity decreases with distance from the mouth over at least a majority of a length of the cavity. In some such embodiments, the cross-sectional size of the cavity may decrease with distance from the mouth over the full length of the cavity. In some such embodiments, the cavity may be a blind hole; in other embodiments the cavity may be a through hole. In some embodiments, the cavity may be a wedge-shaped cavity or a dome-shaped cavity, for example. Such a wedge-shaped or dome-shaped cavity may be symmetrical or rotationally-symmetrical, or asymmetrical. In some embodiments, the smokable material itself may define the cavity for receiving the heater. In some such other embodiments, the article may consist of smokable material that is suitably shaped to define the cavity.
In each of the above-described embodiments of the cartridge or article 40, 50, 60, 70, the smokable material 43 comprises tobacco. However, in other respective embodiments, the smokable material 43 may consist of tobacco, may consist substantially entirely of tobacco, may comprise tobacco and smokable material other than tobacco, may comprise smokable material other than tobacco, or may be free of tobacco. In some embodiments, the smokable material 43 may include an aerosol forming agent, such as glycerol.
In each of the above-described embodiments of the cartridge or article 40, 50, 60, 70, the aerosol containment material is a porous material for the containment of aerosol generated in the cartridge or article 40, 50, 60, 70. In each of the above-described embodiments, the aerosol containment material comprises wadding or fleece with a density of about 100 gsm or about 120 gsm. In other embodiments, the density of the aerosol containment material may be different. However, if the density is too high, the aerosol containment material may act as a filter and attenuate generated aerosol. Alternatively, if the density is too low, the aerosol containment material may not provide effective aerosol containment. An appropriate density, particularly when the aerosol containment material comprises wadding or fleece, may be between about 60 and about 140 gsm, or between about 80 and about 120 gsm. In some embodiments, the aerosol containment material may have a thickness within a range of 1 mm to 2 mm.
In still further embodiments, the aerosol containment material may comprise one or more materials selected from the group consisting of: wadding, fleece, non-woven material, non-woven fleece, woven material, knitted material, nylon, foam, polystyrene, polyester, polyester filament, polypropylene, and a blend of polyester and polypropylene. When a material other than wadding or fleece is used, the material may have a density chosen to have similar thermal properties to wadding or fleece having a density of from about 80 to about 120 gsm. In each of the above-described embodiments of the cartridge 40, 50, 60, 70, the aerosol containment material is free of smokable material. However, this need not always be the case.
In some embodiments, the mass of aerosol containment material is heat resistant at least over the expected range of temperatures of the heating device 20 of the apparatus 1, 2, 3 that will arise in operation, such as for example 150 to 300 degrees Celsius or 170 to 220 degrees Celsius as discussed below, and will not degrade when subjected to such operation temperatures.
In some embodiments, the aerosol containment material helps to ensure that volatilised material generated in the cartridge or article 40, 50, 60, 70 in use does not condense on an inner surface of the chamber of the cartridge or article 40, 50, 60, 70.
In some embodiments, the provision of the mass of aerosol containment material helps to increase the surface area on which aerosol generated in the cartridge or article 40, 50, 60, 70 in use may form. In some embodiments, such a mass of aerosol containment material helps to increase the amount of visible aerosol generated in, or emitted from, the cartridge or article 40, 50, 60, 70 in use, and thus may enhance the consumer experience.
In some embodiments, the aerosol containment material may be omitted.
In each of the above embodiments, the cartridge or article 40, 50, 60, 70 is a consumable cartridge or article. Once all, or substantially all, of the volatile component(s) of the smokable material 43 therein has/have been spent, the user may remove the cartridge or article 40, 50, 60, 70 from the apparatus 1, 2, 3 and dispose of the cartridge or article. The user may subsequently re-use the apparatus 1, 2, 3 with another, unspent cartridge or article 40, 50, 60, 70. However, in other respective embodiments, the cartridges or articles 40, 50, 60, 70 may be non-consumable cartridges, and the combination of the apparatus 1, 2, 3 and the cartridges or articles 40, 50, 60,70 may be disposed of together once the volatile component(s) of the smokable material 43 has/have been spent.
Referring to Figure 10, there is shown a partially cut-away perspective view of an example of an apparatus 1 for heating smokable material to volatilise at least one component of the smokable material. The apparatus is particularly suitable for use with the cartridges 40, 70 and variants thereof discussed above with reference to Figures 1, 2 and 7 to 9. In use, the apparatus 1 is arranged to heat the smokable material 43 in the cartridge 40,70 to volatilise at least one component of the smokable material 43 without combusting, or burning, the smokable material 43. The apparatus 1 comprises a body 10 and a mouthpiece 30. The outward appearance of the apparatus 1 when assembled is defined by the combination of the body 10 and the mouthpiece 30.
The body 10 is generally tubular and elongate, has first and second opposite longitudinal ends 11, 12, and defines an interface for co-operating with the cartridge 40, 70. In this embodiment, the interface comprises a recess 13 for receiving the cartridge 40, 70. In other embodiments, the interface can take a different form, such as a shelf, a surface, or a projection, and optionally requires mechanical mating with the cartridge 40, 70 in order to co-operate with the cartridge 40, 70. The first longitudinal end 11 of the body 10 defines an opening 14 into the recess 13 at a first end of the recess 13. The opening 14 is shaped and sized so that the cartridge 40, 70 is movable through the opening 14 to allow a user to insert the cartridge 40, 70 into the recess 13 and/or to remove the cartridge 40, 70 from the recess 13, as will be described in more detail below. The body 10 houses electrical components of the apparatus 1. The electrical components in this embodiment comprise an electrical power source 15, a controller 16, an actuator 17, and a heating device 20.
In this embodiment, the mouthpiece 30 is generally tubular and elongate and has first and second opposite longitudinal ends 31, 32. The mouthpiece 30 comprises an inlet 34 at the second longitudinal end 32 of the mouthpiece 30, an outlet 35 at the first longitudinal end 31 of the mouthpiece 30, and a channel 36 fluidly connecting the inlet 34 with the outlet 35. The second longitudinal end 32 of the mouthpiece comprises a connector (not shown) that is releasably engageable with a connector (not shown) of the first longitudinal end 11 of the body 10, so as to connect the mouthpiece 30 to the body 10. In other embodiments, the mouthpiece 30 and the body 10 may be permanently connected, such as through a hinge or flexible member. When the apparatus 1 is in use, the first longitudinal end 31 of the mouthpiece 30 forms a first longitudinal end of the apparatus 1, and the second longitudinal end 12 of the body 10 forms a second longitudinal end of the apparatus 1.
The mouthpiece 30 is locatable relative to the body 10 so as to cover the opening 14 into the recess 13. When the mouthpiece 30 is so located relative to the body 10, the first longitudinal end 31 of the mouthpiece 30 forms the first longitudinal end of the apparatus 1, and the channel 36 of the mouthpiece 30 is in fluid communication with the recess 13 via the inlet 34 of the mouthpiece 30. In some embodiments, the mouthpiece 30 may include a feature that would contact the cartridge 40, 70 when the cartridge 40, 70 is in the recess 13, to press the cartridge 40, 70 into the recess 13 and help ensure that the cartridge 40,70 is correctly positioned relative to the heating device 20.

In this embodiment, the recess 13 and the opening 14 into the recess 13 are defined by the body 10 of the apparatus 1. In this embodiment, the heating device 20 comprises a heater 21 extending along a longitudinal axis of the recess 13.
The heater

21 has a rectangular cross-sectional shape in a plane perpendicular to the axis.
5 However, in other embodiments, the cross-sectional shape of the heater 21 may be other than rectangular, such as square, cylindrical, elliptical or polygonal. The heater 21 is suitable for insertion into the cavity 44 of the cartridge 40 shown in Figures 1 and 2 or the cavity 44 of the cartridge 70 of Figures 7 to 9. The heater 21 has a length in the direction of the axis, a width perpendicular to the length, and a height perpendicular to 10 the width and the length. The width and height of the heater 21 are slightly less than the width and height, respectively, of the cavity 44 of the cartridge 40, 70, to facilitate insertion of the heater 21 into the cavity 44. The heating device 20 comprises a retainer 18 that is fixed to the body 10 so as to retain the heater 21 in position relative to the body 10. In this embodiment, the heater 21 extends from a second end of the recess 13 15 to the first end of the recess 13. That is, the heater 21 extends along the full axial length of the recess 13. However, in other embodiments, the heater 21 may extend along only part of the length of the recess 13 from the second end of the recess 13.
In this embodiment, the heater 21 comprises electrically-conductive material.
20 In this embodiment, the electrically-conductive material is copper, but in other embodiments the electrically-conductive material may comprise any one or more of a metal, a metal alloy, steel, stainless steel, copper and nichrome. In this embodiment, the electrically-conductive material has been etched in such a manner as to be patterned to provide electrically-conductive tracks. In other embodiments, the electrically-25 conductive material may be printed in such a manner as to be patterned, or may be patterned by some other process. In still further embodiments, the electrically-conductive material may be non-patterned. For example, in some such embodiments, the electrically-conductive material may be a simple tubular length of the electrically-conductive material. The heater 21 is heatable by passing an electric current through 30 the electrically-conductive material. By suitably patterning the electrically-conductive material, a cross sectional area and length of an electric current flow-path in the electrically-conductive material are set, so that heating of the heater 21 can be achieved by passing a predetermined electric current through the electrically-conductive material.
The heater 21 also comprises a support for supporting the electrically-conductive material. In this embodiment, the support is an electrical insulator and is resistant to heat. More particularly, the support is resistant to heat at least over the expected range of temperatures of the heater 21 that will arise in operation, such as for example 150 to 300 degrees Celsius or 170 to 220 degrees Celsius. In this embodiment, the support is a ceramic, but in other embodiments the support may be made from another material, such as polyimide. As discussed elsewhere herein, the controller 16 is in some embodiments arranged to ensure that the heater 21 is heated to a temperature within this range. Accordingly, the support is able to withstand the heating of the electrically-conductive material during use of the apparatus 1.
In this embodiment, the electrical power source 15 is a rechargeable battery.
In other embodiments, the electrical power source 15 may be other than a rechargeable battery, such as a non-rechargeable battery or a capacitor.
In this embodiment, the controller 16 comprises an integrated circuit (IC), such as an IC on a printed circuit board (PCB). In other embodiments, the controller 16 may take a different form. The controller 16 is for controlling the supply of electrical power from the electrical power source 15 to the heating device 20. The controller 16 is operated in this embodiment by user-actuation of the actuator 17. The actuator 17 is located at the exterior of the body 10 and takes the form of a push-button. In other embodiments, a different form of actuator 17 may be provided, such as a toggle switch, a dial, or the like. Actuation of the actuator 17 by a user causes the controller 16 to cause an electric current to be applied across the electrically-conductive material of the heater 21 of the heating device 20. Such actuation of the actuator 17 may cause completion of an electrical circuit in the controller 16. As the electric current is so applied across the electrically-conductive material, the heater 21 heats up.
In this embodiment, the electrical resistance of the electrically-conductive material changes as the temperature of the heater 21 increases. The controller 16 monitors the electrical resistance of the heated electrically-conductive material, and then adjusts the magnitude of the electrical current applied across the electrically-conductive material on the basis of the monitored electrical resistance as necessary, in order to ensure that the temperature of the heater remains within the above-discussed temperature range of about 150 Celsius to about 300 degrees Celsius, or about 170 degrees Celsius to about 220 degrees Celsius. Within this temperature range, the smokable material 43 in the cartridge 40, 70 is heated sufficiently to volatilise at least one component of the smokable material 43 without combusting the smokable material 43. Accordingly, the controller 16, and the apparatus 1 as a whole, is arranged to heat the smokable material 43 to volatilise the at least one component of the smokable material 43 without combusting the smokable material 43. In other embodiments, the temperature range of heating may be other than this range.
In other embodiments, the temperature of the heater 21 may be controlled in a different manner. For example, in some embodiments the controller 16 may monitor a current flow through the electrically-conductive material, or an output from a sensor for sensing a temperature of, or proximate, the heater 21, and then adjust the magnitude of the electrical current applied across the electrically-conductive material on the basis of the monitored current flow as necessary, in order to ensure that the temperature of the heater remains within the above-discussed temperature range. Other ways of controlling the temperature of the heater 21 could be used in other embodiments.
Although not shown in the Figures, the body 10 has an inlet for admitting air into the apparatus 1 from an exterior of the apparatus 1, and the retainer 18 has a hole therethrough which places the recess 13 in fluid communication with the inlet.
Therefore, when the mouthpiece 30 is connected to the body 10 to assemble the apparatus 1, there is defined an overall flow path that extends from the exterior of the apparatus 1, then through the inlet, then through the hole in the retainer 18, then through the recess 13, then through the channel 36 of the mouthpiece 30 to the exterior of the apparatus 1.

An exemplary operation of the apparatus 1 of this embodiment will now be described. A user ensures that the mouthpiece 30 is at a location relative to the body at which the cartridge 40, 70 is movable through the opening 14. The user then passes the cartridge 40,70 through the opening 14 and into the recess 13, so as to locate 5 the cartridge 40, 70 within the recess 13 with the heater 21 in the cavity 44 of the cartridge 40. The user then moves the mouthpiece 30 relative to the body 10 to a location at which the mouthpiece 30 covers the opening 14, with the first longitudinal end 31 of the mouthpiece 30 forming the first longitudinal end of the apparatus 1, and with the channel 36 of the mouthpiece 30 in fluid communication with the recess 13 via 10 the inlet 34 of the mouthpiece 30. The mouthpiece 30 is retained at this location through engagement of the connector of the mouthpiece 30 with the connector of the body 10.
When the actuator 17 is subsequently actuated by the user, the controller 16 is operated to cause an electric current to be applied across the electrically-conductive material of the heater 21. This application of the electric current causes the heater 21 to heat up so as to heat the smokable material 43 of the cartridge 40, 70.
This causes at least one component of the smokable material 43 to volatilise without combusting the smokable material 43. The user draws on the outlet 35 of the mouthpiece 30.
This causes a reduction in pressure in the recess 13, which causes air to be drawn into the recess 13 and the chamber 42 via the inlet of the body 10 and the hole in the retainer 18, in turn. Typically, this causes the volatilised component(s) of the smokable material 43 to be cooled, so that they condense to form an aerosol in the chamber 42.
The mass of aerosol containment material 45 contains the aerosol generated, so as to help avoid the aerosol condensing on an inner surface of the chamber 42 of the cartridge 40, 70.
The user's continued drawing causes the aerosol to be drawn from the recess 13 and/or from the mass of aerosol containment material 45 and into the user's mouth via the channel 36 of the mouthpiece 30. Each time air is drawn into the chamber 42, aerosol is produced. This can be repeated until the volatile component(s) of the smokable material 43 are exhausted.
When all, or substantially all, of the volatile component(s) of the smokable material 43 of the cartridge 40, 70 has/have been spent, the user may move the mouthpiece 30 relative to the body 10 to a location at which the cartridge 40, 70 is movable through the opening 14. The user may then remove the cartridge 40, 70 from the recess 13 via the opening 14. The user can subsequently insert another, unspent cartridge 40, 70 into the recess 13 and repeat the above process.
Referring to Figure 11, there is shown a partially cut-away perspective view of another example of an apparatus 2 for heating smokable material to volatilise at least one component of the smokable material. The apparatus 2 is usable with the cartridge 50 and variants thereof discussed above with reference to Figures 3 and 4. The apparatus 2 of this embodiment is identical to the apparatus 1 shown in Figure 10 and discussed above, except for the format of the heating device 20 and the controller 16.
Like elements in Figures 10 and 11 are indicated with like reference numerals.
In the apparatus 2 of Figure 11, the heating device 20 comprises a wedge-shaped heater 21 that projects into the recess 13 from the second end of the recess 13. In this embodiment, the heater 21 extends from a second end of the recess 13 to the first end of the recess 13. That is, the heater 21 extends along the full axial length of the recess 13. However, in other embodiments, the heater 21 may extend along only part of the length of the recess 13 from the second end of the recess 13. In this embodiment, the wedge-shaped heater 21 is symmetrical or rotationally-symmetrical. In other embodiments, it may instead be asymmetrical.
The heater 21 is for insertion into the cavity 44 of the cartridge 50 shown in Figures 3 and 4. The heater 21 has an external surface profile that matches, or closely matches, an internal surface profile of the cavity 44 of the cartridge 50.
Therefore, when the heater 21 is located in the cavity 44, the heater 21 is a close fit with the second side of the carrier 41d. This helps provide good conduction of heat from the heater 21 to the carrier 41d and the smokable material 43 thereon.
In this embodiment, the heater 21 is a folded heater 21 comprising a first heater portion 21a and a second heater portion 21b. The heater 21 has a fold 21c therein, and the first heater portion 21a is connected to the second heater portion 21b at the fold 21c.

The fold 21c forms a distal end of the heater 21, which distal end is distal from the retainer 18. The first heater portion 21a defmes an upper surface of the heater 21, and the second heater portion 21b defines a lower surface of the heater 21. In this embodiment, the first and second heater portions 21a, 21b lie substantially in respective 5 first and second planes, and the first and second planes meet at an acute angle. In this embodiment, each of the first and second heater portions 21a, 21b extends from the fold 21c, or the distal end of the heater 21, to a proximal end of the heater 21 at which the heater 21 is attached to the retainer 18. A distance between the first and second heater portions 21a, 21b increases with distance from the fold 21c. In this embodiment, the 10 increase is linear, but in other embodiments the increase may be non-linear.
In this embodiment, each of the first and second heaters portions 21a, 21b comprises electrically-conductive material and a support for supporting the electrically-conductive material. The electrically-conductive material may be of any of the 15 materials and forms described above for the electrically-conductive material of the heater 21 of the apparatus 1 of Figure 10, and so further detail will not be included here.
In this embodiment, the support comprises polyimide, but in other embodiments the support may be a different material, such as a ceramic material. In this embodiment, the support is an electrical insulator and is resistant to heat. More particularly, the 20 support is resistant to heat at least over the expected range of temperatures of the heater 21 that will arise in operation, such as for example 150 to 300 degrees Celsius or 170 to 220 degrees Celsius.
The apparatus 2 of Figure 11 may be manufactured by a method that comprises 25 the steps of providing a heater, and then folding the heater to form the folded heater 21.
In this embodiment of the method, the providing of the heater comprises providing a support body 25 and providing an electrically-conductive body 26 on the support body 25, as shown in Figure 12. In this embodiment, the electrically-conductive body 26 is then patterned, such as by etching or printing, so as to provide discrete first and second 30 regions of electrically-conductive material 26a, 26b on the support body 25, as shown in Figure 13. In this embodiment, the heater is then folded to form the wedge-shaped heater 21 with the regions of electrically-conductive material 26a, 26b at the exterior of the heater 21. In this embodiment, during the folding, the support body 25 is folded but neither of the first and second regions of electrically-conductive material 26a, 26b is folded. As shown in Figure 14, in the wedge-shaped heater 21 so formed, the first heater portion 21a comprises the first region of electrically-conductive material 26a on a first region 25a of the support 25, and the second heater portion 21b comprises the second region of electrically-conductive material 26b on a second region 25b of the support 25.
However, in other embodiments, the apparatus 2 may be manufactured by a different method. For example, in some embodiments, the patterning of the electrically-conductive body 26 may result in the formation of electrically-connected first and second regions of electrically-conductive material 26a, 26b on the support body 25. In the subsequent step of folding the heater, both the support body 25 and one or more electrically-conductive portions that connect the first and second regions of electrically-conductive material 26a, 26b may be folded. In another embodiment, the method may comprise forming the first and second heater portions 21a, 21b separately, and then fixing the first heater portion 21a to the second heater portion 21b so as to form the wedge-shaped heater 21. Other methods for manufacturing the apparatus 2 may instead be used.
In contrast to the controller 16 of the apparatus 1 of Figure 10, the controller 16 of the apparatus 2 of Figure 11 is for controlling the supply of electrical power from the electrical power source 15 to the first heater portion 21a independently of the supply of electrical power from the electrical power source 15 to the second heater portion 21b.
Accordingly, on user-actuation of the actuator 17, the controller 16 may, for example, cause a first electric current to be applied across the electrically-conductive material of one of the first and second heater portions 21a, 21b, and then subsequently cause a second electric current to be applied across the electrically-conductive material of the other of the first and second heater portions 21a, 21b. The second electric current may be applied while the first electric current is applied, or after the first electric current has ceased to be applied. The manner in which the controller 16 causes electric currents to be applied across the electrically-conductive material of the first and second heater portions 21a, 21b may be selectable by a user, such as through the user's suitable actuation of the actuator 17 in one of a plurality of possible ways. That is, in some embodiments, the actuator 17 may be actuatable by a user in a plurality of different ways, each of which ways causes the controller 16 to cause operation of the heating device 20 in a different predetermined manner. Thus, in some embodiments, a user may be able to select which of the first and second heater portions 21a, 21b is to be heated, and thus which of the first and second portions of smokable material 43a, 43b is to be heated. In embodiments in which the first and second portions of smokable material 43a, 43b have different characteristics or comprise different smoke modifying agents, a user is thus able to select or configure the type of aerosol they wish to generate, and thus the experience they wish to have on inhaling the aerosol.
The apparatus 2 of this embodiment may be operated in much the same way as the apparatus 1 of Figure 10. With the cartridge 50 located in the recess 13 with the heater 21 in the cavity 44, the user moves the mouthpiece 30 relative to the body 10 to a location at which the mouthpiece 30 covers the opening 14, as discussed above.
When the actuator 17 is subsequently actuated by the user, the controller 16 is operated to cause an electric current to be applied across the electrically-conductive material of the heating device 20. This application of the electric current causes the first and/or second heater portions 21a, 21b to heat up so as to heat the smokable material 43 of the cartridge 50. When the heater 21 is in the cavity 44 of the cartridge 50, the first heater portion 21a is closer to the first portion 43a of the smokable material 43 than to the second portion 43b of the smokable material 43, and the second heater __ portion 21b is closer to the second portion 43b of the smokable material 43 than to the first portion 43a of the smokable material 43. Therefore, in use, the first heater portion 21a is predominantly for heating the first portion 43a of the smokable material 43, and the second heater portion 21b is predominantly for heating the second portion 43b of the smokable material 43.
In this embodiment, the controller 16 and the apparatus 2 as a whole are configured so that the heating of the first and/or second heater portion 21a, 21b causes at least one component of the smokable material 43 to volatilise without combusting the smokable material 43. The mass of aerosol containment material 45 contains aerosol generated following volatilisation of the component(s) of the smokable material, so as to help avoid the aerosol condensing on an inner surface of the chamber 42 of the cartridge 50. The user inhales the aerosol by drawing on the outlet 35 of the mouthpiece 30, as described above for the embodiment of Figure 10.
Referring to Figure 15, there is shown a partially cut-away perspective view of another example of an apparatus 3 for heating smokable material to volatilise at least one component of the smokable material. The apparatus is usable with the cartridge 60 and variants thereof discussed above with reference to Figures 5 and 6. The apparatus 3 of this embodiment is identical to the apparatus 1 shown in Figure 10 and discussed above, except for the form of the heating device 20. Like elements in Figures 10 and 12 are indicated with like reference numerals.
In the apparatus 3 of Figure 15, the heating device 20 comprises a dome-shaped heater 21 that projects into the recess 13 from the second end of the recess 13. In this embodiment, the heater 21 extends from a second end of the recess 13 along only part of the length of the recess 13 from the second end of the recess 13. The heater 21 is for .. insertion into the cavity 44 of the cartridge 60 shown in Figures 5 and 6.
The heater 21 has an external dome-shaped surface profile that matches, or closely matches, the dome-shaped surface profile of the cavity 44 of the cartridge 60. Therefore, when the heater 21 is located in the cavity 44, the heater 21 is a close fit with the second side of the carrier 41d. This helps provide good conduction of heat from the heater 21 to the carrier 41d and the smokable material 43 thereon. In this embodiment, the external dome-shaped surface profile of the heater 21 comprises a surface that is a combination of curved and polygonal portions. However, in other embodiments, the external dome-shaped surface profile may be defined by a surface of the heater 21 that is only polygonal or only curved.
As for the apparatus 1 of Figure 10, the heater 21 comprises electrically-conductive material and a support for supporting the electrically-conductive material.

The electrically-conductive material and the support may be of any of the materials and forms described above for the electrically-conductive material and the support of the heater 21 of the apparatus 1 of Figure 10, and so further detail will not be included here.
The apparatus 3 of this embodiment may be operated in a similar manner to the apparatus 1 of Figure 10. With the cartridge 60 located in the recess 13 with the heater 21 in the cavity 44, the user moves the mouthpiece 30 relative to the body 10 to a location at which the mouthpiece 30 covers the opening 14, as discussed above.
When the actuator 17 is subsequently actuated by the user, the controller 16 is operated to cause an electric current to be applied across the electrically-conductive material of the heating device 20. This application of the electric current causes the heater 21 to heat up so as to heat the smokable material 43 of the cartridge 60. The heating of the heater 21 causes at least one component of the smokable material 43 to volatilise without combusting the smokable material 43. The mass of aerosol containment material 45 contains aerosol generated following volatilisation of the component(s) of the smokable material, so as to help avoid the aerosol condensing on an inner surface of the chamber 42 of the cartridge 60. The user inhales the aerosol by drawing on the outlet 35 of the mouthpiece 30, as described above for the embodiment of Figure 10. This causes the aerosol to be drawn from the recess 13 and/or from the mass of aerosol containment material 45 and into the user's mouth via the passage 46 of the cartridge 60 and the channel 36 of the mouthpiece 30.
In some embodiments, any one of the apparatuses 1, 2, 3 discussed above may be sold, supplied or otherwise provided separately from the cartridge 40, 50, 60, 70 or article with which the apparatus 1, 2, 3 is usable. However, in some embodiments, one of the apparatuses 1, 2, 3 and one or more of the cartridges 40, 50, 60, 70 or articles may be provided together as a kit.
In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration and example various embodiments in which the claimed invention may be practised and which provide for superior apparatus for heating smokable material to volatilise at least one component of the smokable material and/or superior cartridges or articles for use with such apparatus. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and 5 teach the claimed and otherwise disclosed features. It is to be understood that advantages, embodiments, examples, functions, features, structures and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit 10 of the disclosure. Various embodiments may suitably comprise, consist of, or consist in essence of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. The disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

41

1. A cartridge for use with apparatus for heating smokable material to volatilise at least one component of the smokable material, the cartridge comprising:
a housing defining a chamber, wherein the housing comprises a carrier having a first side and a second side; and smokable material located within the chamber and in contact with the first side of the carrier;
wherein an exterior surface of the cartridge has a cavity for receiving a heater for heating the smokable material, and wherein the second side of the carrier defines at least part of the cavity.

2. A cartridge according to claim 1, wherein the carrier and the cavity are arranged so as to abut a heater of the apparatus for heating smokable material when the heater is received in use in the cavity.

3. A cartridge according to claim 1 or claim 2, wherein the cavity is a blind hole.

4. A cartridge according to any of claims 1 to 3, wherein the cavity is a wedge-shaped cavity.

5. A cartridge according to any of claims 1 to 3, wherein the cavity is a dome-shaped cavity.

6. A cartridge according to any of claims 1 to 5, wherein the carrier comprises a first layer of material and a second layer of material attached to the first layer of material, wherein the smokable material is in contact with the first layer of material, and wherein the second layer of material defines at least part of the cavity.

7. A cartridge according to claim 6, wherein the smokable material is more readily bondable or adherable to the material of the first layer of material than to the material of the second layer of material.

8. A cartridge according to any of claims 1 to 7, wherein the smokable material encircles the carrier.

9. A cartridge according to any of claims 1 to 8, wherein the smokable material is adhered to the carrier

10. A cartridge according to any of claims 1 to 9, wherein the housing comprises a first housing portion, a second housing portion, and a hinge connecting the first housing portion to the second housing portion; wherein the first housing portion contains the smokable material; and wherein the first housing portion is rotatable about the hinge towards the second housing portion to a closed position at which the exterior surface defines the cavity between the first housing portion and the second housing portion;
optionally wherein the first housing portion abuts the second housing portion when the first housing portion is at the closed position.

11. A cartridge according to any of claims 1 to 10, comprising a mass of aerosol containment material located between the smokable material and the housing.

12. A cartridge according to claim 11, wherein the mass of aerosol containment material encircles the smokable material.

13. Apparatus for heating smokable material to volatilise at least one component of the smokable material, the apparatus comprising a heating device having a wedge-shaped or dome-shaped heater for insertion into a cavity of a cartridge or article.

14. Apparatus according to claim 13, wherein the heater is dome-shaped.

15. Apparatus according to claim 13, wherein the heater is wedge-shaped.

16. Apparatus according to any of claims 13 to 15, comprising a controller for controlling the supply of electrical power from an electrical power source to the heater.

17. Apparatus according to any of claims 13 to 16, wherein the heater comprises electrically conductive material, and the heater is heatable by passing an electric current through the electrically conductive material.

18. Apparatus according to claim 17, wherein the heater comprises a support for supporting the electrically-conductive material.

19. A kit comprising a cartridge according to any of claims 1 to 12 and apparatus for heating the smokable material to volatilise at least one component of the smokable material, wherein the apparatus has a heating device comprising a heater for insertion into the cavity.

20. A kit according to claim 19, wherein the apparatus is arranged to heat the smokable material to volatilise the at least one component of the smokable material without combusting the smokable material when the heater is in the cavity.

21. A kit according to claim 19 or claim 20, wherein the apparatus comprises a controller arranged to control heating of the heating device so as to cause heating of the smokable material to volatilise the at least one component of the smokable material without combusting the smokable material when the heater is in the cavity.

22. A kit according to any of claims 19 to 21, wherein the apparatus is according to any of claims 13 to 18.

23. A method of manufacturing apparatus for heating smokable material to volatilise at least one component of the smokable material, the method comprising:
providing a heater; and folding the heater to form a folded heater.

24. A method according to claim 23, wherein the folding comprises folding the heater to form a wedge-shaped heater.

25. A method according to claim 23 or claim 24, wherein the heater comprises electrically conductive material.

26. A method according to claim 25, wherein the heater comprises a support for supporting the electrically-conductive material.